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KLX110
KLX110L
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki KLX110

   Summary of Contents for Kawasaki KLX110

  • Page 1 KLX110 KLX110L Motorcycle Service Manual...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive 10 j Brakes 11 j Suspension 12 j Steering 13 j Frame 14 j Electrical System 15 j Appendix 16 j This quick reference guide will assist...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower pound(s) per square BTDC before top dead center inch °C degree(s) Celsius revolution direct current...
  • Page 7: How To Use This Manual

    NOTE maintenance. • ○ NOTE indicates information that may help Use proper tools and genuine Kawasaki Mo- or guide you in the operation or service of torcycle parts. Special tools, gauges, and the vehicle. testers that are necessary when servicing Kawasaki motorcycles are introduced by the •...
  • Page 9 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-12...
  • Page 10: General Information

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 11 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
  • Page 12 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 13 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 14 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 15: Model Identification

    GENERAL INFORMATION 1-7 Model Identification KLX110CA Left Side View KLX110CA Right Side View Frame Number Engine Number...
  • Page 16 1-8 GENERAL INFORMATION Model Identification KLX110DA Left Side View KLX110DA Right Side View...
  • Page 17: General Specifications

    GENERAL INFORMATION 1-9 General Specifications KLX110CA ∼ CE, KLX110DA ∼ DE Items Dimensions Overall Length 1 560 mm (61.42 in.) Overall Width 650 mm (25.59 in.) Overall Height: KLX110C 955 mm (37.60 in.) KLX110D 990 mm (38.98 in.) Wheelbase 1 075 mm (42.32 in.) Road Clearance: KLX110C 215 mm (8.46 in.)
  • Page 18 1-10 GENERAL INFORMATION General Specifications KLX110CA ∼ CE, KLX110DA ∼ DE Items Valve Timing: Inlet: Open 25° BTDC Close 55° ABDC Duration 260° Exhaust: Open 60° BBDC Close 20° ATDC Duration 260° Lubrication System Forced lubrication (wet sump) Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity...
  • Page 19 GENERAL INFORMATION 1-11 General Specifications KLX110CA ∼ CE, KLX110DA ∼ DE Items Front Tire: Size 2.50-14 4P.R. Make/Type IRC, GS-45F, Tube Rear Tire: Size 3.00-12 4P.R. Make/Type IRC, GS-45F, Tube Rim Size: Front 14 × 1.40 Rear 12 × 1.60 Front Suspension: Type Telescopic fork...
  • Page 20: Unit Conversion Table

    1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 21: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Sprocket Wear Inspection.... 2-27 Torque and Locking Agent....Rear Sprocket Warp Inspection ... 2-27 Specifications ........Drive Chain Guide and Slipper Special Tools ........2-10 Wear Inspection ......2-27 Periodic Maintenance Procedures..
  • Page 22: Periodic Maintenance Chart

    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. Periodic Inspection FREQUENCY Initial Every hours(month (s)) Page OPERATION (12) • • Spark plug - clean and inspect † 2-36 •...
  • Page 23 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Initial Every hours (month (s)) Page OPERATION (12) • • • Engine oil - change 2-19 • • Oil filter - replace 2-20 Fuel hose - replace Every 5 years 2-14 •...
  • Page 24: Torque And Locking Agent

    2-4 PERIODIC MAINTENANCE Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening toque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.
  • Page 25: Periodic Maintenance

    PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Clutch Primary Clutch Hub Nut (KLX110C) Secondary Clutch Hub Nut (KLX110C) Clutch Hub Nut (KLX110D) Primary Gear Nut (KLX110D) Clutch Spring Bolts 0.51 44 in·lb Oil Seal Retaining Plate Screws 0.30 26 in·lb Clutch Adjusting Screw Locknut (KLX110C)
  • Page 26 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Brake Pedal Bolt 0.90 78 in·lb Suspension Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) Steering Stem Nut 0.50 43 in·lb Steering Stem Head Nut Swingarm Pivot Nut Torque Link Nuts Fork Bottom Bolt...
  • Page 27 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Basic Torque for General Fasteners Threads dia. Torque (mm) N·m kgf·m ft·lb 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb 14 ∼ 19 1.4 ∼...
  • Page 28: Specifications

    2-8 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – 1 600 ∼ 1 700 r/min (rpm) Idle Speed – – – Air Cleaner Element Oil High quality foam air filter oil –...
  • Page 29 – – – 80° ∼ 90° Rear – – – Suspension Front Fork Suspension Oil Kawasaki SS-8 or equivalent – – – Amount: KLX110C 165 ±2.5 mL (5.58 ±0.085 US oz) KLX110D 182 ±2.5 mL (5.71 ±0.085 US oz) – – –...
  • Page 30: Special Tools

    2-10 PERIODIC MAINTENANCE Special Tools Steering Stem Nut Wrench: Spark Plug Wrench, Hex 16: 57001-1100 57001-1262 Valve Adjusting Screw Holder: Fork Oil Level Gauge: 57001-1217 57001-1290 Jack: Filler Cap Driver: 57001-1238 57001-1454...
  • Page 31: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures Fuel System Fuel Hose and Connection Inspection ○ The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [A] or the hose to burst.
  • Page 32: Idle Speed Inspection

    2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the throttle grip free play cannot be adjusted with the adjuster at the upper end of the throttle cable, use the lower cable adjuster at the carburetor. • Remove the shroud (see Shroud Removal in the Frame chapter).
  • Page 33: Idle Speed Adjustment

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Idle Speed Adjustment NOTICE The pilot screw [A] is set at the factory and should not be adjusted. But if necessary, set the pilot screw as follows: NOTE ○ For US and CA models, the pilot screw cannot be ad- justed.
  • Page 34: Fuel Hose Replacement

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or flame any- where near the working areas. Do not use gasoline or low flash-point solvents to clean the element.
  • Page 35: Fuel Tap Cleaning

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Fuel Hose [A] • Replace the fuel hose with a new one. • Fix the both ends of the fuel hose with the clamps [A] securely.
  • Page 36: Engine Top End

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Valve Adjusting Covers [A] (see Camshaft Sprocket Re- moval in the Engine Top End chapter) Camshaft Sprocket Cover [B] (see Rocker Arm Removal in the Engine Top End chapter) •...
  • Page 37: Spark Arrester Cleaning

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Spark Arrester Cleaning This vehicle is equipped with a spark arrester. It must be properly maintained to ensure its efficiency. NOTICE The spark arrester must be installed correctly and functioning properly to provide adequate fire pro- tection.
  • Page 38: Clutch Release Adjustment (klx110c)

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Release Adjustment (KLX110C) • Loosen the adjusting screw locknut [A]. • Turn the adjusting screw [B] counterclockwise until it be- comes hard to turn. • Loosen the adjusting screw until the specified value. Clutch Release: 1/4 turn out •...
  • Page 39: Friction And Steel Plates Inspection

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Friction and Steel Plates Inspection • Remove the clutch plates (see Secondary Clutch Disassembly (KLX110C) or Clutch Hub Disassembly (KLX110D) in the Clutch chapter). • Visually inspect the friction and steel plates to see if they show any signs of seizure, or uneven wear.
  • Page 40: Oil Filter Replacement

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during oil change. • Place an oil pan beneath the engine. •...
  • Page 41: Wheel/tires

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Replace the oil filter [A] with a new one. • Apply engine oil to the grommet [B]. • Be sure to install the filter with the grommet facing inside. NOTICE Inside out installation stops oil flow, causing engine seizure.
  • Page 42: Tires Inspection

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tires Inspection As the tire tread wears down, the tire becomes more sus- ceptible the puncture and failure. • Remove any imbedded stones or other foreign particles from the tread. • Visually inspect the tire for cracks and cuts, replacing the tire in case of bad damage.
  • Page 43: Rim Runout Inspection

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Rim Runout Inspection • Place the jack under the frame so that the front/rear wheel off the ground. Special Tool - Jack: 57001-1238 • Inspect the rim for small cracks, dents, bending, or warp- ing.
  • Page 44: Final Drive

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Drive Chain Slack Inspection • Raise the rear wheel off the ground, rotate the rear wheel to find the place where the chain is tightest (because it wears unevenly). • Check the wheel alignment (see Wheel Alignment Inspec- tion in the Final Drive chapter), and adjust it if necessary (see Drive Chain Slack Adjustment).
  • Page 45: Drive Chain Wear Inspection

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Tighten both chain adjuster locknuts securely. • Tighten the axle nut. Torque - Rear Axle Nut: 64 N·m (6.5 kgf·m, 47 ft·lb) • Rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary.
  • Page 46: Drive Chain Lubrication

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Stretch the chain taut by hanging a 10 kg (20 lb) weight [A] on the chain. • Measure the length of 20 links [B] on the straight part [C] of the chain from the pin center of the 1st pin to the pin center of the 21st pin.
  • Page 47: Sprocket Wear Inspection

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Sprocket Wear Inspection • Visually inspect the front and rear sprocket teeth for wear and damage. If they are worn as illustrated or damaged, replace the sprocket. [A] Worn Tooth (Engine Sprocket) [B] Worn Tooth (Rear Sprocket) [C] Direction of Rotation NOTE ○...
  • Page 48: Brake Lever Free Play Adjustment

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Lever Free Play Adjustment • Slide the brake lever dust cover [A] out of place. • Loosen the locknut [B] and turn the adjuster [C] so that the brake lever will have 4 ∼ 5 mm (0.16 ∼ 0.20 in.) of play.
  • Page 49: Brake Pedal Free Play Adjustment

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Brake Pedal Free Play Adjustment • Turn the adjusting nut [A] at the brake cam lever so that the pedal has proper play. • Operate the pedal a few times to see that it returns to its rest position immediately upon release.
  • Page 50: Cam Lever Angle Inspection

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Shoe Lining Thickness [A] Standard: 2.10 ∼ 3.00 mm Front (0.08 ∼ 0.12 in.) 3.85 ∼ 4.15 mm Rear (0.152 ∼ 0.163 in.) (When the wear indicator is within the USABLE RANGE.) Service limit: Front 1.2 mm (0.05 in.) Rear...
  • Page 51 PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures • Before removing the cam lever [A], mark the position [B] of the cam lever. • Remove the brake cam lever bolt [C] and nut [D], and then pull out the brake cam lever from the brake camshaft. •...
  • Page 52: Brake Panel Lubrication

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Panel Lubrication • Disassemble the brake panel (see Brake Panel Disas- sembly in the Brakes chapter). • Clean all old grease out of the brake parts with a cloth. • Apply high-temperature grease to the following. Brake Shoe Anchor Pin [A] Spring Ends [B] Cam Surfaces [C]...
  • Page 53: Rear Shock Absorber Operation Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Drain the fork oil [A] with the fork upside down. NOTE ○ Pump the fork tube several times to discharge the oil. • Pour in the specified type and amount of oil. Suspension Oil - SS-8 (1 L): 44091-0007 Fork Oil Amount: KLX110C Models 165 ±2.5 mL (5.58 ±0.085 US oz) KLX110D Models 182 ±2.5 mL (5.71 ±0.085 US oz)
  • Page 54: Swingarm Pivot Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Swingarm Pivot Inspection • Raise the rear wheel off the ground with the jack. Special Tool - Jack: 57001-1238 • Move the swingarm [A] side to side to check for worn, damaged or loose suspension pivot components. If any play is detected, check for looseness of swingarm pivot shaft nut or for damage to the swingarm rubber bushings.
  • Page 55: Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures • Loosen the front fork upper clamp bolts [A], and remove the steering stem head nut [B] and steering stem head [C]. • Turn the steering stem nut [A] with the steering stem nut wrench [B] to obtain the proper adjustment.
  • Page 56: Frame

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Frame Frame Inspection • Clean the frame with steam cleaner. • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident resulting in injury or death.
  • Page 57: Battery Charging Condition Inspection

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Measure the gap [A] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap. Spark Plug Gap 0.6 ∼ 0.7 mm (0.024 ∼ 0.028 in.) Standard: •...
  • Page 58: Cable Inspection

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that the battery terminals are not corroded. If necessary, remove the battery (see Battery Removal in the Electrical System chapter) and clean the terminals and cable ends using a solution of baking soda and water. •...
  • Page 59: Nut, Bolt, And Fastener Tightness Inspection

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • With the cable disconnected at the both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
  • Page 60 2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes: Rear Brake Adjust Nut Brake Lever Pivot Bolt Brake Pedal Bolt Torque Link Nuts Torque Link Nut Cotter Pins Suspension: Front Fork Clamp Bolts Rear Shock Absorber Mounting Bolts, Nuts Swingarm Pivot Nut Steering: Steering Stem Head Nut Handlebar Holder Bolts...
  • Page 61 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Throttle Grip and Cable ......................Free Play Inspection ......................Free Play Adjustment......................Throttle Cable Replacement ..................... Throttle Cable Lubrication....................Throttle Cable Inspection ....................Choke Cable Removal ...................... Choke Cable Installation ....................
  • Page 62: Exploded View

    3-2 FUEL SYSTEM Exploded View...
  • Page 63: Exploded View

    FUEL SYSTEM 3-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Carburetor Holder Bolts 0.53 46 in·lb Throttle Cable Housing Cap Screws 0.06 5.3 in·lb 3. Throttle Cable 4. Choke Cable 5. Throttle Grip 6. Carburetor Cap 7. Retainer 8. Circlip 9.
  • Page 64 3-4 FUEL SYSTEM Exploded View...
  • Page 65 FUEL SYSTEM 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Cover Screws 0.15 13 in·lb Air Cleaner Housing Bolts 0.36 31 in·lb Air Duct Clamp Screw 0.20 18 in·lb Fuel Tap Mounting Bolts 0.45 39 in·lb Screw (for Seat Hook) 0.51 44 in·lb Screw (for Rubber Band Hook)
  • Page 66: Specifications

    3-6 FUEL SYSTEM Specifications Item Standard Throttle Grip and Cable 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play Carburetor Make/Type KEIHIN PB18 1 600 ∼ 1 700 r/min (rpm) Idle Speed Main Jet Main Air Jet #180 Jet Needle NCFA...
  • Page 67: Special Tool

    FUEL SYSTEM 3-7 Special Tool Fuel Level Gauge: 57001-1017...
  • Page 68: Throttle Grip And Cable

    3-8 FUEL SYSTEM Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment, there will be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle.
  • Page 69: Throttle Cable Lubrication

    FUEL SYSTEM 3-9 Throttle Grip and Cable • Lubricate the cable. • Apply grease to the tips of the cables. • Insert the throttle valve assembly. • Run the throttle cable in accordance with the Cable, Wire and Hose Routing section in the Appendix chapter. •...
  • Page 70: Choke Cable Installation

    3-10 FUEL SYSTEM Throttle Grip and Cable Choke Cable Installation • Installation is the reverse of removal. • Install the choke cable in accordance with the Cable, Wire and Hose Routing section in the Appendix chapter. • After the installation, adjust the cable properly. WARNING Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe...
  • Page 71: Carburetor

    FUEL SYSTEM 3-11 Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carbure- tor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble can be caused by dirt, wear, maladjustment or improper fuel level in the float chamber.
  • Page 72: Float Height Inspection

    3-12 FUEL SYSTEM Carburetor • Check the fuel level in the gauge. Service Fuel Level (below the bottom edge of the carburetor body) Standard: 3.0 ± 1 mm (0.12 ± 0.04 in.) • Screw the carburetor drain plug. • Turn the fuel tap to the OFF position and remove the fuel level gauge.
  • Page 73: Carburetor Removal

    FUEL SYSTEM 3-13 Carburetor Float Bowl Mating Surface [A] Float Valve Needle Rod (contacted but unloaded) [B] Float [C] Float Height [D] NOTE ○ Measure the height with the carburetor upside down. ○ Do not push the needle rod in during the float height measurement.
  • Page 74: Carburetor Installation

    3-14 FUEL SYSTEM Carburetor Carburetor Installation • Installation is the reverse of removal. • Fit the slit [A] and the projection [B], and insert the throttle valve assembly [C] into the carburetor body. • Replace the O-ring with a new one. •...
  • Page 75: Carburetor Cleaning

    FUEL SYSTEM 3-15 Carburetor • Remove the following parts from the carburetor body. Idle Adjusting Screw [A] O-ring [B] Spring [C] Pilot Screw [D] Washer [E] Spring [F] O-ring [G] O-ring [H] Pilot Jet [A] Needle Jet [B] Needle Jet Holder [C] Main Jet [D] Float Valve Needle [E] Float [F]...
  • Page 76: Carburetor Inspection

    3-16 FUEL SYSTEM Carburetor • Immerse all the metal parts in carburetor cleaning solu- tion. • Rinse the parts in water. • After the parts are cleaned, dry them with compressed air. • Blow through the air and fuel passages with compressed air.
  • Page 77 FUEL SYSTEM 3-17 Carburetor • Remove the float valve needle. • Check the float valve needle [A]. If the needle is worn [B] as shown in the figure, replace the valve needle. • Push the rod [C] in the valve needle, and then release it [D].
  • Page 78: Carburetor Assembly

    3-18 FUEL SYSTEM Carburetor Carburetor Assembly • Clean the disassembly parts before assembling. • Clean the fuel and air passages with high flash-point sol- vent and compressed air. • Install the needle jet [A] into the carburetor so that the smaller diameter end [B] of the jet goes in first.
  • Page 79: Air Cleaner

    FUEL SYSTEM 3-19 Air Cleaner Air Cleaner Housing Removal • Remove the shroud (see Shroud Removal in the Frame chapter). • Loosen the clamp screw [A] and pull out the air cleaner duct [B] from the carburetor. • Remove the air cleaner housing mounting bolts [A]. •...
  • Page 80: Air Cleaner Element Installation

    3-20 FUEL SYSTEM Air Cleaner Air Cleaner Element Installation • Installation is the reverse of removal. • When installing the element, coat the lip of the element with a thick layer of all purpose grease [A] to assure a complete seal against the air cleaner element base. Also, coat the base where the lip of the element fits.
  • Page 81: Fuel Tank

    FUEL SYSTEM 3-21 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 82: Fuel Tap Removal

    3-22 FUEL SYSTEM Fuel Tank Fuel Tap Removal • Remove the fuel tank (see Fuel Tank Removal). • Drain the fuel. • Remove the mounting bolts [A] and take off the fuel tap [B]. Fuel Tap Installation • Replace the O-ring [A] with a new one. •...
  • Page 83 FUEL SYSTEM 3-23 Fuel Tank • Turn the fuel tap to the OFF position. • Place a suitable container beneath the carburetor drain hose [A]. • Loosen the drain plug [B] from the bottom of the float bowl and check for water or dirt in the fuel. If any water or dirt comes out, clean the carburetor, fuel filter, fuel tap and fuel tank.
  • Page 85 ENGINE TOP END 4-1 Engine Top End Table of Contents Exploded View........Valve Removal ......4-23 Specifications ........Valve Installation ......4-23 Special Tools ........Valve Guide Removal ....4-24 Camshaft Chain Tensioner ....4-10 Valve Guide Installation ....4-24 Camshaft Chain Tensioner Valve Seat Inspection ....
  • Page 86: Exploded View

    4-2 ENGINE TOP END Exploded View...
  • Page 87 ENGINE TOP END 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Valve Adjusting Cap Bolts 0.53 46 in·lb Cylinder Head Bolts 106 in·lb S, L Cylinder Head Nuts Rocker Shaft Holder Plate Bolts 0.53 46 in·lb (KLX110CA/DA Early Models) Rocker Shaft Holder Plate Bolts 0.53 46 in·lb...
  • Page 88 4-4 ENGINE TOP END Exploded View...
  • Page 89 ENGINE TOP END 4-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Chain Tensioner Cap Bolt 0.53 46 in·lb Camshaft Chain Tensioner Mounting Bolts 0.53 46 in·lb Muffler Cover Screws 0.31 27 in·lb Exhaust Pipe Holder Nuts Muffler Mounting Bolt 87 in·lb Muffler Mounting Nut Spark Arrester Mounting Bolts...
  • Page 90: Specifications

    4-6 ENGINE TOP END Specifications Item Standard Service Limit Rocker Arm, Rocker Arm Shaft 10.000 ∼ 10.015 mm (0.3937 ∼ 0.3943 in.) 10.05 mm (0.396 in.) Rocker Arm Inside Diameter 9.980 ∼ 9.995 mm (0.3929 ∼ 0.3935 in.) Rocker Arm Shaft Diameter 9.95 mm (0.392 in.) Camshaft Cam Height:...
  • Page 91 ENGINE TOP END 4-7 Specifications Item Standard Service Limit Cylinder, Piston 52.997 ∼ 53.009 mm (2.0865 ∼ 2.0870 in.) 53.10 mm (2.0905 Cylinder Inside Diameter in.) 52.969 ∼ 52.981 mm (2.0854 ∼ 2.0859 in.) 52.82 mm (2.080 in.) Piston Diameter 0.010 ∼...
  • Page 92: Special Tools

    4-8 ENGINE TOP END Special Tools Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30: 57001-221 57001-1123 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Piston Pin Puller Assembly: Valve Spring Compressor Adapter, 20: 57001-910 57001-1154 Valve Seat Cutter, 45°...
  • Page 93 ENGINE TOP END 4-9 Special Tools Valve Seat Cutter, 67.5° - 22: Valve Guide Arbor, 4.5: 57001-1207 57001-1331 Compression Gauge Adapter, M10 × 1.0: Valve Guide Reamer, 4.5: 57001-1317 57001-1333 Valve Seat Cutter Holder, 4.5: Filler Cap Driver: 57001-1330 57001-1454...
  • Page 94: Camshaft Chain Tensioner

    4-10 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up cam chain slack. Ob- serve all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 95: Camshaft Chain Tensioner Installation

    ENGINE TOP END 4-11 Camshaft Chain Tensioner Camshaft Chain Tensioner Installation • Remove the tensioner cap bolt and O-ring. • While compressing the push rod [A], turn it clockwise [B] with a standard tip screwdriver until the rod protrusion comes to about 10 mm (0.4 in.) from the tensioner body. NOTICE Do not turn the rod counterclockwise at installation.
  • Page 96: Camshaft

    4-12 ENGINE TOP END Camshaft Camshaft Removal • Remove the rocker arms (see Rocker Arm Removal). • Pull out the camshaft [A]. Camshaft Installation • Clean the camshaft with high flash-point solvent. • Apply clean engine oil to all cam parts. •...
  • Page 97: Kacr Installation

    Camshaft Sprocket Bolts Camshaft Sprocket Cover KACR Inspection The Kawasaki Automatic Compression Release (KACR) momentarily opens the valve on the compression stroke at very low speed. This allows some of the compression pres- sure to escape, making it easy to turn over the engine during starting.
  • Page 98: Camshaft Sprocket Removal

    4-14 ENGINE TOP END Camshaft Camshaft Sprocket Removal • Remove: Camshaft Sprocket Cover Bolts [A] Camshaft Sprocket Cover [B] • Remove the timing inspection cap [A] and rotor nut cap [B]. Special Tool - Filler Cap Driver [C]: 57001-1454 • Turn the alternator rotor nut counterclockwise and align the “T”...
  • Page 99: Camshaft Sprocket Installation

    ENGINE TOP END 4-15 Camshaft • Use a suitable tool [A] or wire to keep the chain [B] from falling down into the cylinder block. NOTICE Always pull the camshaft chain taut while turning the crankshaft when the camshaft chain is loose. This avoids kinking the chain on the lower (crank- shaft) sprocket.
  • Page 100: Camshaft Chain Removal

    4-16 ENGINE TOP END Camshaft • Apply grease to the new O-ring [A] and install the camshaft sprocket cover [B]. • Tighten: Torque - Camshaft Sprocket Cover Bolts [C]: 5.2 N·m (0.53 kgf·m, 46 in·lb) NOTICE Rotation of the crankshaft with improper camshaft timing could cause the valve to contact each other or the piston, and bend.
  • Page 101: Camshaft Chain Installation

    ENGINE TOP END 4-17 Camshaft Camshaft Chain Installation • Install the camshaft chain to the crankshaft, and pull up it through camshaft chain hole of the cylinder. • Keep the chain. • Install the camshaft chain holder. • Tighten: Torque - Camshaft Chain Plate Screws [A]: 5.2 N·m (0.53 kgf·m, 46 in·lb) •...
  • Page 102: Rocker Arm, Rocker Arm Shaft

    4-18 ENGINE TOP END Rocker Arm, Rocker Arm Shaft Rocker Arm Removal • Remove: Camshaft Sprocket (see Camshaft Sprocket Removal) Valve Adjusting Cover Bolts [A] Valve Adjusting Covers [B] • Remove: Rocker Shaft Holder Plate Bolts [A] Rocker Shaft Holder Plate Stopper [B] •...
  • Page 103: Rocker Arm & Arm Shaft Wear Inspection

    ENGINE TOP END 4-19 Rocker Arm, Rocker Arm Shaft Rocker Arm & Arm Shaft Wear Inspection • Visually inspect the area on the rocker arm where the cam rubs. If there is any damage or uneven wear, replace the rocker arm.
  • Page 104: Cylinder Head

    4-20 ENGINE TOP END Cylinder Head Compression Measurement • Warm up the engine thoroughly. • Stop the engine. • Remove the spark plug (see Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter). • Attach compression gauge and adapter firmly into the spark plug hole.
  • Page 105: Cylinder Head Removal

    ENGINE TOP END 4-21 Cylinder Head Cylinder Head Removal • Remove: Muffler (see Muffler Removal) Oil Pipe (see Oil Pipe Removal in the Engine Lubrication System chapter) Spark Plug Cap [A] Intake Pipe Bolts [B] Insulator • Remove: Camshaft Sprocket (see Camshaft Sprocket Removal) Clamp [A] (KLX110D Models) •...
  • Page 106: Cylinder Head Cleaning

    4-22 ENGINE TOP END Cylinder Head Cylinder Head Cleaning • Scrape out any carbon, and wash the head with high flash -point solvent. Cylinder Head Warp Inspection • Lay a straightedge across the lower surface of the cylinder head at several positions. •...
  • Page 107: Valves

    ENGINE TOP END 4-23 Valves Valve Clearance Inspection • Refer to Valve Clearance Inspection in the Periodic Main- tenance chapter. Valve Clearance Adjustment • Refer to Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove: Cylinder Head (see Cylinder Head Removal) Camshaft (see Camshaft Removal) •...
  • Page 108: Valve Guide Removal

    4-24 ENGINE TOP END Valves Valve Guide Removal • Remove: Valve (see Valve Removal) Valve Stem Oil Seal • Heat the area around the valve guide to 120 ∼ 150°C (248 ∼ 302°F). NOTICE Do not heat the cylinder head with a torch. This will warp the cylinder head.
  • Page 109: Valve Seat Inspection

    ENGINE TOP END 4-25 Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seat surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 110: Valve Seat Repair

    4-26 ENGINE TOP END Valves Valve Seat Repair • Repair the valve seat with the valve seat cutters. Special Tools - Valve Seat Cutter Holder, 4.5: 57001-1330 Valve Seat Cutter Holder Bar: 57001-1128 Inlet Special Tools - Valve Seat Cutter, 45° - 27.5: 57001-1114 Valve Seat Cutter, 32°...
  • Page 111 ENGINE TOP END 4-27 Valves Operating Procedures • Clean the seat area carefully. • Coat the seat with machinist’s dye. • Fit a 45° cutter [A] to the holder [B] and slide it into the valve guide. • Press down lightly on the handle [C] and turn it right or left.
  • Page 112 4-28 ENGINE TOP END Valves If the outside diameter of the seating surface is too large, make the 32° grind described below. If the outside diameter [A] of the seating surface is within the specified range, measure the seat width as described below.
  • Page 113: Valve Head Thickness Inspection

    ENGINE TOP END 4-29 Valves • Lap the valve to the seat using a lapper, once the seat width and outside diameter are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head.
  • Page 114: Valve Stem Diameter Inspection

    4-30 ENGINE TOP END Valves Valve Stem Diameter Inspection • Measure the diameter of the valve stem. Valve Stem Diameter [A] Standard: Exhaust valve 4.462 ∼ 4.472 mm (0.1757 ∼ 0.1761 in.) 4.475 ∼ 4.490 mm (0.1762 ∼ 0.1768 in.) Inlet valve Service Limit: Exhaust valve 4.44 mm (0.1748 in.)
  • Page 115 ENGINE TOP END 4-31 Valves • Repeat the measurement in a direction at a right angle to the first. If the reading exceeds the service limit, replace the guide. NOTE ○ The reading is not actual valve/valve guide clearance because the measuring point is above the guide.
  • Page 116 4-32 ENGINE TOP END Valves...
  • Page 117: Cylinder, Piston

    ENGINE TOP END 4-33 Cylinder, Piston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Lower Camshaft Chain Guide [A] • Tap the cylinder [B] lightly with a plastic mallet to separate from the crankcase. • Remove the cylinder base gasket. Cylinder Installation NOTE ○...
  • Page 118: Piston Removal

    4-34 ENGINE TOP END Cylinder, Piston Piston Removal • Remove the cylinder (see Cylinder Removal). • Wrap a clean cloth around the base of the piston. • Use the plier [A] and remove the snap ring [B]. • Remove the piston by pushing the piston pin and pulling it out.
  • Page 119: Cylinder Inside Diameter Measurement

    ENGINE TOP END 4-35 Cylinder, Piston NOTE ○ If a new piston is used, check piston to cylinder clear- ance (see Piston/Cylinder Clearance Inspection), and use new piston rings. • Install the piston so that the “EX” mark [A] on the piston toward exhaust side.
  • Page 120: Piston/cylinder Clearance Inspection

    4-36 ENGINE TOP END Cylinder, Piston Piston/Cylinder Clearance Inspection The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measure- ments and then computing the difference between the two values. Measure the piston diameter as just described, and measure the cylinder diameter at the very bottom of the cylinder.
  • Page 121: Piston Ring End Gap Inspection

    ENGINE TOP END 4-37 Cylinder, Piston Piston Ring End Gap Inspection • Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...
  • Page 122: Piston, Piston Pin, Connecting Rod Wear Inspection

    4-38 ENGINE TOP END Cylinder, Piston Piston Ring/Groove Clearance Standard: 0.020 ∼ 0.060 mm (0.0008 ∼ 0.0024 in.) 0.010 ∼ 0.050 mm (0.0004 ∼ 0.0020 in.) Second Service Limit: 0.16 mm (0.0063 in.) Second 0.15 mm (0.0059 in.) Piston Ring Thickness Standard: 0.77 ∼...
  • Page 123: Piston, Piston Pin, Connecting Rod Inspection

    ENGINE TOP END 4-39 Cylinder, Piston Piston, Piston Pin, Connecting Rod Inspection • Measure the inside diameter of both piston pin holes in the piston. Piston Pin Hole Inside Diameter [A] 13.001 ∼ 13.007 mm (0.5118 ∼ 05121 in.) Standard: Service Limit: 13.08 mm (0.515 in.) If either piston pin hole diameter exceeds the service limit, replace the piston.
  • Page 124: Muffler

    4-40 ENGINE TOP END Muffler Muffler Removal • Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) Screws [A] Exhaust Pipe Covers [B] • Remove the exhaust pipe holder nuts [A]. • Remove the muffler mounting nut [A] and bolt [B]. •...
  • Page 125: Muffler Installation

    ENGINE TOP END 4-41 Muffler Muffler Installation • Installation is the reverse of removal; note the following. • Replace the gasket with a new one. • Tighten: Torque - Exhaust Pipe Holder Nuts: 16 N·m (1.6 kgf·m, 12 ft·lb) • Replace the muffler mounting nut [B] with a new one.
  • Page 127 CLUTCH 5-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Clutch Lever and Cable (KLX110D) ..................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication and Inspection ................Clutch Cover (KLX110C) ......................
  • Page 128: Exploded View

    5-2 CLUTCH Exploded View KLX110C Models...
  • Page 129 CLUTCH 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cover Bolts 78 in·lb Oil Seal Retaining Plate Screws 26 in·lb Primary Clutch Hub Nut Clutch Spring Bolts 0.51 44 in·lb Secondary Clutch Hub Nut Clutch Adjusting Screw Locknut EO: Apply engine oil.
  • Page 130 5-4 CLUTCH Exploded View KLX110D Models...
  • Page 131 CLUTCH 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cover Bolts 78 in·lb Clutch Hub Nut Primary Gear Nut CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. R: Replacement Parts...
  • Page 132: Specifications

    5-6 CLUTCH Specifications Item Standard Service Limit Clutch (KLX110C) Primary Clutch: 104.0 ∼ 104.2 mm (4.094 ∼ 4.102 in.) Primary Clutch Housing 104.5 mm (4.114 in.) Inside Diameter Primary Clutch Shoe Groove 1.0 mm (0.04 in.) 0.5 mm (0.02 in.) Depth Secondary Clutch: 3.1 ∼...
  • Page 133: Special Tools

    CLUTCH 5-7 Special Tools Bearing Driver Set: Clutch Holder 2: 57001-1129 57001-1508 Clutch Holder 1: Gear Holder: 57001-1507 57001-1602...
  • Page 134: Clutch Lever And Cable (klx110d)

    5-8 CLUTCH Clutch Lever and Cable (KLX110D) Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns.
  • Page 135: Clutch Cover (klx110c)

    CLUTCH 5-9 Clutch Cover (KLX110C) Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the kick pedal (see Kick Pedal Removal in the Crankshaft/Transmission chapter). ○ When the clutch cove is to be disassembled, loosen the clutch adjuster locknut [A] before clutch cover removal.
  • Page 136: Clutch Cover Assembly

    5-10 CLUTCH Clutch Cover (KLX110C) • Remove the screws [A] and plate [B]. • Take the oil seal [C] out of the cover with a hook. Clutch Cover Assembly • Replace the O-ring and the oil seal with new ones. •...
  • Page 137: Clutch Cover (klx110d)

    CLUTCH 5-11 Clutch Cover (KLX110D) Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the kick pedal (see Kick Pedal Removal in the Crankshaft/Transmission chapter). • Remove the clutch cover bolts [A]. •...
  • Page 138: Release Shaft Installation

    5-12 CLUTCH Clutch Cover (KLX110D) Release Shaft Installation • Installation is the reverse of removal. • Apply grease to the new oil seal lips. • Press in the oil seal [A] until it bottoms out.
  • Page 139: Clutch Removal (klx110c)

    CLUTCH 5-13 Clutch Clutch Removal (KLX110C) • Remove the clutch cover (see Clutch Cover Removal). • Pull out the clutch release lever [A]. • Remove: Release Ball Assembly [B] Release Cam [C] Ball Bearing [D] Ball Bearing Holder [E] • Loosen the primary clutch hub nut while holding the pri- mary clutch steady with the gear holder.
  • Page 140: Secondary Clutch Disassembly (klx110c)

    5-14 CLUTCH Clutch • Remove: Collar [A] Spacer [B] Secondary Clutch Disassembly (KLX110C) • Remove the secondary clutch (see Clutch Removal). • Unscrew the clutch spring bolts [A] and take off the spring plate [B] and springs [C]. • Remove the clutch hub [A] and clutch wheel [B]. •...
  • Page 141: Clutch Installation (klx110c)

    CLUTCH 5-15 Clutch • Install the clutch wheel on the clutch hub. • Install the clutch spring plate [A] with the springs and spring bolts temporarily and fit the clutch hub and plate assembly into the clutch housing [B]. • Install the last friction plate [A] fitting the tangs in the grooves on the housing as shown.
  • Page 142: Clutch Removal (klx110d)

    5-16 CLUTCH Clutch If the one-way clutch and race dropped from the primary clutch housing, install it as follows. ○ Put the one-way clutch [A] in the clutch housing halfway with the rotation mark [B] facing out. ○ Fit the race [C] into the one-way clutch with the machin- ing unevenness side facing outside.
  • Page 143 CLUTCH 5-17 Clutch • Loosen the clutch hub nut while holding the clutch steady with the gear holder. Special Tool - Gear Holder: 57001-1602 NOTE ○ If the clutch hub nut is difficult to loosen using a gear holder (57001-1602), use the clutch holder 2 (57001 -1508).
  • Page 144: Clutch Hub Disassembly (klx110d)

    5-18 CLUTCH Clutch Clutch Hub Disassembly (KLX110D) • Separate the clutch hub assembly from the clutch hous- ing. • Remove: Clutch Spring Bolts [A] Clutch Spring Plate [B] Clutch Springs [C] Clutch Holder [D] Friction Plates [E] Steel Plates [F] Friction Plates [G] Clutch Hub Assembly (KLX110D) •...
  • Page 145: Primary Clutch Housing Wear Inspection (klx110c)

    CLUTCH 5-19 Clutch • Tighten the clutch hub nut while holding the clutch steady with the gear holder. Special Tool - Gear Holder: 57001-1602 NOTE ○ If the clutch hub nut is difficult to tighten using a gear holder (57001-1602), use the clutch holder 2 (57001 -1508).
  • Page 146: One-way Clutch Inspection (klx110c)

    5-20 CLUTCH Clutch • Measure the groove depth [A]. ○ Use a depth gauge, and measure at several points as shown. If any measurement is less than the service limit, replace the primary clutch hub. Primary Clutch Shoe Groove Depth Standard: 1.0 mm (0.04 in.) Service Limit:...
  • Page 147: Clutch Housing Finger Damage Inspection

    CLUTCH 5-21 Clutch Clutch Housing Finger Damage Inspection • Visually inspect the clutch housing fingers [A] where the friction plate tangs [B] hit them. If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged.
  • Page 149 ENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools .......................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Change ....................... Oil Screen Cleaning ......................Oil Pump..........................
  • Page 150: Exploded View

    6-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 151 ENGINE LUBRICATION SYSTEM 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Pipe Banjo Bolts Oil Pipe Clamp Screw 0.53 46 in·lb Oil Pump Mounting Screws (L = 25) 0.53 46 in·lb Oil Pump Mounting Screw (L = 30) 0.53 46 in·lb Oil Filter Cap Bolts...
  • Page 152: Engine Oil Flow Chart

    6-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Crankshaft 2. Oil Screen 3. Oil Filter 4. Camshaft 5. Oil Pump 6. Oil Pipe...
  • Page 153: Specifications

    ENGINE LUBRICATION SYSTEM 6-5 Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 0.9 L (1.0 US qt) (when filter is not removed) 1.0 L (1.1 US qt) (when filter is removed) 1.1 L (1.2 US qt) (when engine is completely dry) Level Between upper and lower level lines...
  • Page 154: Special Tools

    6-6 ENGINE LUBRICATION SYSTEM Special Tools Oil Pressure Gauge, 5 kgf/cm²: Oil Pressure Cap: 57001-125 57001-1651 Oil Pressure Gauge Adapter, M10 × 1.25: 57001-1182...
  • Page 155: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 6-7 Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
  • Page 156: Oil Screen Cleaning

    6-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Screen Cleaning • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Clutch Cover (see Clutch Cover Removal in the Clutch chapter) Oil Screen [A] •...
  • Page 157: Oil Pump

    ENGINE LUBRICATION SYSTEM 6-9 Oil Pump Oil Pump Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the clutch cover (see Clutch Cover Removal in the Clutch chapter). KLX110C Models • Remove the clutch (see Clutch Removal (KLX110C) in the Clutch chapter).
  • Page 158: Oil Pipe

    6-10 ENGINE LUBRICATION SYSTEM Oil Pipe Oil Pipe Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Banjo Bolts [A] Oil Pipe Clamp Screw [B] Oil Pipe [C] Oil Pipe Installation •...
  • Page 159: Oil Pressure

    ENGINE LUBRICATION SYSTEM 6-11 Oil Pressure Oil Pressure Measurement • Remove the engine guard (see Engine Guard Re- moval/Installation in the Frame chapter). • Remove the bolts [A] and oil filter cap [B]. • Move the spring and the O-ring of the oil filter cap to the oil pressure cap.
  • Page 161 ENGINE REMOVAL/INSTALLATION 7-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 162: Exploded View

    7-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 163 ENGINE REMOVAL/INSTALLATION 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Engine Mounting Nut Middle Engine Mounting Nut Lower Engine Mounting Nut 4. Upper Engine Mounting Bolt (L = 105) 5. Middle Engine Mounting Bolt (L = 125) 6. Lower Engine Mounting Bolt (L = 125) R: Replacement Parts...
  • Page 164: Special Tool

    7-4 ENGINE REMOVAL/INSTALLATION Special Tool Jack: 57001-1238...
  • Page 165: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 7-5 Engine Removal/Installation Engine Removal • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine. NOTICE Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 166: Engine Installation

    7-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the breather tube [A]. • Free the leads from the clamp [B]. • Disconnect: Gear Position Switch Lead Connector [C] Alternator Lead Connector [D] • Remove the engine sprocket (see Engine Sprocket Re- moval in the Final Drive chapter).
  • Page 167 CRANKSHAFT/TRANSMISSION 8-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools & Sealant......................Crankcase ..........................Crankcase Splitting ......................Crankcase Assembly ......................Crankshaft, Connecting Rod ....................8-12 Crankshaft Disassembly ....................8-12 Crankshaft Assembly ......................8-12 Connecting Rod Big End Seizure Inspection ..............8-13 Connecting Rod Big End Radial Clearance Inspection.............
  • Page 168: Exploded View

    8-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 169 CRANKSHAFT/TRANSMISSION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Shift Return Spring Pin (Bolt) Shift Drum Bearing Retaining Screws 0.25 22 in·lb Drive Shaft Bearing Retaining Screw 0.53 46 in·lb Crankcase Bolts (L = 50) 87 in·lb Crankcase Bolts (L = 75) 87 in·lb S, L (1) 6.
  • Page 170 8-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 171 CRANKSHAFT/TRANSMISSION 8-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Kick Pedal Bolt 0.90 78 in·lb Shift Drum Position Lever Pivot Bolt 0.53 46 in·lb Shift Drum Position Plate Screw 0.53 46 in·lb Shift Drum Cam Bolt 0.53 46 in·lb Shift Pedal Bolt 0.53 46 in·lb...
  • Page 172: Specifications

    8-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod: 0.005 ∼ 0.025 mm (0.0002 ∼ 0.0010 in.) Big End Radial Clearance 0.07 mm (0.0028 in.) 0.1 ∼ 0.2 mm (0.004 ∼ 0.008 in.) Big End Side Clearance 0.4 mm (0.016 in.) Crankshaft Runout TIR 0.03 mm (0.001 in.) or less...
  • Page 173: Special Tools & Sealant

    CRANKSHAFT/TRANSMISSION 8-7 Special Tools & Sealant Outside Circlip Pliers: Bearing Driver Set: 57001-144 57001-1129 Bearing Puller: Crankshaft Jig: 57001-158 57001-1174 Crankcase Splitting Tool Assembly: Liquid Gasket, TB1215: 57001-1098 92104-1065...
  • Page 174: Crankcase

    8-8 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Cylinder Head (see Cylinder Head Removal in the En- gine Top End chapter) Cylinder (see Cylinder Removal in the Engine Top End chapter)
  • Page 175: Crankcase Assembly

    CRANKSHAFT/TRANSMISSION 8-9 Crankcase Crankcase Assembly NOTICE Right and left crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. • Chip off the old gasket from the mating surfaces of the crankcase halves.
  • Page 176 8-10 CRANKSHAFT/TRANSMISSION Crankcase • Fit the crankshaft into the right crankcase half using a press [A]. • Install: Transmission Shaft Assemblies [A] Shift Forks [B] • Check that the shift drum is in neutral position. • Make sure that the mating surfaces of the crankcase halves are completely free of oil or contamination.
  • Page 177 CRANKSHAFT/TRANSMISSION 8-11 Crankcase • Install the crankcase bolts in the left and right crankcase half and tighten them, starting with the nearest ones to the crankshaft, then farther ones. Longer Bolts [A] Shorter Bolts [B] L: Apply a non-permanent locking agent. Torque - Crankcase Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 178: Crankshaft, Connecting Rod

    8-12 CRANKSHAFT/TRANSMISSION Crankshaft, Connecting Rod Crankshaft Disassembly NOTICE Since assembly of the crankshaft demands exact- ing tolerance, the disassembly and reassembly of the crankshaft should only be performed by experienced mechanics with the necessary tools and equipment. The crankpin, connecting rod, and right crankshaft are available separately as spare parts, however it is recommended that the crank- shaft assembly be replaced rather than attempting...
  • Page 179: Connecting Rod Big End Seizure Inspection

    CRANKSHAFT/TRANSMISSION 8-13 Crankshaft, Connecting Rod • Check the following items are within specifications after the crankshaft assembly. Connecting Rod Radial Clearance (see Connecting Rod Big End Radial Clearance Inspection) Connecting Rod Side Clearance (see Connecting Rod Big End Side Clearance Inspection) Crankshaft Runout (see Crankshaft Runout Inspection) Connecting Rod Big End Seizure Inspection In the case of serious seizure with damaged flywheels,...
  • Page 180: Crankshaft Alignment

    8-14 CRANKSHAFT/TRANSMISSION Crankshaft, Connecting Rod Crankshaft Alignment If the runout at either point exceeds the service limit, align the flywheels so that the runout falls within the service limit. • In the case of horizontal misalignment, which is the most common, strike the projecting rim of the flywheel with a plastic, soft lead, or brass hammer as indicated in the figure.
  • Page 181: External Shift Mechanism

    CRANKSHAFT/TRANSMISSION 8-15 External Shift Mechanism Shift Pedal Removal • Remove the shift pedal bolt [A] and take off the shift pedal [B] from the shift shaft. Shift Pedal Installation • Install the shift pedal [A] to the shift shaft so that the up- per surface of pedal [B] is level with the upper surface of footpeg [C].
  • Page 182: External Shift Mechanism Inspection

    8-16 CRANKSHAFT/TRANSMISSION External Shift Mechanism ○ Check that the return spring pin [A] is not loose. If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it. Torque - Return Spring Pin: 22 N·m (2.2 kgf·m, 16 ft·lb) ○...
  • Page 183: Transmission

    CRANKSHAFT/TRANSMISSION 8-17 Transmission Shift Drum Removal • Remove: Clutch (see Clutch Removal (KLX110C/D) in the Clutch chapter) External Shift Mechanism (see External Shift Mecha- nism Removal) Shift Drum Allen Bolt [A] Cam Holder [B] Shift Drum Cam Dowel Pin • Split the crankcase (see Crankcase Splitting).
  • Page 184: Transmission Shaft Disassembly

    8-18 CRANKSHAFT/TRANSMISSION Transmission • Apply clean engine oil to the shift fork fingers, and fit each shift fork into its gear-groove so that the shift fork guide pin is in the proper shift drum-groove. NOTE ○ Fingers of the 1st/3rd shift fork are longer than the fin- gers of the 2nd/4th shift fork.
  • Page 185: Shift Fork Bending Inspection

    CRANKSHAFT/TRANSMISSION 8-19 Transmission ○ The output shaft gears can be identified by size; the largest diameter gear is 1st gear, and the smallest is 4th. Be sure that all parts are put back in the correct sequence and facing the proper direction, and that the circlip is properly in place.
  • Page 186: Shift Fork Ear/gear Shift Fork Groove Wear Inspection

    8-20 CRANKSHAFT/TRANSMISSION Transmission Shift Fork Ear/Gear Shift Fork Groove Wear Inspection • Measure the thickness [A] of the shift fork ears. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. Shift Fork Ear Thickness 3.9 ∼...
  • Page 187: Ball Bearing, Needle Bearing, And Oil Seal

    CRANKSHAFT/TRANSMISSION 8-21 Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Wear Inspection NOTICE Do not remove the ball bearings for inspection. Re- moval may damage them. • Check the ball bearings. ○ Since the ball bearings are made to extremely close toler- ances, the wear must be judged by feel rather than mea- surement.
  • Page 188: Kickstarter

    8-22 CRANKSHAFT/TRANSMISSION Kickstarter Kick Pedal Removal • Remove: Bolt [A] Kick Pedal [B] Kick Pedal Installation • Installation is the reverse of removal. ○ Install the kick pedal as shown in the figure. [A] About 16° ○ Tighten: Torque - Kick Pedal Bolt [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb) Kick Shaft Removal •...
  • Page 189: Kick Shaft Inspection

    CRANKSHAFT/TRANSMISSION 8-23 Kickstarter • Apply molybdenum disulfide grease to the inside of the kick gear [A] and kick shaft [B]. • Replace the removed circlips with new ones. ○ When assembling the ratchet gear onto the kick shaft, align the punch mark [A] on the ratchet gear with the punch mark [B] on the kick shaft.
  • Page 191 WHEELS/TIRES 9-1 Wheels/Tires Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Wheels (Rims) ........................Front Wheel Removal ....................... Front Wheel Installation ....................Rear Wheel Removal......................Rear Wheel Installation..................... Wheels Inspection......................Spoke Tightness Inspection ....................Rim Runout Inspection...................... Rim Installation Position....................Axle Inspection........................
  • Page 192: Exploded View

    9-2 WHEELS/TIRES Exploded View...
  • Page 193 WHEELS/TIRES 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Spoke Nipples 0.41 35 in·lb Front Axle Nut Torque Link Nuts Rear Axle Nut G: Apply grease. R: Replacement Parts WL: Apply soap and water solution, or rubber lubricant.
  • Page 194: Specifications

    9-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Size: Front 14 × 1.40 – – – Rear 12 × 1.60 – – – Rim Runout: Axial TIR 0.8 mm (0.031 in.) or less TIR 2.0 mm (0.08 in.) Radial TIR 1.2 mm (0.047 in.) or less TIR 2.0 mm (0.08 in.)
  • Page 195: Special Tools

    WHEELS/TIRES 9-5 Special Tools Rim Protector: Bearing Remover Shaft, 9: 57001-1063 57001-1265 Bearing Driver Set: Bearing Remover Head, 10 × 12: 57001-1129 57001-1266 Jack: 57001-1238...
  • Page 196: Wheels (rims)

    9-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Stabilize the motorcycle with the jack. Special Tool - Jack: 57001-1238 • Apply the rear brake so that the rear wheel does not turn. • Remove: Cotter Pin [A] Front Axle Nut [B] •...
  • Page 197: Rear Wheel Removal

    WHEELS/TIRES 9-7 Wheels (Rims) • Replace the axle nut [B] with a new one. • Insert the axle [A] from right side, and tighten the axle nut. Torque - Front Axle Nut: 44 N·m (4.5 kgf·m, 32 ft·lb) • Insert a new cotter pin [C] to the front axle, and bend it to both sides.
  • Page 198: Rear Wheel Installation

    9-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Installation • Apply high-temperature grease to the oil seal [A]. • Install the collar [B] on the left side of the hub. • Install the rear brake panel. • Engage the drive chain with the rear sprocket, and set the rear wheel to the motorcycle.
  • Page 199: Wheels Inspection

    WHEELS/TIRES 9-9 Wheels (Rims) Wheels Inspection • Raise the front/rear wheel off the ground with the jack. Special Tool - Jack: 57001-1238 • Spin the wheel lightly, and check for roughness or binding. If the roughness or binding is found, replace the hub bear- ings.
  • Page 200: Axle Inspection

    9-10 WHEELS/TIRES Wheels (Rims) Axle Inspection • Visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • Place the front axle in V blocks that are 100 mm (3.94 in.) (Rear Axle: 110 mm (4.33 in.)) [A] apart, and set a dial gauge [B] on the axle at a point halfway between the blocks.
  • Page 201: Tires

    WHEELS/TIRES 9-11 Tires Tire Removal • Remove the wheel (see Front/Rear Wheel Removal). • To maintain wheel balance, mark [A] the valve stem posi- tion on the tire with chalk so that the tire can be reinstalled in the same position. •...
  • Page 202: Air Pressure Inspection/adjustment

    9-12 WHEELS/TIRES Tires ○ Position the tire on the rim so that the air valve [A] is at the tire balance mark [B] (the chalk mark made during removal, or the paint mark on a new tire). • Insert the valve stem into the rim, and screw the nut on loosely.
  • Page 203: Hub Bearings

    WHEELS/TIRES 9-13 Hub Bearings Hub Bearing Removal • Remove the wheel (see Front/Rear Wheel Removal). • To remove the grease seals, pry out the grease seal using a screwdriver. • Using the bearing remover shaft and bearing remover head, remove the hub bearings [A]. Special Tools - Bearing Remover Shaft, 9: 57001-1265 [B] Bearing Remover Head, 10 ×...
  • Page 204: Bearing Lubrication

    9-14 WHEELS/TIRES Hub Bearings Bearing Lubrication • Remove the hub bearings on the front and rear wheel hubs. • Wash the bearings with a high flash-point solvent, dry them (do not spin them while they are dry), and oil them. •...
  • Page 205 FINAL DRIVE 10-1 Final Drive Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Drive Chain..........................10-6 Drive Chain Slack Inspection .................... 10-6 Drive Chain Slack Adjustment ..................10-6 Wheel Alignment Inspection ..................... 10-6 Wheel Alignment Adjustment.................... 10-6 Drive Chain Wear Inspection ....................
  • Page 206: Exploded View

    10-2 FINAL DRIVE Exploded View...
  • Page 207 FINAL DRIVE 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Cover Bolts 0.53 46 in·lb Chain Guide Roller Mounting Bolt Rear Sprocket Nuts Rear Axle Nut 5. KLX110D Models G: Apply grease. HO: Apply heavy oil. R: Replacement Parts...
  • Page 208: Specifications

    10-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack: 11 ∼ 16 mm (0.4 ∼ 0.6 in.) KLX110C Models – – – 8 ∼ 13 mm (0.3 ∼ 0.5 in.) KLX110D Models – – – Drive Chain 20-link Length 254.0 ∼ 254.6 mm (10.00 ∼ 10.02 in.) 259 mm (10.2 in.) Standard Chain: Make...
  • Page 209: Special Tools

    FINAL DRIVE 10-5 Special Tools Outside Circlip Pliers: Bearing Driver Set: 57001-144 57001-1129...
  • Page 210: Drive Chain

    10-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection •...
  • Page 211: Drive Chain Installation

    FINAL DRIVE 10-7 Drive Chain • Remove the clip [A] from the master link using pliers, and remove the chain from the rear sprocket. • Take the chain off the motorcycle, being careful that the chain does not get dirty from contact with the ground. Drive Chain Installation WARNING For safety, use only the standard chain.
  • Page 212 10-8 FINAL DRIVE Drive Chain ○ The upper bolt is longer than the other ones. • Tighten: Torque - Engine Sprocket Cover Bolts [A]: 5.2 N·m (0.53 kgf·m, 46 in·lb)
  • Page 213: Sprockets

    FINAL DRIVE 10-9 Sprockets Engine Sprocket Removal • Remove the engine sprocket cover (see Drive Chain Re- moval). • Remove the circlip [A] and the engine sprocket [B] with the drive chain [C]. Special Tool - Outside Circlip Pliers: 57001-144 •...
  • Page 214: Rear Sprocket Warp Inspection

    10-10 FINAL DRIVE Sprockets Rear Sprocket Warp Inspection • Refer to the Rear Sprocket Warp Inspection in Periodic Maintenance chapter. Coupling Bearing Removal • Pull out the coupling collar from the left. • Remove the oil seal. • Using the bearing driver set [A] or some other suitable tool, remove the bearing [B] by tapping from the drum side.
  • Page 215 BRAKES 11-1 Brakes Table of Contents Exploded View........................11-2 Specifications ......................... 11-6 Special Tools .......................... 11-7 Brake Lever and Cable......................11-8 Brake Lever Free Play Inspection..................11-8 Brake Lever Free Play Adjustment ................... 11-8 Brake Cable Removal ....................... 11-8 Brake Cable Installation ....................11-8 Brake Cable Lubrication....................
  • Page 216: Exploded View

    11-2 BRAKES Exploded View...
  • Page 217 BRAKES 11-3 Exploded View CL: Apply cable lubricant. G: Apply grease. R: Replacement Parts Si: Apply silicone grease.
  • Page 218 11-4 BRAKES Exploded View...
  • Page 219 BRAKES 11-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Pedal Bolt 0.90 78 in·lb Torque Link Nuts Brake Cam Lever Bolt 0.71 62 in·lb G: Apply grease. R: Replacement Parts...
  • Page 220: Specifications

    11-6 BRAKES Specifications Item Standard Service Limit Brake Lever and Pedal 4 ∼ 5 mm (0.16 ∼ 0.20 in.) Brake Lever Free Play – – – 20 ∼ 30 mm (0.79 ∼ 1.18 in.) Brake Pedal Free Play – – – Brake Drum, Brake Shoes Shoe Lining Thickness: 2.10 ∼...
  • Page 221: Special Tools

    BRAKES 11-7 Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238...
  • Page 222: Brake Lever And Cable

    11-8 BRAKES Brake Lever and Cable Brake Lever Free Play Inspection • Refer to the Brake Lever Free Play Inspection in the Pe- riodic Maintenance chapter. Brake Lever Free Play Adjustment • Refer to the Brake Lever Free Play Adjustment in the Pe- riodic Maintenance chapter.
  • Page 223: Brake Pedal And Rod

    BRAKES 11-9 Brake Pedal and Rod Brake Pedal Free Play Inspection • Refer to Brake Pedal Free Play Inspection in the Periodic Maintenance chapter. Brake Pedal Free Play Adjustment • Refer to Brake Pedal Free Play Adjustment in the Periodic Maintenance chapter.
  • Page 224: Brake Panel And Drum

    11-10 BRAKES Brake Panel and Drum Brake Lining Wear Inspection • Refer to Brake Lining Wear Inspection in the Periodic Maintenance chapter. Cam Lever Angle Inspection • Refer to Cam Lever Angle Inspection in the Periodic Main- tenance chapter. Cam Lever Angle Adjustment •...
  • Page 225: Brake Panel Assembly

    BRAKES 11-11 Brake Panel and Drum • Mark the position [A] of the cam lever before removal so that it can be installed later in the same position. • Remove the brake cam lever bolt [B] and nut [C], and then pull out the brake cam lever [D] from the brake camshaft.
  • Page 226: Brake Drum Wear Inspection

    11-12 BRAKES Brake Panel and Drum • Face the triangle mark [A] on the cam surface towards the center of the panel and install the camshaft in the panel. WARNING Ineffective brakes can cause a serious accident resulting in serious injury death. Improper instal- lation will cause ineffective braking.
  • Page 227: Camshaft Wear Inspection

    BRAKES 11-13 Brake Panel and Drum Camshaft Wear Inspection • Measure the shaft diameter [A]. If it is worn down to less than the service limit, replace the shaft. • Measure the inside diameter [B] of the camshaft hole. If it is worn past the service limit, replace the brake panel. Camshaft Diameter Standard: 11.957 ∼...
  • Page 229 SUSPENSION 12-1 Suspension Table of Contents Exploded View........................12-2 Specifications ......................... 12-6 Special Tools .......................... 12-7 Front Fork ..........................12-8 Front Fork Oil Change ...................... 12-8 Front Fork Removal ......................12-8 Front Fork Installation ....................... 12-8 Front Fork Disassembly (each fork leg) ................12-9 Front Fork Assembly......................
  • Page 230: Exploded View

    12-2 SUSPENSION Exploded View...
  • Page 231 SUSPENSION 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) Steering Stem Head Nut Fork Bottom Bolts 5. CA model only R: Replacement Parts...
  • Page 232 12-4 SUSPENSION Exploded View...
  • Page 233 SUSPENSION 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Mounting Bolt (Upper) Rear Shock Absorber Mounting Nut (Upper) Rear Shock Absorber Mounting Nut (Lower) Swingarm Pivot Nut Torque Link Nuts G: Apply grease. R: Replacement Parts...
  • Page 234: Specifications

    Rebound Damping Adjustment Non-Adjustable – – – Compression Damping Adjustment Non-Adjustable – – – Suspension Oil Kawasaki SS-8 or equivalent – – – Amount – – – (KLX110C) 165 ±2.5 mL (5.58 ±0.085 US oz) (KLX110D) 182 ±2.5 mL (6.15 ±0.085 –...
  • Page 235: Special Tools

    SUSPENSION 12-7 Special Tools Fork Cylinder Holder Handle: Front Fork Oil Seal Driver: 57001-183 57001-1219 Fork Cylinder Holder Adapter: Jack: 57001-1011 57001-1238...
  • Page 236: Front Fork

    12-8 SUSPENSION Front Fork Front Fork Oil Change • Refer to the Front Fork Oil Change in the Periodic Main- tenance chapter. Front Fork Removal • Remove: Number Plate (see Number Plate Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) •...
  • Page 237: Front Fork Disassembly (each Fork Leg)

    SUSPENSION 12-9 Front Fork Front Fork Disassembly (each fork leg) • Remove the cap. • Loosen the front fork upper clamp bolt [A]. • Remove the snap ring [B] while pressing the top plug [C], and then remove the top plug with O-ring. •...
  • Page 238: Front Fork Assembly

    12-10 SUSPENSION Front Fork • Separate the inner tube [A] from the outer tube [B] by pulling them out. • Take the cylinder base [A] out of the outer tube [B]. • Remove the retaining ring [A] from the outer tube. •...
  • Page 239 SUSPENSION 12-11 Front Fork • Insert the cylinder base [A] in the cylinder unit [B]. ○ The cylinder base must be installed with the tapered side [C] facing upward. • Insert the inner tube and cylinder unit as a set into the outer tube.
  • Page 240: Inner Tube Inspection

    12-12 SUSPENSION Front Fork Inner Tube Inspection • Visually inspect the inner tube [A]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal and dust seal, replace the oil seal and dust seal whenever the inner tube is replaced.
  • Page 241: Rear Shock Absorber

    SUSPENSION 12-13 Rear Shock Absorber Rear Shock Absorber Removal • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) • Raise the rear wheel off the ground with the jack. Special Tool - Jack: 57001-1238 NOTICE When pulling out the mounting bolts, lift the rear...
  • Page 242: Rear Shock Absorber Inspection

    12-14 SUSPENSION Rear Shock Absorber Rear Shock Absorber Inspection • Remove the rear shock absorber (see Rear Shock Ab- sorber Removal). • Visually inspect the following items. Oil Leakage Crack or Dent If there is any damage to the rear shock absorber, replace •...
  • Page 243: Swingarm

    SUSPENSION 12-15 Swingarm Swingarm Removal • Raise the rear wheel off the ground with the jack. Special Tool - Jack: 57001-1238 • Remove: Drive Chain (see Drive Chain Removal in the Final Drive chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) •...
  • Page 245 STEERING 13-1 Steering Table of Contents Exploded View........................13-2 Special Tools .......................... 13-4 Steering ..........................13-5 Steering Inspection ......................13-5 Steering Adjustment......................13-5 Steering Stem......................... 13-6 Steering Stem, Stem Bearing Removal ................13-6 Steering Stem, Stem Bearing Installation ................. 13-7 Stem Bearing Lubrication....................
  • Page 246: Exploded View

    13-2 STEERING Exploded View...
  • Page 247 STEERING 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Holder Bolts Steering Stem Head Nut Steering Stem Nut 0.50 43 in·lb Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) AD: Apply adhesive cement. G: Apply grease. T: First, tighten the stem nut with 39 N·m (4.0 kgf·m, 29 ft·lb) of torque, then loosen it and retighten it with 4.9 N·m (0.50 kgf·m, 43 in·lb) of torque.
  • Page 248: Special Tools

    13-4 STEERING Special Tools Bearing Puller Adapter: Head Pipe Outer Race Driver, 51.5: 57001-136 57001-1076 Steering Stem Bearing Driver: Steering Stem Nut Wrench: 57001-137 57001-1100 Steering Stem Bearing Driver Adapter, 32: Head Pipe Outer Race Driver, 46.5: 57001-292 57001-1106 Head Pipe Outer Race Press Shaft: Bearing Puller: 57001-1075 57001-1675...
  • Page 249: Steering Inspection

    STEERING 13-5 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter. Steering Adjustment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter.
  • Page 250: Steering Stem

    13-6 STEERING Steering Stem Steering Stem, Stem Bearing Removal • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) • Remove: Number Plate (see Number Plate Removal in the Frame chapter) Handlebar Holder Bolts [A] Handlebar Holders [B]...
  • Page 251: Steering Stem, Stem Bearing Installation

    STEERING 13-7 Steering Stem • To remove the outer races [A] pressed into the head pipe [B], insert a bar [C] into the head pipe, and hammer evenly around the circumference of the opposite race to drive it out. NOTE ○...
  • Page 252 13-8 STEERING Steering Stem • Apply grease liberally to the upper outer race in the head pipe so that the steel balls will stick in place during stem insertion, and install upper steel balls. • Insert the steering stem [A] carefully through the head pipe so that the steel balls on the steering stem does not fall.
  • Page 253: Stem Bearing Lubrication

    STEERING 13-9 Steering Stem • Tighten: Torque - Steering Stem Head Nut [A]: 44 N·m (4.5 kgf·m, 32 ft·lb) Front Fork Clamp Bolts (Upper) [B]: 20 N·m (2.0 kgf·m, 15 ft·lb) Front Fork Clamp Bolts (Lower) [C]: 30 N·m (3.1 kgf·m, 22 ft·lb) •...
  • Page 254: Handlebar

    13-10 STEERING Handlebar Handlebar Removal • Remove: Number Plate (see Number Plate Removal in the Frame chapter) Screws [A] Brake Lever Holder [B] Brake Lever Assembly [C] • Slide out the dust cover [A]. • Loosen the screws [B] and remove the throttle cable hous- ing [C] together with the throttle grip [D] from the handle- bar.
  • Page 255: Handlebar Installation

    STEERING 13-11 Handlebar • Remove: Handlebar Holder Bolts [A] Handlebar Holders [B] Handlebar [C] Handlebar Installation • Apply adhesive to the inside of the left handlebar grip. • Install the left handlebar grip so that the projection of grip aligns with the punch mark of the handlebar. •...
  • Page 256 13-12 STEERING Handlebar • Install the brake lever [A]. ○ Position the brake lever so that the mating surface [B] aligns with the punch mark [C] of the handlebar. • Install the number plate (see Number Plate Installation in the Frame chapter). •...
  • Page 257 FRAME 14-1 Frame Table of Contents Exploded View........................14-2 Special Tool ..........................14-6 Frame ............................. 14-7 Frame Inspection ......................14-7 Engine Guard Removal/Installation .................. 14-7 Shroud ............................ 14-8 Shroud Removal ....................... 14-8 Shroud Installation ......................14-8 Seat ............................14-9 Seat Removal ........................14-9 Seat Installation ........................
  • Page 258: Exploded View

    14-2 FRAME Exploded View...
  • Page 259 FRAME 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Footpeg Bracket Bolts Sidestand Bolt 87 in·lb Sidestand Nut G: Apply grease. R: Replacement Parts...
  • Page 260 14-4 FRAME Exploded View...
  • Page 261 FRAME 14-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Reflector Bracket Screws 0.75 65 in·lb Screw (for Seat Hook) 0.51 44 in·lb Screw (for Rubber Band Hook) 0.51 44 in·lb 4. CA model only...
  • Page 262: Special Tool

    14-6 FRAME Special Tool Jack: 57001-1238...
  • Page 263: Frame

    FRAME 14-7 Frame Frame Inspection • Refer to the Frame Inspection in the Periodic Mainte- nance chapter. Engine Guard Removal/Installation • Remove: Bolts [A] Footpeg Bracket Bolts [B] Engine Guard [C] • Installation is the reverse of removal; note the following. •...
  • Page 264: Shroud

    14-8 FRAME Shroud Shroud Removal • Remove: Side Covers (see Side Cover Removal) Seat (see Seat Removal) Bolts [A] (Both Sides) Screw [B] Fuel Tank Cap [C] Shroud [D] Shroud Installation • Installation is the reverse of removal.
  • Page 265: Seat

    FRAME 14-9 Seat Seat Removal • Remove the seat mounting bolts [A] on both sides. • Take off the seat [B] backward. Seat Installation • Installation is the reverse of removal. ○ Insert the hooks [A] under the washer [B] and the bracket [C].
  • Page 266: Side Covers

    14-10 FRAME Side Covers Side Cover Removal • Remove the bolts [A]. • Pull the side cover [B] outward to clear the stopper. Side Cover Installation • Installation is the reverse of removal. ○ Install the collars to the side cover. ○...
  • Page 267: Number Plate

    FRAME 14-11 Number Plate Number Plate Removal • Remove the band [A] from the handlebar. • Remove the bolt [B] and take off the number plate [C] upward. Number Plate Installation • Install the collar [A] to the number plate. •...
  • Page 268: Fenders

    14-12 FRAME Fenders Front Fender Removal • Remove the bolts [A] and take off the front fender [B]. Front Fender Installation • Installation is the reverse of removal; note the following. ○ Install the collars [A] to the front fender [B]. ○...
  • Page 269: Rear Flap Removal/installation

    FRAME 14-13 Fenders • Remove the bolts [A]. • Remove the bolts [A] and take off the rear fender [B]. • Installation is the reverse of removal. ○ Run the cables and leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Rear Flap Removal/Installation •...
  • Page 270: Footpegs And Bracket

    14-14 FRAME Footpegs and Bracket Footpeg Removal/Installation • Remove: Cotter pin [A] Pivot Pin [B] Spring [C] Footpeg [D] • Installation is reverse of removal; note the following. • Replace the cotter pin with a new one. • Apply grease to the sliding area of the footpeg. •...
  • Page 271: Sidestand

    FRAME 14-15 Sidestand Sidestand Removal • Raise the rear wheel off the ground with the jack. Special Tool - Jack: 57001-1238 • Remove: Spring [A] Sidestand Bolt [B] Sidestand Nut [C] Sidestand [D] Sidestand Installation • Apply grease to the sliding area [A] of the sidestand [B]. •...
  • Page 273 ELECTRICAL SYSTEM 15-1 Electrical System Table of Contents Exploded View........15-2 Starter Motor Clutch Inspection ... 15-29 Specifications ........15-6 Starter Torque Limiter Inspection . 15-29 Special Tools and Sealant ....15-7 Ignition System ........15-30 Wiring Diagram........15-8 Crankshaft Sensor Removal ..15-30 Precautions........
  • Page 274: Exploded View

    15-2 ELECTRICAL SYSTEM Exploded View...
  • Page 275 ELECTRICAL SYSTEM 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Regulator Mounting Screw 0.53 46 in·lb Ignition Coil Mounting Bolt 0.30 26 in·lb Gear Position Switch Screws 0.30 26 in·lb Spark Plug 115 in·lb 5. Battery 6. Starter Relay 7.
  • Page 276 15-4 ELECTRICAL SYSTEM Exploded View...
  • Page 277 ELECTRICAL SYSTEM 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Starter Motor Terminal Screw 0.20 18 in·lb Terminal Cover Plate Screws 0.20 18 in·lb Brush Holder Plate Screws 0.09 8.0 in·lb End Cover Screws 0.45 39 in·lb Starter Motor Mounting Screws 0.53 46 in·lb Alternator Cover Bolts (L=25)
  • Page 278: Specifications

    15-6 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Type Sealed Battery (wet) – – – Model Name FTH4L-BS – – – Capacity 12 V 3 Ah – – – Voltage 12.6 V or more – – – Gross Weight 1.4 kg (3.1 lb) –...
  • Page 279: Special Tools And Sealant

    ELECTRICAL SYSTEM 15-7 Special Tools and Sealant Rotor Puller M18 × 1.5, M16 × 1.5: Peak Voltage Adapter: 57001-1099 57001-1415 Rotor Puller, M16/M18/M20/M22 × 1.5: Needle Adapter Set: 57001-1216 57001-1457 Flywheel Holder: Flywheel Puller, M28 × 1.0: 57001-1313 57001-1471 Hand Tester: Liquid Gasket, TB1211F: 57001-1394 92104-0004...
  • Page 280: Wiring Diagram

    15-8 ELECTRICAL SYSTEM Wiring Diagram KLX110CA Model...
  • Page 281 ELECTRICAL SYSTEM 15-9 Wiring Diagram KLX110DA Model...
  • Page 282 15-10 ELECTRICAL SYSTEM Wiring Diagram KLX110CB Models ∼...
  • Page 283 ELECTRICAL SYSTEM 15-11 Wiring Diagram KLX110DB Models ∼...
  • Page 284: Precautions

    15-12 ELECTRICAL SYSTEM Precautions There are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.
  • Page 285: Electrical Wiring

    ELECTRICAL SYSTEM 15-13 Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 286: Battery

    15-14 ELECTRICAL SYSTEM Battery Battery Removal • Remove: Seat (see Seat Removal in the Frame chapter) Left Side Cover (see Side Cover Removal in the Frame chapter) Battery Holder Bolts [A] • Slide the battery, and disconnect the negative (–) cable [B] and then positive (+) cable [C].
  • Page 287 ELECTRICAL SYSTEM 15-15 Battery NOTICE Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. DANGER Sulfuric acid in battery electrolyte can cause severe burns.
  • Page 288 15-16 ELECTRICAL SYSTEM Battery • Check the electrolyte flow. If no air bubbles [A] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [B] a few times. NOTE ○ Be careful not to have the battery fall down. •...
  • Page 289: Precautions

    Newly activated sealed batteries require an initial charge. Standard Charge: 0.9 A × 5 ∼ 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Battery Mate 150-9 OptiMate PRO 4-S/PRO S/PRO2 Yuasa MB-2040/2060...
  • Page 290: Interchange

    15-18 ELECTRICAL SYSTEM Battery DANGER Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri- ous injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before turning on the charger.
  • Page 291 ELECTRICAL SYSTEM 15-19 Battery • Determine the battery condition after refresh charge. ○ Determine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below. Criteria Judgement 12.6 V or higher Good 12.0 ∼...
  • Page 292: Charging System

    15-20 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Left Side Cover (see Side Cover Removal in the Frame chapter) Seat (see Seat Removal in the Frame chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) ○...
  • Page 293: Alternator Rotor Removal

    ELECTRICAL SYSTEM 15-21 Charging System Alternator Rotor Removal • Remove: Alternator Cover (see Alternator Cover Removal) Starter Idle Gear and Washers • Wipe oil off the outer circumference of the rotor. • Hold the alternator rotor steady with the flywheel holder [A], and remove the alternator rotor nut [B].
  • Page 294: Stator Removal

    15-22 ELECTRICAL SYSTEM Charging System • Hold the rotor steady with the flywheel holder [A], tighten the rotor nut [B]. Torque - Alternator Rotor Nut: 53.9 N·m (5.50 kgf·m, 39.8 ft·lb) Special Tool - Flywheel Holder: 57001-1313 • Install the alternator cover (see Alternator Cover Installa- tion).
  • Page 295 ELECTRICAL SYSTEM 15-23 Charging System • Check the alternator output voltage, do the following pro- cedures. ○ Remove: Left Side Cover (see Side Cover Removal in the Frame chapter) Seat (see Seat Removal in the Frame chapter) ○ Clear the leads from the clamp [A]. ○...
  • Page 296: Charging Voltage Inspection

    15-24 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection • Remove: Seat (see Seat Removal in the Frame chapter) Left Side Cover (see Side Cover Removal in the Frame chapter) • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions.
  • Page 297 ELECTRICAL SYSTEM 15-25 Charging System • With the Kawasaki hand tester, measure the internal re- sistance in both directions between the terminals. Special Tool - Hand Tester: 57001-1394 If the reading is not the specified value, replace the reg- ulator/rectifier.
  • Page 298 15-26 ELECTRICAL SYSTEM Charging System Charging System Troubleshooting • Recharge the battery if it is discharged.
  • Page 299 ELECTRICAL SYSTEM 15-27 Charging System Charging System Circuit (KLX110CA/DA Models) 1. Load 2. Main Fuse 10 A 3. Battery 12 V 3 Ah 4. Regulator/Rectifier 5. Alternator Charging System Circuit (KLX110CB/DB Models ∼) 1. Load 2. Main Fuse 10 A 3.
  • Page 300: Starter Motor Clutch

    15-28 ELECTRICAL SYSTEM Starter Motor Clutch Starter Motor Clutch/Starter Motor Clutch Gear Removal • Remove: Alternator Rotor (see Alternator Rotor Removal) • Remove the bolts [A] and take off the starter motor clutch [B] from the rotor. Special Tool - Flywheel Holder [C]: 57001-1313 •...
  • Page 301: Starter Motor Clutch Inspection

    ELECTRICAL SYSTEM 15-29 Starter Motor Clutch Starter Motor Clutch Inspection • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Alternator Cover (see Alternator Cover Removal) Starter Motor Idle Gear [A] • Turn the torque limiter [A] by hand. The starter motor clutch gear [B] should turn clockwise freely [C] but should not turn counterclockwise.
  • Page 302: Ignition System

    15-30 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Crankshaft Sensor Removal •...
  • Page 303: Spark Plug Cleaning And Inspection

    ELECTRICAL SYSTEM 15-31 Ignition System Measuring Coil Resistance If the arcing tester is not available, the coil can be checked for a broken or badly shorted winding with an ohmmeter. However, an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage.
  • Page 304 15-32 ELECTRICAL SYSTEM Ignition System Ignition Coil Primary Peak Voltage Check • Disconnect the spark plug cap from the spark plug, but do not remove the spark plug. • Connect the good spark plug [A] to the spark plug cap, then touch the engine with it.
  • Page 305: Crankshaft Sensor Inspection

    ELECTRICAL SYSTEM 15-33 Ignition System Crankshaft Sensor Peak Voltage Check • To check the peak voltage, do the following procedures. ○ Disconnect the alternator lead connector from the main harness (see Alternator Cover Removal). NOTE ○ Measure the voltage with each lead connected cor- rectly.
  • Page 306 15-34 ELECTRICAL SYSTEM Ignition System...
  • Page 307 ELECTRICAL SYSTEM 15-35 Ignition System Ignition System Circuit (KLX110CA/DA Models) 1. Engine Stop Switch 2. Engine Starter Button 3. Main Fuse 10 A 4. Battery 12 V 3 Ah 5. Crankshaft Sensor 6. IC Igniter 7. Ignition Coil 8. Spark Plug...
  • Page 308 15-36 ELECTRICAL SYSTEM Ignition System Ignition System Circuit (KLX110CB/DB Models ∼) 1. Engine Stop Switch 2. Engine Starter Button 3. Main Fuse 10 A 4. Battery 12 V 3 Ah 5. Crankshaft Sensor 6. IC Igniter 7. Ignition Coil 8. Spark Plug...
  • Page 309: Electrical Starter System

    ELECTRICAL SYSTEM 15-37 Electrical Starter System Starter Motor Removal NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove: Exhaust Pipe Cover (see Muffler Removal in the Engine Top End chapter) •...
  • Page 310 15-38 ELECTRICAL SYSTEM Electrical Starter System NOTE ○ Hold the carbon brush leads [A], using the suitable tool [B] as shown. • Pull out the carbon brush spring [A]. • Remove the brush holder screws [B] with lockwashers and flat washers. •...
  • Page 311: Starter Motor Assembly

    ELECTRICAL SYSTEM 15-39 Electrical Starter System Starter Motor Assembly • Smooth the commutator surface if necessary with fine emery paper (more than #600). • Blow or wipe the parts of the starter motor to clean the dust or any carbon particles. •...
  • Page 312: Starter Motor Brush Inspection

    15-40 ELECTRICAL SYSTEM Electrical Starter System • Hold the (–) carbon brush in the brush holder so that a suitable tool [A] could hold the (–) carbon brush lead [B] as shown. • Install the (+) carbon brush spring. • Hold the (+) carbon brush lead with a suitable tool.
  • Page 313: Armature Inspection

    ELECTRICAL SYSTEM 15-41 Electrical Starter System • Measure the outer diameter [A] of the commutator [B]. Replace the starter motor with a new one if the commu- tator diameter is less than the service limit. Commutator Diameter Standard: 22.0 mm (0.87 in.) Service Limit: 21.5 mm (0.85 in.) Armature Inspection...
  • Page 314 15-42 ELECTRICAL SYSTEM Electrical Starter System • Connect a digital meter [A] and 12 V battery [B] to the starter relay [C] as shown in the figure. If the relay does not work as specified, the relay is defec- tive. Replace the relay. KLX110CA/DA Models [D] KLX110CB/DB Models ∼...
  • Page 315 ELECTRICAL SYSTEM 15-43 Electrical Starter System Electrical Starter System Circuit (KLX110CA/DA Models) 1. Engine Stop Switch 2. Engine Starter Button 3. Starter Motor 4. Starter Relay 5. Main Fuse 10 A 6. Battery 12 V 3 Ah 7. Starter Lockout Switch (KLX110D Models) 8.
  • Page 316 15-44 ELECTRICAL SYSTEM Electrical Starter System Electrical Starter System Circuit (KLX110CB/DB Models ∼) 1. Engine Stop Switch 2. Engine Starter Button 3. Starter Motor 4. Starter Relay 5. Main Fuse 10 A 6. Battery 12 V 3 Ah 7. Starter Lockout Switch (KLX110D Models) 8.
  • Page 317: Switches And Sensors

    ELECTRICAL SYSTEM 15-45 Switches and Sensors Switch Inspection • Using a digital meter, check to see that only the con- nections shown in the table have continuity (about zero ohms). If the switch has an open or short, repair it or replace it with a new one.
  • Page 318: Fuses

    15-46 ELECTRICAL SYSTEM Fuses Main Fuse 10 A Removal • Remove: Seat (see Seat Removal in the Frame chapter) Left Side Cover (see Side Cover Removal in the Frame chapter) • Remove the main fuse [A]. Main Fuse 10 A Inspection •...
  • Page 319 APPENDIX 16-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................16-2 Troubleshooting Guide ......................16-10...
  • Page 320 16-2 APPENDIX Cable, Wire, and Hose Routing...
  • Page 321 APPENDIX 16-3 Cable, Wire, and Hose Routing 1. Brake Cable 2. Throttle Cable 3. Battery Positive (+) Cable 4. Route the starter motor cable through the inside of engine mount. 5. Igniter...
  • Page 322 16-4 APPENDIX Cable, Wire, and Hose Routing...
  • Page 323 APPENDIX 16-5 Cable, Wire, and Hose Routing 1. Left Switch Housing Lead Connector 2. Clamps 3. Alternator Lead Connector 4. Battery Negative (–) Cable 5. Damper 6. Fuse 7. Starter Relay Leads 8. Gear Position Switch Lead Connector 9. Starter Motor Cable 10.
  • Page 324 16-6 APPENDIX Cable, Wire, and Hose Routing...
  • Page 325 APPENDIX 16-7 Cable, Wire, and Hose Routing 1. Throttle Cable 2. Clutch Cable (KLX110D Models) 3. Route the clutch cable in front of the band of number plate. 4. Starter Lockout Switch Lead (KLX110D Models) 5. Left Switch Housing Lead 6.
  • Page 326 16-8 APPENDIX Cable, Wire, and Hose Routing...
  • Page 327 APPENDIX 16-9 Cable, Wire, and Hose Routing 1. Clamps 2. Regulator/Rectifier 3. Throttle Cable 4. Clutch Cable (KLX110D Models) 5. Engine Ground Lead Terminal...
  • Page 328: Troubleshooting Guide

    16-10 APPENDIX Troubleshooting Guide This is not an exhaustive list, giving every Spark plug dirty, broken or gap maladjusted possible cause for each problem listed. it is Spark plug cap or ignition coil lead trouble meant simply as a rough guide to assist the Spark plug cap shorted or not in good con- troubleshooting for some of the more common tact...
  • Page 329: Engine Overheating

    APPENDIX 16-11 Troubleshooting Guide Compression low: Cylinder head not sufficiently tightened Spark plug loose down Cylinder head not sufficiently tightened No valve clearance down Cylinder, piston worn No valve clearance Piston ring bad (worn, weak, broken or Cylinder, piston worn sticking) Piston ring bad (worn, weak, broken or Piston ring/groove clearance excessive...
  • Page 330: Clutch Operation Faulty

    16-12 APPENDIX Troubleshooting Guide Clutch Operation Faulty: Spark plug incorrect Clutch slipping: Overheating No clutch release play (KLX110C) Piston slap: No clutch lever play (KLX110D) Cylinder/piston clearance excessive Clutch cable maladjusted (KLX110D) Cylinder, piston worn Clutch inner cable sticking (KLX110D) Connecting rod bent Friction plate worn or warped Piston pin, piston pin hole worn...
  • Page 331: Battery Trouble

    APPENDIX 16-13 Troubleshooting Guide Brake noise: Steering stem head nut loose Brake linings over worn or worn unevenly Front, rear axle runout excessive Drum worn unevenly or scored Handlebar pulls to one side: Brake spring(s) weak or broken Frame bent Foreign matter in hub Rear wheel misalignment Brake not properly adjusted...
  • Page 332 MODEL APPLICATION Year Model Beginning Frame No. □ JKALXSC1 ADA71826 2010 KLX110CA JKALX110CCDA71829 □ 2010 KLX110DA JKALXSD1 ADA71830 □ JKALXSC1 BDA76725 2011 KLX110CB JKALX110CCDA77275 □ 2011 KLX110DB JKALXSD1 BDA76735 □ JKALXSC1 CDA81071 2012 KLX110CC JKALX110CCDA81841 □ 2012 KLX110DC JKALXSD1 CDA81072 □...

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