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Manuals
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Kawasaki Manuals
Motorcycle
KLX 110 - BROCHURE 2009
Service manual
Special Tools - Kawasaki KLX110 Service Manual
Motorcycle.
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Also See for KLX110
Service manual
-
248 pages
Owner's manual
-
122 pages
Brochure
-
13 pages
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Page
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Go
Page 1
Page 2
Page 3 - GENERAL INFORMATION
Page 4
Page 5
Page 6
Page 7 - How to use this manual
Page 8
Page 9
Page 10 - General information
Page 11
Page 12
Page 13
Page 14
Page 15 - Model Identification
Page 16
Page 17 - General Specifications
Page 18
Page 19
Page 20 - Unit Conversion Table
Page 21 - Table Of Contents
Page 22 - Periodic Maintenance Chart
Page 23
Page 24 - Torque and Locking Agent
Page 25 - Periodic maintenance
Page 26
Page 27
Page 28 - Specifications
Page 29
Page 30 - Special Tools
Page 31 - Periodic Maintenance Procedures
Page 32 - Idle Speed Inspection
Page 33 - Idle Speed Adjustment
Page 34 - Fuel Hose Replacement
Page 35 - Fuel Tap Cleaning
Page 36 - Engine Top End
Page 37 - Spark Arrester Cleaning
Page 38 - Clutch Release Adjustment (KLX110C)
Page 39 - Friction and Steel Plates Inspection
Page 40 - Oil Filter Replacement
Page 41 - Wheel/Tires
Page 42 - Tires Inspection
Page 43 - Rim Runout Inspection
Page 44 - Final Drive
Page 45 - Drive Chain Wear Inspection
Page 46 - Drive Chain Lubrication
Page 47 - Sprocket Wear Inspection
Page 48 - Brake Lever Free Play Adjustment
Page 49 - Brake Pedal Free Play Adjustment
Page 50 - Cam Lever Angle Inspection
Page 51
Page 52 - Brake Panel Lubrication
Page 53 - Rear Shock Absorber Operation Inspection
Page 54 - Swingarm Pivot Inspection
Page 55 - Stem Bearing Lubrication
Page 56 - Frame
Page 57 - Battery Charging Condition Inspection
Page 58 - Cable Inspection
Page 59 - Nut, Bolt, and Fastener Tightness Inspec...
Page 60
Page 61
Page 62 - Exploded View
Page 63 - Exploded view
Page 64
Page 65
Page 66 - Specifications
Page 67 - Special Tool
Page 68 - Throttle Grip and Cable
Page 69 - Throttle Cable Lubrication
Page 70 - Choke Cable Installation
Page 71 - Carburetor
Page 72 - Float Height Inspection
Page 73 - Carburetor Removal
Page 74 - Carburetor Installation
Page 75 - Carburetor Cleaning
Page 76 - Carburetor Inspection
Page 77
Page 78 - Carburetor Assembly
Page 79 - Air Cleaner
Page 80 - Air Cleaner Element Installation
Page 81 - Fuel Tank
Page 82 - Fuel Tap Removal
Page 83
Page 84
Page 85
Page 86 - Exploded View
Page 87
Page 88
Page 89
Page 90 - Specifications
Page 91
Page 92 - Special Tools
Page 93
Page 94 - Camshaft Chain Tensioner
Page 95 - Camshaft Chain Tensioner Installation
Page 96 - Camshaft
Page 97 - KACR Installation
Page 98 - Camshaft Sprocket Removal
Page 99 - Camshaft Sprocket Installation
Page 100 - Camshaft Chain Removal
Page 101 - Camshaft Chain Installation
Page 102 - Rocker Arm, Rocker Arm Shaft
Page 103 - Rocker Arm & Arm Shaft Wear Inspection
Page 104 - Cylinder Head
Page 105 - Cylinder Head Removal
Page 106 - Cylinder Head Cleaning
Page 107 - Valves
Page 108 - Valve Guide Removal
Page 109 - Valve Seat Inspection
Page 110 - Valve Seat Repair
Page 111
Page 112
Page 113 - Valve Head Thickness Inspection
Page 114 - Valve Stem Diameter Inspection
Page 115
Page 116
Page 117 - Cylinder, Piston
Page 118 - Piston Removal
Page 119 - Cylinder Inside Diameter Measurement
Page 120 - Piston/Cylinder Clearance Inspection
Page 121 - Piston Ring End Gap Inspection
Page 122 - Piston, Piston Pin, Connecting Rod Wear ...
Page 123 - Piston, Piston Pin, Connecting Rod Inspe...
Page 124 - Muffler
Page 125 - Muffler Installation
Page 126
Page 127
Page 128 - Exploded View
Page 129
Page 130
Page 131
Page 132 - Specifications
Page 133 - Special Tools
Page 134 - Clutch Lever and Cable (KLX110D)
Page 135 - Clutch Cover (KLX110C)
Page 136 - Clutch Cover Assembly
Page 137 - Clutch Cover (KLX110D)
Page 138 - Release Shaft Installation
Page 139 - Clutch Removal (KLX110C)
Page 140 - Secondary Clutch Disassembly (KLX110C)
Page 141 - Clutch Installation (KLX110C)
Page 142 - Clutch Removal (KLX110D)
Page 143
Page 144 - Clutch Hub Disassembly (KLX110D)
Page 145 - Primary Clutch Housing Wear Inspection (...
Page 146 - One-Way Clutch Inspection (KLX110C)
Page 147 - Clutch Housing Finger Damage Inspection
Page 148
Page 149
Page 150 - Exploded View
Page 151
Page 152 - Engine Oil Flow Chart
Page 153 - Specifications
Page 154 - Special Tools
Page 155 - Engine Oil and Oil Filter
Page 156 - Oil Screen Cleaning
Page 157 - Oil Pump
Page 158 - Oil Pipe
Page 159 - Oil Pressure
Page 160
Page 161
Page 162 - Exploded View
Page 163
Page 164 - Special Tool
Page 165 - Engine Removal/Installation
Page 166 - Engine Installation
Page 167
Page 168 - Exploded View
Page 169
Page 170
Page 171
Page 172 - Specifications
Page 173 - Special Tools & Sealant
Page 174 - Crankcase
Page 175 - Crankcase Assembly
Page 176
Page 177
Page 178 - Crankshaft, Connecting Rod
Page 179 - Connecting Rod Big End Seizure Inspectio...
Page 180 - Crankshaft Alignment
Page 181 - External Shift Mechanism
Page 182 - External Shift Mechanism Inspection
Page 183 - Transmission
Page 184 - Transmission Shaft Disassembly
Page 185 - Shift Fork Bending Inspection
Page 186 - Shift Fork Ear/Gear Shift Fork Groove We...
Page 187 - Ball Bearing, Needle Bearing, and Oil Se...
Page 188 - Kickstarter
Page 189 - Kick Shaft Inspection
Page 190
Page 191
Page 192 - Exploded View
Page 193
Page 194 - Specifications
Page 195 - Special Tools
Page 196 - Wheels (Rims)
Page 197 - Rear Wheel Removal
Page 198 - Rear Wheel Installation
Page 199 - Wheels Inspection
Page 200 - Axle Inspection
Page 201 - Tires
Page 202 - Air Pressure Inspection/Adjustment
Page 203 - Hub Bearings
Page 204 - Bearing Lubrication
Page 205
Page 206 - Exploded View
Page 207
Page 208 - Specifications
Page 209 - Special Tools
Page 210 - Drive Chain
Page 211 - Drive Chain Installation
Page 212
Page 213 - Sprockets
Page 214 - Rear Sprocket Warp Inspection
Page 215
Page 216 - Exploded View
Page 217
Page 218
Page 219
Page 220 - Specifications
Page 221 - Special Tools
Page 222 - Brake Lever and Cable
Page 223 - Brake Pedal and Rod
Page 224 - Brake Panel and Drum
Page 225 - Brake Panel Assembly
Page 226 - Brake Drum Wear Inspection
Page 227 - Camshaft Wear Inspection
Page 228
Page 229
Page 230 - Exploded View
Page 231
Page 232
Page 233
Page 234 - Specifications
Page 235 - Special Tools
Page 236 - Front Fork
Page 237 - Front Fork Disassembly (each fork leg)
Page 238 - Front Fork Assembly
Page 239
Page 240 - Inner Tube Inspection
Page 241 - Rear Shock Absorber
Page 242 - Rear Shock Absorber Inspection
Page 243 - Swingarm
Page 244
Page 245
Page 246 - Exploded View
Page 247
Page 248 - Special Tools
Page 249 - Steering Inspection
Page 250 - Steering Stem
Page 251 - Steering Stem, Stem Bearing Installation
Page 252
Page 253 - Stem Bearing Lubrication
Page 254 - Handlebar
Page 255 - Handlebar Installation
Page 256
Page 257
Page 258 - Exploded View
Page 259
Page 260
Page 261
Page 262 - Special Tool
Page 263 - Frame
Page 264 - Shroud
Page 265 - Seat
Page 266 - Side Covers
Page 267 - Number Plate
Page 268 - Fenders
Page 269 - Rear Flap Removal/Installation
Page 270 - Footpegs and Bracket
Page 271 - Sidestand
Page 272
Page 273
Page 274 - Exploded View
Page 275
Page 276
Page 277
Page 278 - Specifications
Page 279 - Special Tools and Sealant
Page 280 - Wiring Diagram
Page 281
Page 282
Page 283
Page 284 - Precautions
Page 285 - Electrical Wiring
Page 286 - Battery
Page 287
Page 288
Page 289 - Precautions
Page 290 - Interchange
Page 291
Page 292 - Charging System
Page 293 - Alternator Rotor Removal
Page 294 - Stator Removal
Page 295
Page 296 - Charging Voltage Inspection
Page 297
Page 298
Page 299
Page 300 - Starter Motor Clutch
Page 301 - Starter Motor Clutch Inspection
Page 302 - Ignition System
Page 303 - Spark Plug Cleaning and Inspection
Page 304
Page 305 - Crankshaft Sensor Inspection
Page 306
Page 307
Page 308
Page 309 - Electrical Starter System
Page 310
Page 311 - Starter Motor Assembly
Page 312 - Starter Motor Brush Inspection
Page 313 - Armature Inspection
Page 314
Page 315
Page 316
Page 317 - Switches and Sensors
Page 318 - Fuses
Page 319
Page 320
Page 321
Page 322
Page 323
Page 324
Page 325
Page 326
Page 327
Page 328 - Troubleshooting guide
Page 329 - Engine overheating
Page 330 - Clutch operation faulty
Page 331 - Battery trouble
Page 332
/
332
Contents
Table of contents
Troubleshooting
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Special Tools
Outside Circlip Pliers:
57001-144
Bearing Driver Set:
57001-1129
FINAL DRIVE 10-5
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Quick Links:
Wheel/Tires
Ignition System
Camshaft Chain Tensioner
Carburetor
Before servicing
Idle Speed Adjustment
Air Cleaner Element Cleaning
Torque and Locking Agent
Unit Conversion Table
Engine Lubrication System
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Chapters
Table Of Contents
9
Periodic Maintenance
21
Fuel System
61
Engine Top End
85
Clutch
127
Engine Lubrication System
149
Table Of Contents
161
Crankshaft/transmission
167
Wheels/tires
191
Final Drive
205
Brakes
215
Suspension
229
Steering
245
Frame
257
Electrical System
273
Table of Contents
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Kawasaki KLX110 Service Manual
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This manual is also suitable for:
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