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   Summary of Contents for Kawasaki KLX140

  • Page 3 GENERAL INFORMATION Quick Reference Guide MAINTENANCE AND ADJUSTMENT This Quick Reference Guide will assist you in finding the information you’re looking for. TROUBLESHOOTING GUIDE STORAGE A Table of Contents is included after the Foreword.
  • Page 4 IMPORTANT INFORMATION • This vehicle is designed for the operator only, no passengers. • This vehicle is an off-road motorcycle only and was not manufactured for use on public streets, roads or highways. • Respect the environment and the rights of other people. •...
  • Page 5 Whenever you see the symbols shown below, IMPORTANT heed their instructions! Always follow safe operat- Off-road motorcycling is a wonderful sport, ing and maintenance practices. and we hope you will enjoy it to the fullest. How- ever, if improperly conducted, this sport has the DANGER potential to cause environmental problems as well as conflicts with other people.
  • Page 6 IMPORTANT NOTE TO PARENTS ABOUT SAFE RIDING Your youngster’s safety will depend on your commitment to always provide a safe riding environment and a properly maintained vehicle. As with any moving vehicle there are possible safety risks; be sure to heed these precautions.
  • Page 7 10. Encourage your child not to ride beyond his or her skill lever or faster than conditions safely allow. Have them practice advanced riding maneuvers under controlled conditions. 11. Tell someone where you and your child are planning to ride and when you Intend to return. Discuss the ride with your child before you leave so he or she will know in advance what riding techniques may be necessary to negotiate the terrain safely.
  • Page 9 FOREWORD We wish to thank you for choosing this Kawasaki Motorcycle. It is the end product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, and performance. By giving your motorcycle the proper care and maintenance outlined in this manual, you will be helping to ensure it a long, trouble-free life.
  • Page 10 TABLE OF CONTENTS SPECIFICATIONS..........Valve Clearance ..........GENERAL INFORMATION......Spark Arrester ..........Location of Parts ........... Drive Chain............ Side Stand............. Handlebar............Fuel Tap............Brakes ............Fuel ............... Steering ............Engine Stop Switch ........Front Suspension .......... Starter Button ..........Rear Suspension........... Starting the Engine ........
  • Page 11: Specifications

    SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall length 1 820 mm (71.7 in.) B: 1 895 mm (74.6 in.) Overall width 790 mm (31.1 in.) Overall height 1 050 mm (41.3 in.) B: 1 075 mm (42.3 in.) Wheelbase 1 260 mm (49.6 in.) B: 1 285 mm (50.6 in.) Road clearance 235 mm (9.3 in.)
  • Page 12 SPECIFICATIONS TRANSMISSION Transmission type 5-speed, return shift Clutch type Wet, multi disc Drive system Chain drive Gear ratios: 1st gear 2.667 (40/15) 2nd gear 1.895 (36/19) 3rd gear 1.474 (28/19) 4th gear 1.182 (26/22) 5th gear 1.000 (24/24) Primary reduction ratio 2.880 (72/25) Final reduction ratio 3.571 (50/14)
  • Page 13 SPECIFICATIONS Tire size, type: 70/100-17 40M, IRC., LTD. IX05H Front B: 70/100-19 42M, IRC., LTD. IX05H 90/100-14 49M, IRC., LTD. IX05H Rear B: 90/100-16 52M, IRC., LTD. IX05H Rim size: Front 17 × 1.40 B: 19 × 1.40 Rear 14 × 1.60 B: 16 ×...
  • Page 14: General Information

    GENERAL INFORMATION GENERAL INFORMATION Location of Parts 1. Clutch Lever 5. Front Brake Lever 2. Engine Stop Switch 6. Throttle Grip 3. Choke Knob 7. Starter Button 4. Front Brake Fluid Reservoir 8. Fuel Tank Cap...
  • Page 15 GENERAL INFORMATION 9. Front Fork 16. Brake Caliper 10. Fuel Tank 17. Engine Oil Drain Plug 11. Fuel Tap 18. Side Stand 12. Carburetor 19. Drive Chain 13. Seat 20. Swingarm 14. Air Cleaner Element 21. Chain Guide 15. Brake Disc 22.
  • Page 16 GENERAL INFORMATION 23. Muffler 27. Chain Adjuster 24. Fuse 28. Rear Brake Fluid Reservoir 25. Battery 29. Oil Filler Cap/Dipstick 26. Rear Axle Nut 30. Rear Brake Pedal...
  • Page 17: Side Stand

    GENERAL INFORMATION Side Stand Fuel Tap The motorcycle is equipped with a side stand. The fuel tap has three position: OFF, ON, and RES (reserve). For normal operation, turn the fuel tap lever to the ON position. If the fuel runs out with the tap in the ON position, the last approximately 1.1 L (0.29 US gal) of usable fuel remains can be used by turning the tap lever to the RES position.
  • Page 18: Fuel

    GENERAL INFORMATION NOTE Fuel Since riding distance is limited when on RES, re- fuel at the earliest opportunity. The required of fuel is specified under “Fuel Re- Make certain that the fuel tap lever is turned to ON quirements”. (not RES), after filling up the fuel tank. The capacity of the fuel tank is 5.8 L (1.5 US gal).
  • Page 19 GENERAL INFORMATION WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 20 U.S. and (up to 17.2%). Fuel containing these oxygenates Canada which are required to sell such reformu- can also be used in your Kawasaki. lated fuels as part of a strategy to reduce exhaust emissions.
  • Page 21: Engine Stop Switch

    When not operating your Kawasaki for 30 to 60 days, mix a fuel stabilizer (such as STA-BIL) with the gasoline in the fuel tank. Fuel stabilizer additives inhibit oxidation of the fuel which minimizes gummy deposits.
  • Page 22: Starter Button

    GENERAL INFORMATION Starter Button Starting the Engine • This motorcycle has the starter button. The starter Turn the fuel tap lever to the ON position. button operates the electric starter when the clutch lever pulled in. A. ON Position • Shift the transmission into neutral.
  • Page 23 GENERAL INFORMATION NOTICE • Check that the engine stop switch is in the position. Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the battery power recover.
  • Page 24 GENERAL INFORMATION NOTICE NOTE When the clutch lever is pulled, the motorcycle can Do not let the engine idle longer than five be started with the transmission in any gear. minutes, or engine overheating and damage may occur. A. Starter Button •...
  • Page 25: Moving Off

    GENERAL INFORMATION Moving Off Shifting Gears • Check that the side stand is up. This motorcycle is equipped with a 5-speed “return • Shift into 1st gear. shift” transmission. The neutral is located halfway • Open the throttle slowly. between 1st and 2nd gear. “Return shift” means that when shifting up or down, each gear must be engaged before the next higher or lower gear may be selected.
  • Page 26: Stopping The Motorcycle

    GENERAL INFORMATION NOTICE Stopping the Motorcycle When changing gears, press firmly on the shift pedal to ensure proper shifting. Care- For maximum deceleration, close the throttle and less, incomplete shifting can cause the apply both front and rear brakes. Pull in the clutch transmission to jump out of gear and lead to lever as the motorcycle comes to a stop.
  • Page 27: Stopping The Engine

    GENERAL INFORMATION Stopping the Engine Break-In • Shift the transmission into the neutral position. The first one hour that the motorcycle is ridden is • Close the throttle completely. designed as the break-in period. If the motorcycle is • not used carefully during this period, you may very Push the engine stop switch to the position.
  • Page 28: Daily Pre-ride Checks

    GENERAL INFORMATION Daily Pre-Ride Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure a safe, reliable ride. If any irregularities are found during these checks, refer to the appropriate section and take the action required to return the motorcycle to a safe operating condition.
  • Page 29 GENERAL INFORMATION Frame Tires ..........Overall condition good No wear or damage Air pressure correct Air valve cap installed Spokes ..........No looseness Drive Chain ........Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ....Function properly Lever and pedal play correct No leakage Throttle ..........
  • Page 30: Maintenance And Adjustment

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and ex- haust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency.
  • Page 31 You should keep a maintenance record for your vehicle. To assist you in keeping this record, we have provided space at the end of this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. You should also retain copies of maintenance work orders, receipts, etc., as verifica- tion of this maintenance.
  • Page 32 MAINTENANCE AND ADJUSTMENT TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 33: Periodic Maintenance Chart

    Periodic Maintenance Chart to keep the motorcycle in good running condition. † : Replace, add, adjust, clean or torque if necessary. (K) : Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer. : Emission-related Item 1.
  • Page 34 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Item) FREQUENCY Initial Every 5 hours 50 hours Page hours (12 (1 month) (6 months) OPERATION months) • • • Brake adjustment - inspect † • • • Brake fluid level - check † •...
  • Page 35 MAINTENANCE AND ADJUSTMENT FREQUENCY Initial Every 5 hours 50 hours Page hours (12 (1 month) (6 months) OPERATION months) • • Battery - inspect † • • Battery terminal - inspect † • • • Chassis parts - lubricate • •...
  • Page 36 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement (Engine and Chassis Related Item) FREQUENCY Initial Every 5 hours 50 hours Page hours (12 (1 month) (6 months) OPERATION months) • • • Engine oil - change • • • Oil filter - replace –...
  • Page 37: Engine Oil

    MAINTENANCE AND ADJUSTMENT NOTICE Engine Oil Racing the engine before the oil reaches ev- ery part can cause engine seizure. In order for the engine, transmission and clutch to function properly, maintain the engine oil at the • If the motorcycle has just been used, wait several proper level, and change the oil and oil filter period- minutes for all the oil to drain down.
  • Page 38 MAINTENANCE AND ADJUSTMENT NOTICE NOTE Do not pinch the O-ring when installing the dipstick Be careful not to allow any dirt or foreign ma- on the oil filler neck. terials to enter the engine. When the O-ring comes off from the oil filler neck, •...
  • Page 39 MAINTENANCE AND ADJUSTMENT • WARNING Replace the oil filter element with a new one. • Apply the grease oil to the grommet. Engine oil is a toxic substance. Dispose of • Install the oil filter element with the grommet to- used oil properly.
  • Page 40 SJ, SL, SM and JASO MA, MA1, MA2 rating Viscosity: SAE 10W-40 *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Con- sistent use of these products meets or exceeds war- ranty and service requirements and can help to ex-...
  • Page 41: Spark Plug

    MAINTENANCE AND ADJUSTMENT Spark Plug The spark plug should be taken out periodically for inspection and regapping. Measure the gap with a wire-type thickness gauge. If incorrect, adjust the gap to the specified value by bending the outer elec- trode. Spark Plug Gap 0.6 ~ 0.7 mm CR7HSA...
  • Page 42 Standard Spark Plug NGK CR7HSA NOTE If the spark plug is replaced, use the genuine Kawasaki spark plug. Spark Plug Removal and Installation • Clean the cylinder head around the spark plug cap hole before removing the spark plug.
  • Page 43: Air Cleaner

    MAINTENANCE AND ADJUSTMENT NOTE Air Cleaner In dusty areas, the element should be cleaned more frequently than recommended interval. A clogged air cleaner restricts the air intake, in- After riding through rain or on muddy roads, the creases fuel consumption, reduces engine power, element should be cleaned immediately.
  • Page 44 MAINTENANCE AND ADJUSTMENT • • Remove the bolts and remove the air cleaner Remove the wing bolt, and take out the air cleaner cover. element. A. Air Cleaner Cover A. Air Cleaner Element B. Bolts B. Wing Bolt • Cover a clean, lint-free towel on the air cleaner housing to keep dirt from entering the carburetor.
  • Page 45 MAINTENANCE AND ADJUSTMENT WARNING Element Cleaning and Installation • Clean the element in a bath of a high flash point A clogged air cleaner may allow dirt and solvent or hot soapy water. Rinse the element with dust to enter the carburetor and the throttle clear water to remove all traces of the cleaning may stick resulting in a hazardous operating solution.
  • Page 46 MAINTENANCE AND ADJUSTMENT cause tearing. In this case, too much oil is better than too little. Finally pat the inside of the element with a paper towel to remove any excess oil. • Before installation, check the element for damage such as tears, hardening, or shrinkage.
  • Page 47 MAINTENANCE AND ADJUSTMENT • Oil Draining Install an air cleaner element with its pointing end • facing toward the rear of the motorcycle. Inspect the hose or plug to see if any oil or water has run down. A. Pointing end A.
  • Page 48: Throttle Cable

    MAINTENANCE AND ADJUSTMENT • If there is improper play, adjust it. • Throttle Cable Pull the rubber boot off the upper end of the throttle cable. • Loosen the locknut on the upper end of the throttle Throttle Cable Adjustment cable and turn the adjuster to obtain the specified Inspect the throttle grip for smooth operation in play.
  • Page 49 MAINTENANCE AND ADJUSTMENT • • Install the rubber boot. Pull the rubber boot off the top of the carburetor • If the free play cannot be set by adjusting the upper and make the necessary free play adjustment with cable adjuster, use the adjuster on the lower end the adjuster on the lower end of the cable.
  • Page 50: Choke Knob

    MAINTENANCE AND ADJUSTMENT • Check if the throttle grip moves smoothly from full Choke Knob open to close, and the throttle closes quickly and completely in all steering positions by the return spring. If not, check the throttle cable routing, grip Choke Knob Adjustment free play, and cable damage.
  • Page 51 MAINTENANCE AND ADJUSTMENT • • Pull the choke knob fully up and set it where the Pull the rubber boot off the adjuster, and adjust knob stops. with the adjuster so that the knob can be pushed back with a finger. A.
  • Page 52: Idle Speed

    MAINTENANCE AND ADJUSTMENT • Adjust the idling speed 1 350 a 1 450 r/min (rpm) Idle Speed by turning the idling adjusting screw. The following procedure covers the idling adjust- ment, which should be performed whenever the idle speed is disturbed. Idling Adjustment •...
  • Page 53: Clutch

    MAINTENANCE AND ADJUSTMENT If the clutch lever play cannot be adjusted at the Clutch clutch lever, make the adjustment further down the cable as follows. • Loosen the locknut at the clutch lever. Clutch Lever Adjustment • Turn the adjuster in all the way, then tighten the Proper clutch lever play is 2 a 3 mm (0.08 a 0.12 locknut.
  • Page 54: Valve Clearance

    Periodic Main- tenance Chart. Inspection and adjustment should be done only by an authorized Kawasaki dealer. NOTE If the engine is hot, wait until the engine cools. Valve clearance must be checked when the en-...
  • Page 55: Spark Arrester

    MAINTENANCE AND ADJUSTMENT • Remove the muffler end mounting bolts. Spark Arrester This vehicle is equipped with a spark arrester. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester. NOTICE The spark arrester must be installed cor- rectly and functioning properly to provide...
  • Page 56 MAINTENANCE AND ADJUSTMENT • • Take off the spark arrester mounting bolts. Remove the spark arrester. A. Spark Arrester Mounting Bolts A. Spark Arrester B. Gasket • With a wire brush, remove the carbon off the inside of the spark arrester and muffler. •...
  • Page 57: Drive Chain

    MAINTENANCE AND ADJUSTMENT Chain Slack Inspection • Drive Chain Raise the rear wheel off the ground, then rotate the rear wheel to find the place where the chain is For safety and to prevent excessive wear, the drive tightest (because it wears unevenly). •...
  • Page 58 MAINTENANCE AND ADJUSTMENT • In addition to checking the slack, rotate the rear wheel to inspect the drive chain for damaged rollers, loose pins and links and the sprockets for unevenly or excessively worn and damaged teeth. • If there are any such defects, replace the drive chain and/or the sprockets.
  • Page 59 MAINTENANCE AND ADJUSTMENT • • Tighten both chain adjuster locknuts. Measure the 20-link section on a straight part of • the chain from the center of the 1st pin to the cen- Torque the axle nut to the specified torque. ter of the 21st pin.
  • Page 60 MAINTENANCE AND ADJUSTMENT NOTE Chain Guide Wear Inspection • Visually inspect the drive chain guide and replace The drive system was designed for use with it if excessively worn or damaged. a DAIDO D.I.D 428H (KLX140A: 122-link, KLX140B: 126-link) chain. For maximum stretch resistance and safety, a genuine part must be used for replacement.
  • Page 61 MAINTENANCE AND ADJUSTMENT Chain Slipper Wear Inspection Sprocket Wear Inspection • • Visually inspect the front end of the chain slippers Visually inspect the sprocket teeth and replace the on the swingarm and replace them if worn or dam- sprocket if its teeth are worn or damaged. aged.
  • Page 62: Handlebar

    MAINTENANCE AND ADJUSTMENT Chain Lubrication Handlebar Lubrication of the drive chain is necessary after rid- ing in the rain or mud, or any time the chain appears dry. A heavy oil such as SAE90 is preferred to a To suit various riding positions, the handlebar lighter oil because it will stay on the chain longer and can be adjusted by turning the handlebar holders provide better lubrication.
  • Page 63 MAINTENANCE AND ADJUSTMENT • • Loosen the handlebar holder nuts, turn the han- Align the gap at the rear with the punch mark on dlebar holders 180°, and securely tighten the nuts. the handlebar. A. Front A. Handlebar Holders B. Handlebar Clamps B.
  • Page 64: Brakes

    MAINTENANCE AND ADJUSTMENT • Check the front brake for the proper brake effect, Brakes or no brake drag. Disc and disc pad wear is automatically compen- sated for and has no effect on the brake lever or pedal action. There are no parts on the brakes that require adjustment except brake lever position.
  • Page 65 Check for brake hose damage. defective. Have the brake checked immedi- ately by an authorized Kawasaki dealer. Brake Fluid Level Inspection (Front and Rear Reservoirs) Disc Brake Fluid...
  • Page 66 MAINTENANCE AND ADJUSTMENT • If the brake fluid in the front or rear reservoir is be- low the minimum level line, check for fluid leaks in the brake line and fill the reservoir to the maxi- mum level line. (The step inside the front and rear reservoirs indicate the maximum level.) A.
  • Page 67 (front or rear) brake caliper is less than 1 mm (0.04 in.), have both pads in the caliper replaced as a set. Pad replacement should be done by an authorized Kawasaki dealer. Usable Brake Pad Range A. Rear Reservoir B.
  • Page 68: Steering

    MAINTENANCE AND ADJUSTMENT Steering Adjustment • Steering Raise the front wheel off the ground using a jack (special tool). • The steering should always be kept adjusted so Remove the handlebar. • that the handlebar will turn freely but not have ex- Loosen the left and right front fork upper clamp cessive play.
  • Page 69 MAINTENANCE AND ADJUSTMENT • • Turn the steering stem locknut with a stem nut Install the handlebar. wrench (special tool) to obtain the proper adjust- NOTE ment. Tighten the two clamp bolts alternately two times to ensure even tightening torque. •...
  • Page 70: Front Suspension

    • Visually inspect the front fork for oil leakage, scor- ing or scratches on the outer surface of the inner tube. • If necessary, repair or replace by an authorized Kawasaki dealer. A. Inner Tube...
  • Page 71: Rear Suspension

    Visually inspect the rear shock absorber for oil leakage. • If necessary, repair or replace by an authorized Kawasaki dealer. Rear Shock Absorber Adjustment The spring preload of the shock absorber can be adjusted or the spring can be replaced with an op- tional one to suit various riding conditions.
  • Page 72 MAINTENANCE AND ADJUSTMENT NOTICE Rebound Damping Adjuster Settings Do not force the rebound and compression damping force adjusters beyond the fully seated position, or the adjusting mechanism may be damaged. Compression Damping Adjustment (KLX140B ONLY) To adjust the rear shock absorber compression damping, turn the compression damping adjuster on the gas reservoir with a standard tip screwdriver.
  • Page 73 If the spring action feels too soft or too stiff, have it adjusted by an authorized Kawasaki dealer. NOTE The installation and removal of the rear shock ab- sorber should be done by an authorized Kawasaki dealer. A. 1st (Softest) B. 2nd C. 3rd D.
  • Page 74: Wheels

    MAINTENANCE AND ADJUSTMENT Spokes and Rims Wheels The spokes on both wheels must all be securely and evenly tightened and not be allowed to loosen. Unevenly tightened or loose spokes will cause the Tire Air Pressure rim to warp, the nipples and spokes to fatigue more Tire air pressure affects traction, handling, and tire quickly, and the spokes to break.
  • Page 75 MAINTENANCE AND ADJUSTMENT Bead Protector Rim Runout There is a bead protector on the both wheels. The Set up a dial gauge on the side of the rim and bead protector prevents the tire and tube from slip- rotate the wheel to measure its axial runout. The ping on the rim and damaging the valve stem.
  • Page 76 MAINTENANCE AND ADJUSTMENT Rim Runout A. Axial Rim Runout Measurement A. Rim B. Radial Runout C. Axial Runout Rim Runout Maximum Limit Axial 2.0 mm (0.08 in.) Radial A. Radial Rim Runout Measurement...
  • Page 77: Hoses Inspection

    MAINTENANCE AND ADJUSTMENT • Check the hose are securely connected and Hoses Inspection clamps are tightened correctly. Check the brake and fuel hoses for cracks or de- terioration, and the connections for looseness in ac- cordance with the Periodic Maintenance Chart. •...
  • Page 78: Battery

    MAINTENANCE AND ADJUSTMENT Self-discharge Battery Approx. Number of Days from 100% charged to 100% discharged The battery installed in this motorcycle is a sealed Temperature Lead-Antimony Lead-Calcium type, so it is not necessary to check the battery elec- trolyte level or add distilled water. Battery Battery However, in order to maximize battery life and en-...
  • Page 79 (check with til you are ready to reinstall the battery in the mo- your Kawasaki dealer). If you will not be using the torcycle (see Battery Installation). motorcycle for longer than two weeks, the battery NOTICE should be charged using an appropriate charger.
  • Page 80 MAINTENANCE AND ADJUSTMENT • WARNING Remove the bolt and remove the seat. Lead is a toxic substance. Battery posts, ter- minals and related accessories contain lead and lead compounds. Wash hands after han- dling. Battery Removal • Remove the bolt and remove the side cover. A.
  • Page 81 MAINTENANCE AND ADJUSTMENT • Battery Installation Disconnect the cables from the battery, first from • the (–) terminal and then the (+) terminal. Place the battery in the battery case. • Install the battery holder and tighten the bolts. • Connect the red cable to the (+) terminal, and then connect the black cable to the (–) terminal.
  • Page 82: Fuse

    MAINTENANCE AND ADJUSTMENT WARNING Fuse Substituting fuses can cause wiring to over- heat, catch fire and/or fail. Do not use any The main fuse (10 A) is mounted on the starter substitute for the standard fuse. Replace the relay under the seat. If a fuse fails during operation, blown fuse with a new one of the correct ca- inspect the electrical system to determine the cause, pacity, as specified on the junction box and...
  • Page 83: Tightening Torques Of Nuts And Bolts

    MAINTENANCE AND ADJUSTMENT Tightening Torques of Nuts and Bolts Location of nuts and bolts Before the first ride of each day of operation, check the tightness of the nuts and bolts shown below. Check also that all cotter pins are in place and in good condition. 1.
  • Page 84 MAINTENANCE AND ADJUSTMENT 18. Spark Plug 26. Rear Axle Nut 19. Cylinder Head Bolts 27. Rear Brake Caliper Bolts ® 20. Muffler End Mounting Bolts 28. UNI-TRAK Lever Rod Bolt 21. Spark Arrester Mounting Bolts 29. Rear Brake Pedal Pivot Bolt 22.
  • Page 85 MAINTENANCE AND ADJUSTMENT Torque table Tighten all nuts and bolts to the proper torque using an accurate torque wrench. An insufficiently tightened nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider.
  • Page 86 MAINTENANCE AND ADJUSTMENT Part Name N·m kgf·m ft·lb Brake Caliper Bolts (Front) (Rear) Brake Disc Mounting Bolts (Front) (87 in·lb) (Rear) (87 in·lb) Engine Bracket Nut/Bolt Engine Mounting Bolts Front Axle Nut Front Fork Clamp Bolts Handlebar Clamp Bolts Side Stand Bolt Side Stand Nut Swingarm Pivot Shaft Nut 11.0...
  • Page 87 MAINTENANCE AND ADJUSTMENT Part Name N·m kgf·m ft·lb Rear Shock Absorber Lower Nut 21 (KLX140A) Rear Shock Absorbor Lower Bolt 29 (KLX140B) Spokes (18 in·lb) Steering Stem Head Nut Steering Stem Locknut (43 in·lb) ® UNI-TRAK Arm Bolt ® UNI-TRAK Rod Bolts Rear Sprocket Nuts Front Brake Master Cylinder Clamp Bolts...
  • Page 88: Cleaning Your Motorcycle

    General Precautions • Avoid all harsh chemicals, solvents, detergents, Frequent and proper care of your Kawasaki mo- and household cleaning products such as ammo- torcycle will enhance its appearance, optimize over- nia-based window cleaners. all performance, and extend its useful life. Covering •...
  • Page 89 MAINTENANCE AND ADJUSTMENT • from the detergent can damage parts of your mo- If the boot is damaged, replace it with a new one. torcycle). If the boot is not positioned in the groove correctly, • Use a soft cloth to dry your motorcycle. As you dry, replace it in the correct position.
  • Page 90 The semi-gloss finish effect may be lost when the Avoid using abrasive pads or brushes to finish is excessively rubbed. clean plastic parts, as they will damage the • If any doubt, consult an authorized Kawasaki part’s finish. dealer. Painted Surfaces Chrome and Aluminum...
  • Page 91: Lubrication

    MAINTENANCE AND ADJUSTMENT Leather, Vinyl, and Rubber Lubrication If your motorcycle has leather accessories, special care must be taken. Use a leather cleaner/treatment to clean and care for leather accessories. Washing Lubricate the areas shown in the illustrations of leather parts with detergent and water will damage this section with either motor oil or regular grease, them, shortening their life.
  • Page 92 MAINTENANCE AND ADJUSTMENT • Rear brake pedal Apply an aerosol cable lubricant with a pressure • Rear brake rod joints lubricator on all cables: • • Foot peg Clutch cable • Throttle cable • Hot starter cable Cable Lubrication...
  • Page 93 MAINTENANCE AND ADJUSTMENT Drive Chain Lubrication Apply grease to the following points: • Lubricate the drive chain after riding through rain Upper end of clutch cable • Upper end of throttle cable or on wet track, or any time that the chain appears •...
  • Page 94: Troubleshooting Guide

    TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE NOTE Fuel-air mixture incorrect • Idle adjusting screw improperly adjusted This troubleshooting guide is not exhaustive and • Air cleaner element clogged does not give every possible cause for each prob- lem listed. It is meant simply as a quick guide to Compression low assist you in troubleshooting for some of the more •...
  • Page 95 TROUBLESHOOTING GUIDE Clutch not operating smoothly – Shock absorption too hard • Tire air pressure too high Clutch slipping • Friction plate worn Shock absorption too soft • • Clutch springs weak Tire air pressure too high • Front fork spring worn Clutch doesn’t disengaging properly •...
  • Page 96: Storage

    Remove the spark plug and spray fogging oil, • Install the oil drain plugs and fill in fresh engine oil. such as Kawasaki K-Kare Fogging oil (part num- • Empty the fuel tank and the carburetor float bowl. ber K61030-002), directly into the cylinder. Kick (Fuel will deteriorate if left for a long time.)
  • Page 97: After Storage

    STORAGE • Cover the motorcycle to keep dust and dirt away After Storage from it. • Remove the plastic bag from the muffler. • Make sure the spark plug is tight. NOTE Fit the plug cap securely onto the spark plug, and pull the cap lightly to make sure that it is properly installed.
  • Page 98: Environmental Protection

    ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION Kawasaki subscribes to the guidelines of Tread Lightly! a program dedicated to protecting the great outdoors through education and fostering responsible enjoyment of public lands. When using your Kawasaki motorcycle, please follow these Tread Lightly! guidelines: Tread Lightly! ravel responsibly on designated roads and trails or in permitted areas.
  • Page 99: Wiring Diagram

  • Page 100: Your Warranty/owner Satisfaction

    You can find the warranty period in the Kawasaki Limited Warranty Certificate your Kawasaki dealer provided to you at the time of sale. The warranty does not cover the cost of regularly-scheduled maintenance. The warranty also does not apply to the normal wear of items such as tires, brake pads, transmission drive belts, chains, sprockets, etc.
  • Page 101: Your Warranty/owner Satisfaction

    Whether you do it yourself or take your vehicle to a Kawasaki dealer, be sure to record your service in the Maintenance Record section of this Owner’s Manual. Keep all receipts for the service and/or items necessary to perform the maintenance so that in the event of a failure you can document the service history.
  • Page 102: Your Warranty/owner Satisfaction

    Kawasaki dealer for inspection and diag- nosis. You can go to any Kawasaki dealer for warranty repairs. Your Kawasaki dealer will inspect your vehicle and give you the results of the inspection. The dealer will perform the repairs at no cost to you if it is determined that the problem is covered by the warranty.
  • Page 103: Your Warranty/owner Satisfaction

    YOUR WARRANTY/OWNER SATISFACTION Please send your correspondence to: Consumer Services Kawasaki Motors Corp., U.S.A. P.O. Box 25252 Santa Ana, CA 92799-5252 (949) 460-5688...
  • Page 104: Reporting Safety Defects

    If the CPSC receives similar complaints, it may open an investigation and if it finds that a safety defect exists in a group of vehicles, if may order a recall and remedy campaign. However, the CPSC cannot become involved in individual problems between you, your dealer, or Kawasaki Motors Corporation, U.S.A.
  • Page 105: Maintenance Record

    MAINTENANCE RECORD MAINTENANCE RECORD Owner Name........................... Address ............................Phone Number ..........................Engine Number ..........................Vehicle Number..........................Selling Dealer Name ........................Address ............................Phone Number ..........................Warranty Start Date ........................Note: Keep this information and a spare key in a secure location. Date Odometer Reading Maintenance Performed...
  • Page 106 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address...
  • Page 107 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address...
  • Page 108 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address...
  • Page 109 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address...
  • Page 110 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address...

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