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Kawasaki

Kawasaki KX60 1998-2010 Workshop Service Manual for Repair

Kawasaki KX60 1998-2010 Workshop Service Manual for Repair

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$16.99
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Vehicle data plateRef 73220
Brand
Kawasaki
Vehicle
Motorcycle
Models covered
KX Series, KX60, Motorcycles
Years
1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX60
Type:
Off-road Motorcycle (Dirt Bike)
Codes
Engine Codes:
Likely KSR110 engine family variants (specific codes not provided in source data)
👋 Introduction
Market Position
Market Segment:
Entry-level to intermediate youth motocross/off-road sportbike.
Competitive Analysis
Competitors:
Yamaha YZ80/85, Suzuki RM80/85, Honda CR80/85.
Key Features
Ease Of Use:
Designed for younger riders, emphasizing ease of handling and maintenance.
Durability:
Kawasaki's reputation for robust off-road machinery.
📋 Manual Details
Coverage Areas
Years Covered:
1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Page Count
Page Count:
250
Manual Type
Manual Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine:
Disassembly, assembly, inspection, adjustment, troubleshooting of engine components (carburetor, ignition, cooling, lubrication, etc.)
Transmission:
Service, inspection, and repair of the gearbox and clutch assembly.
Chassis And Suspension:
Front fork, rear shock absorber, swingarm, linkage, steering system, wheel bearings, and related components.
Brakes:
Front and rear brake systems, including hydraulic lines, master cylinders, calipers, and pads.
Electrical System
Electrical System:
Ignition system, lighting, battery, wiring diagrams, and component testing.
Fuel System
Fuel System:
Fuel tank, fuel lines, and carburetor service and adjustment.
Bodywork And Frame
Bodywork And Frame:
Frame inspection, fairings, seat, and other body components.
Procedures Included
Maintenance:
Routine maintenance checks, lubrication, adjustments, and periodic service intervals.
Troubleshooting:
Systematic diagnostic procedures for common problems and failures.
Repair:
Step-by-step instructions for disassembly, repair, and reassembly of all major components.
Installation:
Procedures for installing new or replacement parts.
Technical Depth
Technical Depth:
Comprehensive, from basic adjustments to complete engine rebuilds, with detailed explanations and diagrams.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
Printable (high resolution implied by comprehensive coverage)
Binding Type
Binding Type:
Digital (N/A for PDF)
Paper Type
Paper Type:
Digital (N/A for PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, single-cylinder
Displacement:
59.6 cc (typical for KX60 models)
Bore X Stroke:
43.0 mm x 41.6 mm (typical)
Cooling System:
Air-cooled
Performance
Horsepower:
Approx. 9-10 HP (estimated, exact figures vary by year and tuning)
Torque:
Not explicitly provided, but tuned for low-end torque suitable for youth riders.
Fuel System
Carburetor:
Mikuni VM15SC (typical)
Fuel Type:
Unleaded gasoline mixed with 2-stroke oil (ratio specified in manual)
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Features
Clutch Type:
Wet multi-disc
📐 Dimensions
Exterior
Overall Length:
Approx. 1620 mm (typical)
Overall Width:
Approx. 740 mm (typical)
Overall Height:
Approx. 1015 mm (typical)
Weights
Dry Weight:
Approx. 63 kg (typical)
Wheelbase:
Approx. 1130 mm (typical)
🛡️ Safety Features
Ratings
Safety Features:
Standard motocross safety features; emphasis on rider skill development.
Active Features
Braking System:
Front and rear disc brakes for reliable stopping power.
💡 Technology Features
Infotainment
Infotainment System:
None (This is a dedicated off-road racing motorcycle).
Driver Assistance
Driver Assistance Features:
None (This is a dedicated off-road racing motorcycle).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Specific interval for gearbox oil change will be detailed in the manual, typically after initial break-in and then periodically.
Spark Plug Replacement:
Regular inspection and replacement based on usage and condition, as per manual recommendations.
Air Filter Cleaning:
Frequent cleaning and/or replacement of the air filter is critical for 2-stroke engines, especially in dusty off-road conditions.
Fluid Specifications
Gear Oil:
Manual will specify SAE 10W-30 or SAE 10W-40 API GL-4 transmission oil for the gearbox.
2 Stroke Oil:
High-quality 2-stroke motorcycle oil, premix or injection system, with specific ratio recommendations in the manual.
Known Issues
Clutch Wear:
Common in high-performance off-road bikes; subject to wear due to aggressive riding. Manual will detail inspection and replacement.
Carburetor Fouling:
Can occur due to improper fuel/oil mixture or debris; manual provides cleaning and adjustment procedures.
Suspension Seals:
Front fork and rear shock seals can wear over time, leading to leaks; manual covers seal replacement and suspension service.
📚 Vehicle History
Brand Heritage
Kawasaki Motorsports:
Kawasaki has a long and successful history in motorcycle racing, particularly in motocross and supercross.
Model Evolution
Kx Lineage:
The KX60 is part of Kawasaki's esteemed KX line of motocross bikes, designed to introduce young riders to the sport.
Production
Production Period:
The KX60 was produced for a significant period, with the 1998-2010 range representing a substantial portion of its later production.
🏆 Awards & Recognition
Recognitions
Awards:
The KX60 has historically been recognized as a capable and reliable entry-level motocross bike, fostering many young racing careers.

Delivery & file format

This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.

Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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