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Table of Contents

   Also See for Kawasaki KLX110

   Summary of Contents for Kawasaki KLX110

  • Page 2 GENERAL INFORMATION Quick Reference Guide MAINTENANCE AND ADJUSTMENT This Quick Reference Guide will assist you in finding the information you’re looking for. TROUBLESHOOTING GUIDE STORAGE A Table of Contents is included after the Foreword.
  • Page 3 IMPORTANT INFORMATION • This vehicle is designed for the operator only, no passengers. • This vehicle is an off-road motorcycle only and was not manufactured for use on public streets, roads or highways. • Respect the environment and the rights of other people. •...
  • Page 5 NOTICE Whenever you see the symbols shown below, heed their instructions! Always follow safe operat- NOTICE is used to address practices not re- ing and maintenance practices. lated to personal injury. DANGER NOTE DANGER indicates a hazardous situation ○ NOTE indicates information that may help or guide which, if not avoided, will result in death or you in the operation or service of the vehicle.
  • Page 6 IMPORTANT Off-road motorcycling is a wonderful sport, and we hope you will enjoy it to the fullest. How- ever, if improperly conducted, this sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not occur.
  • Page 7 IMPORTANT NOTE TO PARENTS ABOUT SAFE RIDING Your youngster’s safety will depend on your commitment to always provide a safe riding environment and a properly maintained vehicle. As with any moving vehicle there are possible safety risks; be sure to heed these precautions.
  • Page 8 10. Encourage your youngster not to ride beyond his or her skill level or faster than conditions safely allow. Have them practice advanced riding maneuvers under controlled conditions. 11. Tell someone where you and your youngster are planning to ride and when you intend to return. Discuss the ride with your youngster before you leave so he or she will know in advance what riding techniques may be necessary to negotiate the terrain safely.
  • Page 9 WARNING Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemi- cals known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 10 FOREWORD We wish to thank you for choosing this Kawasaki motorcycle. It is the end product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, and performance. By giving your motorcycle the proper care and maintenance outlined in this manual, you will be helping to ensure it a long, trouble-free life.
  • Page 11: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS..........Carburetor ............. GENERAL INFORMATION......Clutch ............LOCATION OF LABELS........ Valve Clearance ..........Location of Parts ........... Spark Arrester ..........Side Stand ............. Drive Chain............ Fuel Tap............Handlebar............Fuel ............... Brakes ............Throttle Limiting Screw ........Steering ............Engine Stop Switch ........
  • Page 12: Specifications

    SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length 1 560 mm (61.4 in.) Overall Width 650 mm (25.6 in.) Overall Height: KLX110C 955 mm (37.6 in.) KLX110D 990 mm (39.0 in.) Wheelbase 1 075 mm (42.3 in.) Road Clearance: KLX110C 215 mm (8.5 in.) KLX110D 265 mm (10.4 in.) Curb Mass...
  • Page 13 SPECIFICATIONS Lubrication System Forced lubrication (wet sump) Spark Plug NGK CR6HSA TRANSMISSION Transmission Type 4-speed, constant mesh, return shift Clutch Type: KLX110C Centrifugal and wet, multi disc KLX110D Wet, multi disc Driving System Chain drive Gear Ratio: 3.000 (36/12) 1.938 (31/16) 1.350 (27/20) 1.087 (25/23) Primary Reduction Ratio...
  • Page 14 Front Telescopic fork Rear Swingarm (mono-shock) Front Suspension Travel: KLX110C 110 mm (4.3 in.) KLX110D 140 mm (5.5 in.) Rear Wheel Travel: KLX110C 110 mm (4.3 in.) KLX110D 132 mm (5.2 in.) Front Fork Oil: Type Kawasaki Fork Oil SS8...
  • Page 15 SPECIFICATIONS Amount (Per One Unit): KLX110C 165 mL (5.6 US oz.) KLX110D 182 mL (6.2 US oz.) BRAKES Type: Front Drum brake Rear Drum brake ELECTRICAL EQUIPMENT Battery 12 V 3 Ah Specifications are subject to change without notice.
  • Page 16: General Information

    If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct po- sition. NOTE 1.
  • Page 17 GENERAL INFORMATION 2. Important Information 3. Vehicle Emission Control Information 4. Noise Emission Control Information...
  • Page 19: Location Of Parts

    GENERAL INFORMATION Location of Parts 1. Clutch Lever (KLX110D 3. Front Brake Lever 6. Fuel Tank Cap Model) 4. Throttle Grip 2. Engine Stop Switch 5. Starter Button...
  • Page 20: Engine Oil Drain Bolt

    GENERAL INFORMATION 7. Front Fork 12. Air Cleaner 17. Side Stand 8. Brake Cable 13. Oil Filter Cap 18. Swingarm 9. Choke Knob 14. Engine Oil Drain Bolt 19. Drive Chain 10. Fuel Tap 15. Shift Pedal 11. Brake Cam Lever 16.
  • Page 21 GENERAL INFORMATION 20. Muffler 24. Throttle Limiting Screw 27. Oil Level Inspection 21. Rear Shock Absorber 25. Kick Pedal Window 22. Seat 26. Rear Brake Pedal 28. Carburetor 23. Fuel Tank...
  • Page 22: Side Stand

    GENERAL INFORMATION Side Stand Fuel Tap The motorcycle is equipped with a side stand. The fuel tap has three position; OFF, ON, and RES (reserve). For normal operation, turn the fuel tap lever to the ON position. If the fuel runs out with the tap in the ON position, the last approximately 0.4 L (0.11 US gal) of usable fuel remains can be used by turning the tap lever to the RES position.
  • Page 23: Fuel

    GENERAL INFORMATION NOTE Fuel ○ Since riding distance is limited when on RES, re- fuel at the earliest opportunity. ○ The required of fuel is specified under “Fuel Re- Make certain that the fuel tap lever is turned to ON quirement”.
  • Page 24 GENERAL INFORMATION WARNING Minimum Octane Rating Method Rating Gasoline is extremely flammable and can be explosive under certain conditions, creating (RON + MON) Antiknock Index the potential for serious burns. Move the en- gine stop switch to the position. Do not smoke.
  • Page 25 5% methanol. Fuel system damage and blends during refueling. performance problems may result. When not operating your Kawasaki for 30 to 60 days, mix a fuel stabilizer (such as Gasoline/Ether Blends - The most common ether STA-BIL) with the gasoline in the fuel tank.
  • Page 26: Throttle Limiting Screw

    3/8 or 1/2 of full throttle. Kawasaki recommends raising the level of the throttle limiting screw step-by-step as follows; The 3/8 degree screw can be used for the beginning...
  • Page 27: Engine Stop Switch

    A. Throttle Limiting Screw B. Throttle Grip C. Locknut NOTICE Use only the Kawasaki screws supplied with the motorcycle. Substituting non standard screws can damage the throttle housing. NOTE ○ Store the uninstalled throttle limiting screw in a location where they will not be lost.
  • Page 28: Starter Button

    GENERAL INFORMATION Starter Button This motorcycle has the starter button. A. Engine Stop Switch B. Indicator Light (LED) A. Starter Button...
  • Page 29: Kick Pedal

    GENERAL INFORMATION Kick Pedal Starting the Engine • This motorcycle is equipped with a kick starting Turn the fuel tap lever to the ON position. system. When using the kick pedal, make sure that the transmission is in neutral. A. Fuel Tap B.
  • Page 30 GENERAL INFORMATION • Check that the engine stop switch is in the position. A. Choke Knob NOTE A. Engine Stop Switch ○ When the engine is already warm or on hot days, Position open the throttle part way instead of using the •...
  • Page 31 GENERAL INFORMATION ○ For KLX110D model; when using the kick pedal, make sure that the transmission is in neutral, and do not pull in the clutch lever. A. Starter Button NOTICE Do not operate the starter continuously for A. Kick Pedal more than 5 seconds, or the starter will overheat and the battery power will drop NOTE...
  • Page 32 GENERAL INFORMATION NOTICE Do not let the engine idle longer than five minutes, or engine overheating and damage may occur. A. Clutch Lever B. Starter Lockout Switch • Gradually push the choke knob back a little at a time as necessary to keep the engine running properly during warm-up.
  • Page 33: Moving Off

    GENERAL INFORMATION Moving Off Shifting Gears KLX110C Model KLX110C Model • • Check that the side stand is up. Close the throttle completely. • • Shift into 1st gear. Shift into the next higher or lower gear. • • Open the throttle slowly. Open the throttle slowly.
  • Page 34 GENERAL INFORMATION WARNING pedal, gently release the clutch lever, then release the shift pedal. Downshifting to a lower gear at high speed • To shift up to the next gear, pull in the clutch lever, causes engine rpm to increase excessively, lift the shift pedal with your toes, gently release the potentially damaging the engine and it may clutch lever, and then release the shift pedal.
  • Page 35: Stopping The Motorcycle

    GENERAL INFORMATION Stopping the Motorcycle Stopping the Engine • For maximum deceleration, close the throttle and Shift the transmission into the neutral position. • apply both front and rear brakes. Pull in the clutch Close the throttle completely. • lever as the motorcycle comes to a stop (KLX110D Push the engine stop switch to the position.
  • Page 36: Break-in

    GENERAL INFORMATION Break-In The first one hour that the motorcycle is ridden is designed as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a “broken down” instead of a “bro- ken in”...
  • Page 37: Daily Pre-ride Checks

    GENERAL INFORMATION Daily Pre-Ride Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure a safe, reliable ride. If any irregularities are found during these checks, refer to the appropriate section and take the action required to return the motorcycle to a safe operating condition.
  • Page 38 GENERAL INFORMATION Frame Tires ..........Overall condition good No wear or damage Pressure correct Air valve cap installed Spokes ........No looseness Drive Chain ......... Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ....Function properly Lever and pedal play correct No wear to brake lining Throttle ........
  • Page 39: Maintenance And Adjustment

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and ex- haust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency.
  • Page 40 You should keep a maintenance record for your vehicle. To assist you in keeping this record, we have pro- vided space at the end of this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. You should also retain copies of maintenance work orders, receipts, etc., as ver- ification of this maintenance.
  • Page 41 MAINTENANCE AND ADJUSTMENT TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 42: Periodic Maintenance Chart

    MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accor- dance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. 1. Periodic Inspection (Engine Related Item) FREQUENCY Initial Every...
  • Page 43 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Item) FREQUENCY Initial Every 5 hours 50 hours 100 hours Page (1 month) (6 months) (12 months) OPERATION Brake - adjust † Every ride 75, 76 Brake lining wear - inspect † Every ride •...
  • Page 44 MAINTENANCE AND ADJUSTMENT FREQUENCY Initial Every 5 hours 50 hours 100 hours Page (1 month) (6 months) (12 months) OPERATION • • Battery - inspect † • • Battery terminal - inspect † • • • General lubrication - perform •...
  • Page 45 Every 5 years • • K Front fork oil - change – †: Replace, add, adjust, clean or torque if necessary. K: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer. ○ : Emission-related Item...
  • Page 46: Engine Oil

    MAINTENANCE AND ADJUSTMENT Oil Level Inspection • Engine Oil If the oil has just been changed, let the motorcycle sit a few minutes allowing the oil to settle. • In order for the engine, transmission and clutch Start the engine and run it for several minutes at to function properly, maintain the engine oil at the idle speed.
  • Page 47: Oil And/or Oil Filter Change

    MAINTENANCE AND ADJUSTMENT NOTE Oil and/or Oil Filter Change ○ The engine oil and/or oil filter should be changed If no oil appears in the oil level inspection window, periodically to ensure long engine life. tip the motorcycle slightly to the right until oil is •...
  • Page 48 MAINTENANCE AND ADJUSTMENT WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local author- ities for approved disposal methods or pos- sible recycling. • When the oil filter is replaced, remove the engine guard and oil filter cap bolts and take off the cap with O-ring and spring.
  • Page 49 MAINTENANCE AND ADJUSTMENT • • Replace the oil filter element with a new one. Install the spring to the oil filter cap. • • Install the oil filter element with the grommet to- Install the oil filter cap with the high-temperature ward the engine.
  • Page 50: Recommended Engine Oil

    4-stroke oils with API SG, SH, SJ, SL, SM and JASO MA, MA1, MA2 rating Viscosity: SAE 10W-40 *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Con- sistent use of these products meets or exceeds war- •...
  • Page 51: Spark Plug

    MAINTENANCE AND ADJUSTMENT • Check the oil level and oil leakage. Spark Plug The spark plug should be taken out periodically for inspection and regapping. Measure the gap with a wire-type thickness gauge. If incorrect, adjust the gap to the specified value by bending the outer elec- trode.
  • Page 52 MAINTENANCE AND ADJUSTMENT • If the plug is oily or has carbon built up on it, clean Apply a suitable wrench to the spark plug. • it. The plug may also be cleaned using a high flash Loosen and remove the spark plug. •...
  • Page 53: Air Cleaner

    MAINTENANCE AND ADJUSTMENT Element Removal and Inspection • Air Cleaner Remove the bolts on the right and left sides. • Clear the projections from the grommets and hook A clogged air cleaner restricts the air intake, in- portions from the slots, and remove the side cov- creases fuel consumption, reduces engine power, ers.
  • Page 54 MAINTENANCE AND ADJUSTMENT • Remove the screws and air cleaner cover. A. Screw B. Bolts A. Screws C. Fuel Tank Cap B. Air Cleaner Cover D. Shroud • Install the fuel tank cap.
  • Page 55 MAINTENANCE AND ADJUSTMENT • Take out the air cleaner element. A. Wire Screen B. Air Cleaner Cover A. Air Cleaner Element • • Inspect the element. If it is dirty, clean it. Also Check inside of the intake tract and carburetor for check if the element is in good condition (no tears, dirt.
  • Page 56 MAINTENANCE AND ADJUSTMENT • NOTICE After cleaning, let the filter dry completely. Satu- rate the element with a high-quality foam air fil- A clogged air cleaner may allow dirt and dust ter oil and make sure that the oil is evenly ap- to enter the engine, causing it to wear exces- plied throughout the element.
  • Page 57 MAINTENANCE AND ADJUSTMENT • • Install the air cleaner element in the housing, and Insert the hook and projection into the slot and make sure the sealing surface of the element is grommet. seated properly. • Install the air cleaner cover and tighten the screws. Tightening Torque Air Cleaner Cover Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)
  • Page 58: Throttle Cable

    MAINTENANCE AND ADJUSTMENT Oil Draining • Throttle Cable Inspect the plug to see if any oil or water has run down. Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle cable in accordance with the Periodic Maintenance Chart.
  • Page 59 MAINTENANCE AND ADJUSTMENT • • If there is improper play, adjust it. Install the rubber boot. • • Pull the rubber boot off the upper end of the throttle If the free play cannot be set by adjusting the upper cable.
  • Page 60: Carburetor

    MAINTENANCE AND ADJUSTMENT • Check if the throttle grip moves smoothly from full Carburetor open to close, and the throttle closes quickly and completely in all steering positions by the return spring. If not, check the throttle cable routing, grip The following procedure covers the idle adjust- free play, and cable damage.
  • Page 61: Clutch

    MAINTENANCE AND ADJUSTMENT Clutch KLX110C Model Clutch Adjustment • Loosen the locknut. • Turn the clutch release adjusting screw counter- clockwise until it becomes hard to turn, and then back it out a quarter turn. A. Idle Adjusting Screw • Open and close the throttle a few times to make sure the idle speed does not change, and readjust if necessary.
  • Page 62: Clutch Lever Adjustment

    MAINTENANCE AND ADJUSTMENT • Start the engine and check the clutch by operating If the clutch lever free play cannot be adjusted at the shift pedal. the clutch lever, make the adjustment further down the cable as follows. KLX110D Model •...
  • Page 63: Valve Clearance

    Valve clearance for each valve should be checked and adjusted in accordance with the Periodic Main- tenance Chart. Inspection and adjustment should be done by an authorized Kawasaki dealer.
  • Page 64: Spark Arrester

    MAINTENANCE AND ADJUSTMENT • Remove the right side cover (see Air Cleaner sec- Spark Arrester tion). • Remove the screws and muffler cover. This vehicle is equipped with a spark arrester. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester.
  • Page 65 MAINTENANCE AND ADJUSTMENT • • Remove the bolts and pull the spark arrester. With a wire brush, remove the carbon off the inside of the spark arrester and muffler. A. Bolts B. Spark Arrester A. Spark Arrester • Install the spark arrester into the rear end of the muffler.
  • Page 66: Drive Chain

    MAINTENANCE AND ADJUSTMENT • Adjust the drive chain if its slack is out of specifi- Drive Chain cation. For safety and to prevent excessive wear, the drive chain must be checked, adjusted, and lubricated be- fore riding. If the chain becomes badly worn or mal- adjusted - either too loose or too tight - it could jump off the sprockets or break.
  • Page 67 MAINTENANCE AND ADJUSTMENT A. Torque Link Nut A. Rear Axle Nut B. Cotter Pin B. Adjusting Nut C. Locknut • Remove the cotter pin from the rear axle nut. D. Marks • Loosen the rear axle nut and both chain adjuster E.
  • Page 68 MAINTENANCE AND ADJUSTMENT • ○ Tighten both chain adjuster locknuts. It should be within 30 degrees. • ○ Tighten the axle nut to the specified torque. Loosen once and tighten again when the slot goes past the nearest hole. Tightening Torque Rear Axle Nut: 64 N·m (6.5 kgf·m, 47 ft·lb) •...
  • Page 69 MAINTENANCE AND ADJUSTMENT WARNING A loose axle nut and torque link nut can lead to an accident resulting in serious injury or death. Tighten the axle nut and torque link nut to the proper torque and install new cot- ter pins. •...
  • Page 70 MAINTENANCE AND ADJUSTMENT NOTE ○ The drive system was designed for use with a DAIDO DID 420DX 90-links chain. For maximum stretch resistance and safety, a genuine part must be used for replacement. ○ To minimize any chance of the master link coming apart, the master link clip must be installed with the closed end of the “U”...
  • Page 71 MAINTENANCE AND ADJUSTMENT Chain Slipper Wear Inspection Sprocket Wear Inspection • • Visually inspect the chain slipper on the swingarm Visually inspect the sprocket teeth and replace the and replace it if worn or damaged. sprocket if its teeth are worn or damaged. Sprocket Teeth Wear A.
  • Page 72: Handlebar

    MAINTENANCE AND ADJUSTMENT Chain Lubrication Handlebar Lubrication of the drive chain is necessary after rid- ing in the rain or mud, or any time the chain appears dry with a high quality lubricant for drive chains. To keep the handlebar properly secured in place, •...
  • Page 73: Brakes

    Check the front brake for the proper brake effect, brake cam lever. Replace excessively worn or no brake drag. brake linings. Inspection and replacement of any brake components should be performed by an authorized Kawasaki dealer.
  • Page 74 USABLE RANGE when the brake is fully applied, the brake shoe linings have worn past the service limit. In this case, the brake shoes must be replaced and the drum and other brake parts ex- amined by an authorized Kawasaki dealer.
  • Page 75 MAINTENANCE AND ADJUSTMENT A. Rear Brake Panel A. Locknut B. USABLE RANGE B. Adjuster C. Brake Lining Wear Indicator C. 4 ~ 5 mm (0.16 ~ 0.20 in.) • Rotate the wheel to check for brake drag. Front Brake Lever Play Inspection •...
  • Page 76 MAINTENANCE AND ADJUSTMENT Front Brake Lever Play Adjustment • Slide the front brake lever dust cover back. • Loosen the locknut at the front brake lever, screw the adjuster fully in, and tighten the locknut. • Loosen the nuts at the lower end of the front brake cable.
  • Page 77 MAINTENANCE AND ADJUSTMENT WARNING Rear Brake Pedal Play Inspection • The brake pedal play should have 20 ~ 30 mm (0.8 An improperly adjusted brake could drag ~ 1.2 in.) when the pedal is pushed down lightly and cause the brake to overheat, damaging by hand.
  • Page 78: Steering

    MAINTENANCE AND ADJUSTMENT Steering The steering should always be kept adjusted so that the handlebar will turn freely but not have ex- cessive play. The steering play must be checked in accordance with the Periodic Maintenance Chart. Steering Inspection • To check the steering adjustment, raise the front wheel off the ground using a jack (special tool: 57001-1238).
  • Page 79 MAINTENANCE AND ADJUSTMENT • Steering Adjustment Remove the handlebar clamp bolts and take out • Raise the front wheel off the ground using a jack the handlebar. (special tool: 57001-1238). • Unlock the clamp of the number plate. • Remove the bolt. •...
  • Page 80 MAINTENANCE AND ADJUSTMENT • Loosen the steering stem head nut and left and right front fork clamp bolts (upper). A. Steering Stem Locknut B. Stem Nut Wrench (Special Tool: 57001-1100) • Apply the specified torques to the steering stem A. Steering Stem Head Nut head nut and front fork clamp bolts (upper).
  • Page 81: Front Suspension

    If the inner tube is badly bent or creased, tube. replace it. Excessive bending, followed by • If necessary, repair or replace by an authorized subsequent straitening, can weaken the in- Kawasaki dealer. ner tube.
  • Page 82: Rear Suspension

    80 ∼ 100 kPa (0.8 ∼ 1.0 kgf/cm², 12 ∼ 14 psi) leakage. • If necessary, repair or replace by an authorized NOTE Kawasaki dealer. ○ Tire air pressure should be checked when the tires are cold, before you ride the motorcycle.
  • Page 83 MAINTENANCE AND ADJUSTMENT Spokes and Rims Rim Runout The spokes on both wheels must all be securely Set up a dial gauge on the side of the rim and and evenly tightened and not be allowed to loosen. rotate the wheel to measure its axial runout. The Unevenly tightened or loose spokes will cause the difference between the highest and lowest readings rim to warp, the nipples and spokes to fatigue more...
  • Page 84 MAINTENANCE AND ADJUSTMENT NOTE ○ The welding spot of the rim may show exces- sive runout. Disregard this when measuring rim runout. Rim Runout A. Axial Rim Runout Measurement A. Rim B. Axial Runout C. Radial Runout Rim Runout Maximum Limit Axial *TIR 2.0 mm (0.08 in.) Radial...
  • Page 85: Hoses Inspection

    MAINTENANCE AND ADJUSTMENT Hoses Inspection Battery Check the fuel hose for cracks or deterioration, The battery installed in this motorcycle is a sealed and the connections for looseness in accordance type, so it is not necessary to check the battery elec- with the Periodic Maintenance Chart.
  • Page 86 12.6 volts, the battery should be discharged discharged charged using an appropriate charger (check with a Kawasaki dealer). If you will not be using the 7 mA 60 Days 119 Days motorcycle for longer than two weeks, the battery...
  • Page 87 If the above chargers are not available, use equiv- alent one. Lead is a toxic substance. Battery posts, ter- For more details, ask a Kawasaki dealer. minals and related accessories contain lead and lead compounds. Wash hands after han- Battery Charging - •...
  • Page 88 MAINTENANCE AND ADJUSTMENT NOTICE Installing the (–) cable to the (+) terminal of the battery or the (+) cable to the (–) termi- nal of the battery can seriously damaged the electrical system. • Put a light coat of grease on the terminals to pre- vent corrosion.
  • Page 89: Fuse

    MAINTENANCE AND ADJUSTMENT WARNING Fuse Substituting fuses can cause wiring to over- heat, catch fire and/or fail. Do not use any The fuse and spare fuse are mounted behind the substitute for the standard fuse. Replace the left side cover. If a fuse fails during operation, in- blown fuse with a new one of the correct ca- spect the electrical system to determine the cause, pacity, as specified on the fuse.
  • Page 90: Tightening Torques Of Nuts And Bolts

    MAINTENANCE AND ADJUSTMENT Tightening Torques of Nuts and Bolts Location of nuts and bolts Before the first ride of each day of operation, check the tightness of the nuts and bolts shown below. Check also that all cotter pins are in place and in good condition. 1.
  • Page 91: Spark Plug

    MAINTENANCE AND ADJUSTMENT 12. Rear Shock Absorber Nut 15. Steering Stem Head Nut 20. Kick Pedal Bolt (Lower) 16. Brake Cam Lever Bolt 21. Footpeg Mounting Bolts 13. Muffler Body Mounting Bolt 17. Rear Axle Nut 22. Exhaust Pipe Holder Nuts and Nut 18.
  • Page 92 MAINTENANCE AND ADJUSTMENT Torque Table Tighten all nuts and bolts to the proper torque using an accurate torque wrench. An insufficiently tightened nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider.
  • Page 93 MAINTENANCE AND ADJUSTMENT Fastener N·m kgf·m ft·lb Remarks Rear Shock Absorber Bolt and Nut (Upper) Rear Shock Absorber Nut (Lower) Swingarm Pivot Shaft Nut Torque Link Nuts Handlebar Clamp Bolts Steering Stem Head Nut Footpeg Mounting Bolts Side Stand Bolt 87 in·lb Side Stand Nut R: Replacement Parts...
  • Page 94: Cleaning Your Motorcycle

    Avoid all harsh chemicals, solvents, detergents, and household cleaning products such as ammo- General Precautions nia-based window cleaners. Frequent and proper care of your Kawasaki mo- • Gasoline, brake fluid, and coolant will damage the torcycle will enhance its appearance, optimize over- finish of painted and plastic surfaces: wash them all performance, and extend its useful life.
  • Page 95 MAINTENANCE AND ADJUSTMENT • Plastic Parts Use a soft cloth to dry your motorcycle. As you dry, inspect your motorcycle for chips and scratches. After washing use a soft cloth to gently dry plastic Do not let the water air dry as this can damage parts.
  • Page 96: Lubrication

    MAINTENANCE AND ADJUSTMENT Chrome and Aluminum Lubrication Chrome and uncoated aluminum parts can be treated with a chrome/aluminum polish. Coated aluminum should be washed with a mild neutral de- Lubricate the areas shown in the illustrations of tergent and finished with a spray polish. Aluminum this section with either motor oil or regular grease, wheels, both painted and unpainted can be cleaned in accordance with the Periodic Maintenance Chart...
  • Page 97 MAINTENANCE AND ADJUSTMENT • • Rear Brake Pedal Shift Pedal • • Rear Brake Rod Joint Side Stand • Kick Pedal • Footpeg...
  • Page 98 MAINTENANCE AND ADJUSTMENT Apply an aerosol cable lubricant with a pressure Apply grease to the following points: • lubricator on all cables: Clutch Inner Cable Upper End (KLX110D Model) • • Clutch Cable (KLX110D Model) Throttle Inner Cable Upper End •...
  • Page 99 MAINTENANCE AND ADJUSTMENT Chain Lubrication Lubrication of the drive chain is necessary after rid- ing in the rain or mud, or any time the chain appears dry with a high quality lubricant for drive chains. • Apply lubricant to the side of the rollers so that it will penetrate to the rollers and bushings.
  • Page 100: Troubleshooting Guide

    TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE NOTE Engine does not turn over: • ○ Valve seized This troubleshooting guide is not exhaustive and • Cylinder or piston seized does not give every possible cause for each prob- • Crankshaft seized lem listed. It is meant simply as a quick guide to •...
  • Page 101 TROUBLESHOOTING GUIDE • Spark plug cap or high-tension wiring defective Poor low-speed performance - • Spark plug cap not contacting properly Spark weak: • Spark plug type incorrect • Spark plug dirty, broken, or gap improperly ad- • Crankshaft sensor defective justed •...
  • Page 102 TROUBLESHOOTING GUIDE • Valve not seating properly (valve bent, worn, or Fuel/air mixture incorrect: • carbon accumulation on the seating surface) Main jet clogged or wrong size • • Piston ring worn, weak, broken, or sticking Jet needle or needle jet worn •...
  • Page 103 TROUBLESHOOTING GUIDE Improper acceleration: Fuel/air mixture incorrect: • • Choke valve closed Main jet clogged or wrong size • • Carburetor fuel level too high or too low Carburetor fuel level too low • • Main jet clogged Carburetor holder loose •...
  • Page 104 TROUBLESHOOTING GUIDE • • Clutch release mechanism defective Gear groove worn • • Clutch hub or housing unevenly worn Gear dogs and/or dog grooves worn • Shift drum groove worn • Clutch not disengaging properly: Gear positioning lever spring broken or weak •...
  • Page 105 TROUBLESHOOTING GUIDE Other noise: Drive chain noise: • • Connecting rod small end clearance excessive Drive chain slack improperly adjusted • • Connecting rod big end clearance excessive Drive chain worn • • Piston ring worn, broken or stuck Rear and/or engine sprocket(s) worn •...
  • Page 106 TROUBLESHOOTING GUIDE • Exhaust smoke - Tire air pressure too low Excessively white: Handlebar shakes or vibrates excessively: • Piston oil ring worn • Tire worn • Cylinder worn • Swingarm bushing damaged • Valve oil seal damaged • Rim warped or out of balance •...
  • Page 107 TROUBLESHOOTING GUIDE Shock absorption unsatisfactory (suspension Battery trouble - too soft): Battery discharged: • Front fork oil level insufficient and/or front fork • Charge insufficient leaking oil • Battery faulty (too low terminal voltage) • Front fork oil viscosity too low •...
  • Page 108: Storage

    STORAGE STORAGE WARNING Before Storage Gasoline is extremely flammable and can be explosive under certain conditions, creating When the motorcycle is to be stored for any length the potential for serious burns. Move the en- of time, it should be prepared for storage as follows. •...
  • Page 109: After Storage

    STORAGE After Storage • Remove the plastic bag from the muffler. • Make sure the spark plug is tight. NOTE ○ Fit the plug cap securely onto the spark plug, and pull the cap lightly to make sure that it is properly installed.
  • Page 110: Environmental Protection

    ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION Kawasaki subscribes to the guidelines of Tread Lightly! a program dedicated to protecting the great outdoors through education and fostering responsible enjoyment of public lands. When using your Kawasaki motorcycle, please follow these Tread Lightly! guidelines: Tread Lightly! ravel responsibly on designated roads and trails or in permitted areas.
  • Page 111: Wiring Diagram

  • Page 112 WIRING DIAGRAM KLX110D Model...
  • Page 113: Your Warranty/owner Satisfaction

    You can find the warranty period in the Kawasaki Limited Warranty Certificate your Kawasaki dealer provided to you at the time of sale. The warranty does not cover the cost of regularly-scheduled maintenance. The warranty also does not apply to the normal wear of items such as tires, brake pads, transmission drive belts, chains, sprockets, etc.
  • Page 114 Whether you do it yourself or take your vehicle to a Kawasaki dealer, be sure to record your service in the Maintenance Record section of this Owner’s Manual. Keep all receipts for the service and/or items necessary to perform the maintenance so that in the event of a failure you can document the service history.
  • Page 115 Kawasaki dealer for inspection and diag- nosis. You can go to any Kawasaki dealer for warranty repairs. Your Kawasaki dealer will inspect your vehicle and give you the results of the inspection. The dealer will perform the repairs at no cost to you if it is determined that the problem is covered by the warranty.
  • Page 116 Want to Contact Kawasaki? This owner’s manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you.
  • Page 117: Maintenance Record

    MAINTENANCE RECORD MAINTENANCE RECORD Owner Name........................... Address ............................Phone Number ..........................Engine Number ..........................Vehicle Number..........................Selling Dealer Name ........................Address ............................Phone Number ..........................Warranty Start Date ........................Note: Keep this information and a spare key in a secure location. Date Traveled Distance Maintenance Performed...
  • Page 118 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address...
  • Page 119 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address...
  • Page 120 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address...
  • Page 121 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address...

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