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KLX110
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki KLX110

   Summary of Contents for Kawasaki KLX110

  • Page 1 KLX110 Motorcycle Service Manual...
  • Page 3 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 Electrical System 14 j Troubleshooting 15 j This quick reference guide will assist you in locating a desired topic or pro-...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2001 Kawasaki Heavy Industries, Ltd. 8th Edition (1): May 16, 2008 (K)
  • 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 BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the California Air Resources Board. 1. Crankcase Emission Control System This system eliminates the release of cranckcase vapors into the atmosphere.
  • Page 8 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 9: How To Use This Manual

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- • torcycle parts. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Torque and Locking Agent...................... Special Tools and Sealants ....................1-11 Cable, Wire and Hose Routing ....................1-17 Unit Conversion Table ......................1-22...
  • Page 12: General Information

    1-2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descrip- tions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.
  • Page 13 GENERAL INFORMATION 1-3 Before Servicing (11) Press When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (12)Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing (19)Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent...
  • Page 15: Model Identification

    GENERAL INFORMATION 1-5 Model Identification KLX110-A1 Left Side View KLX110-A1 Right Side View...
  • Page 16: General Specifications

    Forced lubrication (wet sump) Engine Oil: Grade API SE, SF or SG API SH or SJ with JASO MA, MA1 or MA2 (KLX110-A1 ∼ A6F) API SH, SJ or SL with JASO MA, MA1 or MA2 (KLX110A7F ∼) Viscosity SAE 10W-40 Capacity 1.1 L (1.2 US gt): (when engine is completely dry)
  • Page 17 25.5° Trail 54 mm (2.1 in.) Front Tire: Type C803 Size 2.50 - 14 4PR 2.50 - 14 M/C 4PR (KLX110-A2 ∼) Rear Tire: Type C803 Size 3.00 - 12 4PR 3.00 - 12 M/C 4PR (KLX110-A2 ∼) Rim Size: Front 14 ×...
  • Page 18: Torque And Locking Agent

    46 in·lb Valve Adjusting Cap Bolts 0.53 46 in·lb Spark Arrester Mounting Bolts 78 in·lb Clutch Clutch Cover Screws (KLX110-A1 ∼ A7F) 0.53 46 in·lb Clutch Cover Bolts (KLX110A8F ∼) 78 in·lb Clutch Cover Plate Screws 26 in·lb Clutch Hub Nut (Primary) Clutch Hub Nut (Secondary) Clutch Spring Bolts (KLX110-A1 ∼...
  • Page 19 0.53 46 in·lb Shift Return Spring Pin Shift Drum Allen Bolt 0.53 46 in·lb Magneto Flywheel Nut 10 mm (KLX110-A1) Magneto Flywheel Nut 12 mm (KLX110-A2 ∼) Clutch Hub Nut Wheels/Tires Spoke Nipples 0.12 10 in·lb Front Axle Nut Rear Axle Nut...
  • Page 20 Electrical System Gear Position Switch Screw 26 in·lb Spark Plug 113 in·lb Magneto Flywheel Nut 10 mm (KLX110-A1) Magneto Flywheel Nut 12 mm (KLX110-A2 ∼) Exciter Coil Mounting Screws 0.53 46 in·lb Crankshaft Sensor Mounting Screw 26 in·lb Magneto Cover Screws (KLX110-A1 ∼ A7F) 0.53...
  • Page 21: Special Tools And Sealants

    GENERAL INFORMATION 1-11 Special Tools and Sealants Oil Pressure Gauge, 5 kgf/cm²: Fork Cylinder Holder Handle: 57001-125 57001-183 Steering Stem Bearing Driver: Compression Gauge, 20 kgf/cm²: 57001-137 57001-221 Inside Circlip Pliers: Valve Spring Compressor Assembly: 57001-143 57001-241 Outside Circlip Pliers: Bearing Puller Adapter: 57001-144 57001-317...
  • Page 22 1-12 GENERAL INFORMATION Special Tools and Sealants Fork Cylinder Holder Adapter: Crankcase Splitting Tool Assembly: 57001-1011 57001-1098 Fuel Level Gauge: Steering Stem Nut Wrench: 57001-1017 57001-1100 Oil Seal & Bearing Remover: Valve Seat Cutter, 45° - 27.5: 57001-1058 57001-1114 Rim Protector: Valve Seat Cutter, 32°...
  • Page 23 GENERAL INFORMATION 1-13 Special Tools and Sealants Valve Seat Cutter Holder Bar: Bearing Puller Stud: 57001-1128 57001-1190 Bearing Driver Set: Valve Seat Cutter, 45° - 22: 57001-1129 57001-1205 Valve Spring Compressor Adapter, 20: Valve Seat Cutter, 32° - 22: 57001-1154 57001-1206 Crankshaft Jig: Valve Seat Cutter, 67.5°...
  • Page 24 1-14 GENERAL INFORMATION Special Tools and Sealants Valve Adjusting Screw Holder: Bearing Remover Head, 10 × 12: 57001-1217 57001-1266 Front Fork Oil Seal Driver: Fork Oil Level Gauge: 57001-1219 57001-1290 Jack: Flywheel Holder: 57001-1238 57001-1313 Spark Plug Wrench, Hex 16: Compression Gauge Adapter, M10 ×...
  • Page 25 Clutch Holder 1: 57001-1331 57001-1507 Valve Guide Reamer, 4.5: Clutch Holder 2: 57001-1333 57001-1508 Hand Tester: Oil Pressure Cap: 57001-1394 57001-1651 Peak Voltage Adapter: Pilot Screw Adjuster 57001-1415 57001-1665 Flywheel Puller, M28 × 1.0: Kawasaki Bond (Silicone Sealant): 57001-1471 56019-120...
  • Page 26 1-16 GENERAL INFORMATION Special Tools and Sealants Kawasaki Bond(Liquid Gasket - Black): 92104-1003...
  • Page 27: Cable, Wire And Hose Routing

    GENERAL INFORMATION 1-17 Cable, Wire and Hose Routing Dummy Page...
  • Page 28 1-18 GENERAL INFORMATION Cable, Wire and Hose Routing...
  • Page 29 15. Choke Knob 16. Ignition Coil 17. Ground Lead 18. Brake Cable 19. Bend the clamp as shown. 20. Approx. 15 mm (0.59 in.) 21. Connect the connector of magneto lead inside of the crankcase breather hose. A: KLX110-A3 ∼...
  • Page 30 1-20 GENERAL INFORMATION Cable, Wire and Hose Routing...
  • Page 31 GENERAL INFORMATION 1-21 Cable, Wire and Hose Routing 1. Frame 2. Align the damper center with the frame hole. 3. Apply adhesive to diagonal line portion. 4. Clamp 5. Run the carburetor drain hose into a hole of the engine guard. 6.
  • Page 32: Unit Conversion Table

    1-22 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 micro μ...
  • Page 33 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Sprocket Wear Inspection.... 2-16 Specifications ........Chain Slipper Wear Inspection ..2-17 Periodic Maintenance Procedures..Brakes..........2-17 Fuel System........Brake Lever, Brake Pedal Free Fuel Hose and Connections Play Inspection......
  • Page 34: 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. FREQUENCY Initial Every 5 hours 50 hours 100 hours Page OPERATION month) months) months) • • •...
  • Page 35: Specifications

    Engine Lubrication System Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA, MA1 or MA2 (KLX110-A1 ∼ A6F) API SH, SJ or SL with JASO MA, MA1 or MA2 (KLX110A7F ∼) Viscosity SAE 10W-40 Capacity 1.1 L (1.2 us qt)
  • Page 36 2-4 PERIODIC MAINTENANCE Specifications Special Tools - Valve Adjusting Screw Holder: 57001-1217 Jack: 57001-1238 Fork Oil Level Gauge: 57001-1290 Steering Stem Nut Wrench: 57001-1100...
  • Page 37: Periodic Maintenance Procedures

    Pour high-flash point solvent through the tap in all lever positions. • Dry the tank and tap with compressed air. • Install the tap in the tank. Torque - Fuel Tap Bolts: 4.9 N·m (0.5 kgf·m, 43 in·lb) KLX110-A3 ∼ • Install the fuel tank.
  • Page 38: Throttle Grip Free Play Inspection

    2-6 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Grip Free Play Inspection 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 39: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-7 Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. • Turn the handlebar from side to side while idling the en- gine. If handlebar movement changes the idle speed, the throt- tle cable may be improperly adjusted or incorrectly routed, or it may be damaged.
  • Page 40: Engine Top End

    2-8 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING Clean the element in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean the element.
  • Page 41: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-9 Periodic Maintenance Procedures • Turn the camshaft sprocket plate [A] counterclockwise and align the line [B] on the camshaft sprocket with the projection [C] on the mating surface of the cylinder head. • Measure the clearance of each valve by inserting a thick- ness gauge [A] between the adjusting screw and the valve stem.
  • Page 42: Clutch

    2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Scrape carbon deposits off the spark arrester [A]. • Install the spark arrester and torque the spark arrester mounting bolts. Torque - Spark Arrester Mounting Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb) • Install the muffler cover.
  • Page 43: Oil Level Inspection

    Pour in the specified type and amount of oil. Recommended Engine Oil Type: API SE, SF or SG API SH or SJ with JASO MA, MA1 or MA2 (KLX110-A1 ∼ A6F) API SH, SJ or SL with JASO MA, MA1 or MA2 (KLX110A7F ∼) Viscosity: SAE 10 W-40 Capacity: 1.1 L (1.2 us qt)
  • Page 44: Oil Filter Element Replacement

    2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ Do not add any chemical additive to the oil. Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch. ○ Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospher ic conditions in your riding area.
  • Page 45: Wheel Bearing Inspection

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Wheel Bearing Inspection • Raise the front wheel off the ground. • Turn the end of handlebar to left or right fully, feel the excessive play for front wheel bearing by pushing and pulling [A] the tire. •...
  • Page 46: Final Drive

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Chain Slack Inspection • Support the mortorcycle perpendicular to the ground. NOTE ○ Clean the drive chain if it is dirty, and lubricate it if it appears dry. • Rotate the rear wheel to find the position where the chain is tightest.
  • Page 47: Chain Wear Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axel, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 48: Chain Lubrication

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Stretch the chain taut by hanging a 98 N (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 pin center of the 1st pin to pin center of the 21st pin.
  • Page 49: Chain Slipper Wear Inspection

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Chain Slipper Wear Inspection • Visually inspect the chain slipper [A] on the swingarm and replace it if worn or damaged. Brakes Brake Lever, Brake Pedal Free Play Inspection • Check the front brake lever free play [A] when the brake is lightly applied.
  • Page 50: Front Brake Lever Free Play Adjustment

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Front Brake Lever Free Play Adjustment • Loosen the locknut at the front brake lever, screw the ad- juster fully in, and tighten the locknut. • Loose the nuts [A] at the lower end of the brake cable. •...
  • Page 51 PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Check that the brake cam lever [A] comes to an 80° ∼ 90° angle [B] with the brake rod or cable [C] when the brake is fully applied. If it does not, adjust the brake cam lever angle. Cam Lever Angle 80°...
  • Page 52: Cam Lever Angle Adjustment

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cam Lever Angle Adjustment CAUTION Do not depress the brake pedal deeply in order to separate the brake rod from the brake cam lever joint, this may extend the brake spring beyond its allowable spring extension. Rotate the rear brake panel clockwise as far as it will go with the brake rod inserted into the brake cam lever joint, then depress the brake pedal lightly,...
  • Page 53: Suspension

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Suspension Fork Oil Level Adjustment (Simplify) • Using the jack under the frame, and stabilize the motor- cycle. Special Tool - Jack: 57001-1238 • Remove the number plate. • Remove the cap from the top of the fork tubes, and push down the top plug [A] and remove the circlip [B] from each fork tube.
  • Page 54: Front Fork Inner Tube Inspection

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check both top plug O-ring [A] for damage and replace them if necessary. • Push down the top plug and install the circlip. • Assemble the other fork tube in the same way as de- scribed above.
  • Page 55: Swingarm Pivot Inspection

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures • Check the rubber bushings [A]. If they are worn, cracked, hardened, or otherwise dam- aged, replace them. Swingarm Pivot Inspection • Check for wear or damage to the shock absorber and the swing arm mount pivot point while compressing [A] the rear suspension a few times.
  • Page 56: Steering

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection • Using the jack, raise the front wheel off the ground. Special Tool - Jack: 57001-1238 • With the front wheel pointing straight ahead, alternately nudge each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 57: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Mount the handlebar holders [B] so that the arrows [C] on the holder point at the front [A]. ○ Align the punch mark [D] on the handlebar to the mating surface of each clamps of the handlebar. •...
  • Page 58: General Lubrication

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...
  • Page 59: Nut, Bolt And Fastener Tightness

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Nut, Bolt and Fastener Tightness Tightness Inspection • Check the tightness of bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 61 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Throttle Grip and Cable ......................Free Play Inspection ......................Free Play Adjustment......................Throttle Cable and Choke Cable Installation ..............Cable Lubrication and Inspection..................Carburetor ..........................Idle Speed Inspection ....................... Idle Speed Adjustment......................
  • Page 62: Exploded View

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

    FUEL SYSTEM 3-3 Exploded View 1. Throttle Cable 2. Throttle Grip 3. Carburetor Cap 4. Spring 5. Retainer 6. Circlip 7. Jet Needle 8. Throttle Valve 9. Choke Cable 10. Idle Adjusting Screw 11. Spring 12. Air Screw 13. Pilot Jet 14.
  • Page 64 3-4 FUEL SYSTEM Exploded View...
  • Page 65 5. Element 6. Fuel Tank Cover (KLX110A8F ∼, United States and Canada Models) AD: Apply adhesive. G: Apply grease. O: High-quality foam-air filter oil. T1: 4.9 N·m (0.5 kgf·m, 43 in·lb): KLX110-A3 ∼ A: KLX110A8F ∼ (United States and Canada Models)
  • Page 66: Specifications

    3-6 FUEL SYSTEM Specifications Item Standard Service Limit Throttle Grip and Cable 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Carburetor Make/Type KEIHIN PB18 – – – Main Jet – – – Main Air Jet #180 –...
  • Page 67: Throttle Grip And Cable

    FUEL SYSTEM 3-7 Throttle Grip and Cable Free Play Inspection • Refer to the Throttle Grip Free Play Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter. Throttle Cable and Choke Cable Installation •...
  • Page 68: Carburetor

    3-8 FUEL SYSTEM Carburetor Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Idle Speed Adjustment • Refer to the Idle Speed Adjustment in the Periodic Main- tenance chapter. Fuel Level Inspection WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions.
  • Page 69: Fuel Level Adjustment

    FUEL SYSTEM 3-9 Carburetor • Read the fuel level in the gauge and compare it to the specification. Fuel Level 3.0 ±1 mm (0.12 ±0.04 in.) below the bottom edge of carburetor body • Screw in the carburetor drain plug. •...
  • Page 70: Float Removal

    3-10 FUEL SYSTEM Carburetor Float Removal • Remove the carburetor and disassembly the float bowl. • Drive out the pivot pin [A] and remove the float [B] and float valve as a set. Fuel System Cleanliness Inspection WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions.
  • Page 71: Carburetor Installation

    FUEL SYSTEM 3-11 Carburetor • Unscrew the cap [A] and pull out the throttle cable lower end with the throttle valve, spring and jet needle as a set. WARNING If dirt or dust allowed to pass through into the car- buretor, the throttle may become stuck, possibly causing an accident.
  • Page 72: Carburetor Disassembly

    3-12 FUEL SYSTEM Carburetor CAUTION Do not use compressed air on an assembled carbu- retor, or the float may be deformed by the pressure. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbu- retor with a cleaning solution.
  • Page 73: Carburetor Assembly

    FUEL SYSTEM 3-13 Carburetor • Remove the following parts from the carburetor body. Idle Adjusting Screw [A] O-ring [B] Spring [C] Air 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 74: Carburetor Inspection

    3-14 FUEL SYSTEM Carburetor Carburetor Inspection 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 75 FUEL SYSTEM 3-15 Carburetor • Check the main jet [A], needle jet holder [B] and pilot jet [C] for any damage. If they are damaged, replace them with new ones. • Remove the throttle valve [A] and jet needle. • Inspect the outside of the throttle valve for scratches and abnormal wear.
  • Page 76: Air Cleaner

    3-16 FUEL SYSTEM Air Cleaner Air Cleaner Housing Removal • Remove the left shroud. • Loosen the air cleaner duct clamp [A]. • Unscrew the air cleaner mounting bolts [A] and remove the air cleaner housing [B]. Air Cleaner Housing Installation •...
  • Page 77: Element Installation

    FUEL SYSTEM 3-17 Air Cleaner • Stuff a clean, lint-free towel into the carburetor so that no dirt is allowed to enter the carburetor. • Wipe out the inside of the air cleaner housing [A] and the wire screen [B] with a clean damp towel. CAUTION Check inside of the inlet tract and carburetor for dirt.
  • Page 78: Fuel Tank

    3-18 FUEL SYSTEM 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 79: Fuel Tap Inspection

    Pour high-flash point solvent through the tap in all lever positions. • Dry the tank and tap with compressed air. • Install the tap in the tank. Torque - Fuel Tap Bolts: 4.9 N·m (0.5 kgf·m, 43 in·lb) KLX110-A3 ∼ • Install the fuel tank.
  • Page 81 ENGINE TOP END 4-1 Engine Top End Table of Contents Exploded View........Valve Clearance Inspection ..4-21 Specifications ........Valve Clearance Adjustment..4-21 Camshaft Chain Tensioner ....Valve Seat Inspection ....4-21 Camshaft Chain Tensioner Valve Seat Repair ......4-22 Removal ........
  • Page 82: Exploded View

    4-2 ENGINE TOP END Exploded View...
  • Page 83 16. Valve Stem 17. Camshaft 18. Camshaft Sprocket 19. Chain Guide 20. Camshaft Chain 21. Chain Guide (KLX110-A2∼) 22. Chain Guide (KLX110-A1) 23. Camshaft Chain Holder T1: 5.2 N·m (0.53 kgf·m, 46 in·lb) T2: 8.8 N·m (0.9 kgf·m, 78 in·lb) T3: 12 N·m (1.2 kgf·m, 104 in·lb)
  • Page 84 4-4 ENGINE TOP END Exploded View...
  • Page 85 1. Camshaft Chain Tensioner 2. Piston 3. Piston Pin 4. Cylinder 5. Muffler 6. Damper (KLX110-A1) 7. Exhaust Pipe Holder Nuts T1: 5.2 N·m (0.53 kgf·m, 46 in·lb) T2: 8.8 N·m (0.9 kgf·m, 78 in·lb) EO: Apply engine oil. L: Apply non-permanent locking agent.
  • Page 86: Specifications

    4-6 ENGINE TOP END Specifications Item Standard Service Limit Camshaft Camshaft: Cam height: 29.021 mm ∼ 29.201 mm Exhaust 28.92 mm (1.1426 ∼ 1.1496 in.) (1.139 in.) 28.984 mm ∼ 29.164 mm 28.88 mm Inlet (1.1411 ∼ 1.1482 in.) (1.137 in.) Rocker Arms, Shaft: rocker Arm Inside Diameter 10.000 ∼...
  • Page 87 ENGINE TOP END 4-7 Specifications Item Standard Service Limit Cylinder, Piston 52.997 ∼ 53.009 mm Cylinder Inside Diameter 53.10 mm (2.0865 ∼ 2.0870 in.) (2.091 in.) 52.981 ∼ 52.993 mm Piston Outside Diameter 52.83 mm (2.0859 ∼ 2.0863 in.) (2.080 in.) 0.010 ∼...
  • Page 88: Camshaft Chain Tensioner

    4-8 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION 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 89: Camshaft Chain Tensioner Installation

    ENGINE TOP END 4-9 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 suitable screwdriver until the rod protrusion comes to about 10 mm from the tensioner body. CAUTION Do not turn the rod counterclockwise at installation.
  • Page 90: Replacement Chain Tensioner Installation

    4-10 ENGINE TOP END Camshaft Chain Tensioner Replacement Chain Tensioner Installation ○ A replacement chain tensioner (spare parts) has a push rod holder plate. • Apply a non-permanent locking agent to the threads of the tensioner mounting bolts. • Install the tensioner on the cylinder block, and tighten the mounting bolts.
  • Page 91: Camshaft Sprocket

    ENGINE TOP END 4-11 Camshaft Sprocket Camshaft Sprocket Removal • Remove: Left Shroud Engine Sprocket Cover (see Final Drive chapter) Magneto Cover (see Electrical System chapter) • Remove the camshaft sprocket cover bolts [A] and take off the cover [B]. •...
  • Page 92: Camshaft Sprocket Installation

    4-12 ENGINE TOP END Camshaft Sprocket Camshaft Sprocket Installation • Check crankshaft position to see that the "T" mark [A] on the magneto flywheel aligns with the index mark [B] on the crankcase. • Remember to pull the camshaft chain taut before rotating the crankshaft.
  • Page 93: Camshaft Chain Removal

    ENGINE TOP END 4-13 Camshaft Sprocket Camshaft Chain Removal • Drain the engine oil. • Remove: Left Shroud Camshaft Chain Tensioner Camshaft Sprocket Cylinder Head Magneto Cover (see Electrical System chapter) Magneto Flywheel (see Electrical System chapter) Woodruff Key (see Electrical System chapter) •...
  • Page 94: Rocker Arm, Rocker Arm Shaft

    4-14 ENGINE TOP END Rocker Arm, Rocker Arm Shaft Rocker Arm Removal • Remove Left Shroud Camshaft Sprocket Cover Camshaft Chain Tensioner Camshaft Sprocket Bolts [A] Camshaft Sprocket [B] Valve Adjusting Cover Bolts [A] Valve Adjusting Covers [B] Rocker Arm Shaft Stopper Screws [C] Rocker Arm Shaft Stopper [D] •...
  • Page 95: Rocker Arm & Arm Shaft Wear

    ENGINE TOP END 4-15 Rocker Arm, Rocker Arm Shaft Rocker Arm & Arm Shaft Wear • Visually inspect where the cam and valve stem wear on each arm. If there is any damage or uneven wear, replace the arm. ○ Measure the inside diameter [A] of each rocker arm with a cylinder gauge.
  • Page 96: Camshaft

    4-16 ENGINE TOP END Camshaft Camshaft Removal • Remove: Left Shroud Camshaft Chain Tensioner Camshaft Sprocket Rocker Arms • Pull out the camshaft [A]. Camshaft Installation • Clean the camshaft with a high-flash-point solvent. • Apply clean engine oil to all cam parts. •...
  • Page 97: Cylinder Head

    ENGINE TOP END 4-17 Cylinder Head Compression Measurement • Warm up the engine thoroughly • Stop the engine. • Remove the spark plug and attach compression gauge and adapter firmly into the spark plug hole. Special Tools - Compression Gauge: 57001-221 [A] Compression Gauge Adapter, M10 ×...
  • Page 98: Cylinder Head Removal

    4-18 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove the right and left shrouds. • Remove the exhaust pipe holder nuts [A], and muffler mounting bolt [B] and then the muffler with the exhaust pipe holder. • Remove the oil pipe banjo bolts [A], screws [B], and take off the oil pipe [C].
  • Page 99: Cylinder Head Installation

    ENGINE TOP END 4-19 Cylinder Head Cylinder Head Installation • Check to see that the two dowel pins [A] are in place on the cylinder. • Install a new cylinder head gasket [B]. • Fit the cylinder head onto the cylinder block using a screwdriver or wire to keep the chain from falling down into the cylinder block.
  • Page 100: Valve/valve Guide

    4-20 ENGINE TOP END Valve/Valve Guide Valve Removal • Remove: Cylinder Head Rocker Arm & Rocker Arm Shaft Camshaft • Using the valve spring compressor assembly to press down the valve spring retainer, remove the split keeper. Special Tools - Valve Spring Compressor Assembly: 57001 -241 [A] Valve Spring Compressor Adapter, 57001-1154 [B]...
  • Page 101: Valve Guide Installation

    ENGINE TOP END 4-21 Valve/Valve Guide Valve Guide Installation ○ Valve guides are identical. • Lightly oil the valve guide outer surface. • Heat the cylinder head around the valve guide hole to about 120° ∼ 150°C (250° ∼ 302°F). •...
  • Page 102: Valve Seat Repair

    4-22 ENGINE TOP END Valve/Valve Guide 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 103 ENGINE TOP END 4-23 Valve/Valve Guide Operating Procedures • Clean the seat area carefully. • Coat the seat with machinist’s dye. • Fit a 45° cutter to the holder and slide it into the valve guide. • Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth.
  • Page 104 4-24 ENGINE TOP END Valve/Valve Guide ○ To make the 32° grind, fit a 32° cutter to the holder, and slide it into the valve guide. ○ Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. CAUTION The 32°...
  • Page 105: Valve Head Thickness Inspection

    ENGINE TOP END 4-25 Valve/Valve Guide Valve Head Thickness Inspection • Measure the thickness of valve head. Valve Head Thickness [A] Standard: Exhaust valve 1.15 ∼ 1.45 mm (0.0453 ∼ 0.0571 in.) 0.85 ∼ 1.15 mm (0.0335 ∼ 0.0453 in.) Inlet valve Service Limit: Exhaust valve 0.5 mm (0.02 in.)
  • Page 106: Valve To Guide Clearance Measurement

    4-26 ENGINE TOP END Valve/Valve Guide Valve to Guide Clearance Measurement If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the valve guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 107 ENGINE TOP END 4-27 Valve/Valve Guide...
  • Page 108: Cylinder, Piston

    4-28 ENGINE TOP END Cylinder, Piston Cylinder Removal • Remove the cylinder head. • Take out the cylinder block with lower camshaft chain guide, and remove the gasket. There are knock pins on the cylinder base. • Wrap a clean cloth [A] around the base of the piston so that no parts or dirt will fall into the crankcase.
  • Page 109: Piston Removal

    ENGINE TOP END 4-29 Cylinder, Piston Piston Removal • Remove the cylinder. • Remove: Pliers [A] Snap Ring [B] • Remove the piston by pushing its pin pull out the side that the snap ring was removed. Use the piston pin puller assembly [A] if the pin is tight.
  • Page 110: Cylinder Inside Diameter Measurement

    4-30 ENGINE TOP END Cylinder, Piston NOTE ○ If a new piston is used, check piston to cylinder clear- ance (see Piston/Cylinder Clearance), and use new pis- ton rings. • Install the piston so that the EX mark [A] on the piston faces to exhaust side.
  • Page 111: Piston/cylinder Clearance Inspection

    ENGINE TOP END 4-31 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 112: Piston Ring End Gap Inspection

    4-32 ENGINE TOP END 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 113: Piston, Piston Pin, Connecting Rod Wear Inspection

    ENGINE TOP END 4-33 Cylinder, Piston Piston Ring Groove Width Standard: 0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.) 0.80 ∼ 0.82 mm (0.0315 ∼ 0.0323 in.) Second Service Limit: 0.90 mm (0.035 in.) Second 0.90 mm (0.035 in.) If the clearance exceeds the service limit, remove the pis- ton rings, and measure the thickness of the piston rings and the width of the ring grooves.
  • Page 114 4-34 ENGINE TOP END Cylinder, Piston Measure the inside diameter [A] of the connecting rod small end. Connecting Rod Small End Inside Diameter 13.003 ∼ 13.014 mm (0.5119 ∼ 0.5124 in.) Standard: Service limit 13.05 mm (0.5138 in.) If the inside diameter exceeds the service limit, replace the connecting rod.
  • Page 115: Muffler

    ENGINE TOP END 4-35 Muffler Muffler Removal • Unscrew the muffler mounting bolt [A]. • Remove the exhaust pipe holder nuts [A]. • Pull out the muffler mounting bolt and remove the muffler assembly. Muffler Installation • Check the gasket and replace it if damaged. •...
  • Page 117 CLUTCH 5-1 Clutch Table of Contents Exploded View (KLX110-A1) ....................Exploded View (KLX110-A2 ∼ ) ....................Specifications ......................... Clutch Cover........................... Clutch Cover and Oil Screen Removal ................Clutch Cover and Oil Screen Installation ................Clutches..........................Clutch Removal......................... Clutch Installation......................Secondary Clutch Disassembly ..................
  • Page 118: Exploded View (klx110-a1)

    5-2 CLUTCH Exploded View (KLX110-A1)
  • Page 119 CLUTCH 5-3 Exploded View (KLX110-A1) 1. Clutch Cover 2. Primary Clutch Shoe Linings 3. Outer Race 4. One-way Clutch 5. Primary Clutch Housing 6. Clutch Spring Plate 7. Clutch Spring 8. Secondary Clutch Hub 9. Friction Plate 10. Steel Plate 11.
  • Page 120: Exploded View (klx110-a2 ~ )

    5-4 CLUTCH Exploded View (KLX110-A2 ∼ )
  • Page 121 5.0 N·m (0.51 kgf·m, 44 in·lb): KLX110-A3 ∼ T4: 19 N·m (1.9 kgf·m, 14 ft·lb) T5: 72 N·m (7.3 kgf·m, 53 ft·lb) T6: 22 N·m (2.2 kgf·m, 16 ft·lb) T7: 5.2 N·m (0.53 kgf·m, 46 in·lb): KLX110-A2 ∼ A7F 8.8 N·m (0.9 kgf·m, 78 in·lb): KLX110A8F ∼...
  • Page 122: Specifications

    24.00 mm (0.94 in.) 23.00 mm (0.91 in.) (KLX110-A1) Clutch Spring Free Length 22.04 mm (0.87 in.) 20.35 mm (0.80 in.) (KLX110-A2 ∼ ) Kick Shaft 15.941 ∼ 15.968 mm Kick Shaft Diameter 15.92 mm (0.6268 in.) (0.6276 ∼ 0.6287 in.) 16.000 ∼...
  • Page 123: Clutch Cover

    Kick Pedal [A] Footpeg [B] Engine Guard [C] Brake Pedal (hanging) [D] • Remove: Clutch Cover Screws [A] (KLX110-A1 ∼ A7F) Clutch Cover Bolts [A] (KLX110A8F ∼) Clutch Cover [B] • Unscrew the clutch adjusting screw locknut [A]. • The release plate [B] and the release shaft (adjusting screw) [C] come out with the cover.
  • Page 124: Clutch Cover And Oil Screen Installation

    • Install the clutch cover. Be sure that the release cam [A], and release ball assembly [B] are not falling down. KLX110-A1 ∼ A7F • Tighten the clutch cover screws following the tightening sequence. Torque - Clutch Cover Screws: 5.2 N·m (0.53 kgf·m, 46 in·lb)
  • Page 125: Clutches

    Install the spacer [A] to the drive shaft. • Insert the secondary clutch. ○ Be sure to install the spacer [B] between secondary clutch housing and clutch wheel. (KLX110-A1) ○ Hard to install the secondary clutch, turn the drive shaft while pushing the clutch. •...
  • Page 126 • Install: Needle Bearing [A] Primary Clutch Housing [B] Needle Bearing [C] Primary Clutch Sleeve [D] KLX110-A2 ∼ If the primary clutch housing disassembled, assemble it as follows. ○ Install the gear [B] to the primary clutch housing [A]. ○...
  • Page 127: Secondary Clutch Disassembly

    CLUTCH 5-11 Clutches • Install the plate with the line mark [A] facing out, noting the proper position. • Install the primary clutch shoe linings. • Tighten the primary clutch nut while holding the primary clutch steady with the primary clutch holder. Special Tool - Primary Clutch Holder: 57001-1507 Torque - Primary Clutch Hub Nut: 72 N·m (7.3 kgf·m, 53 ft·lb)
  • Page 128: Secondary Clutch Assembly

    Tighten the clutch spring bolts. Torque - Secondary Clutch Spring Bolts: 3.4 N·m (0.35 kgf·m, 30 in·lb) 5.0 N·m (0.51 kgf·m, 44 in·lb) KLX110-A3 ∼ Primary Clutch Housing Wear Inspection • Measure the inside diameter [A] of the clutch housing slid- ing surface.
  • Page 129: Primary Clutch Shoe Lining Wear Inspection

    CLUTCH 5-13 Clutches Primary Clutch Shoe Lining Wear Inspection • Remove the primary clutch hub (see Clutch Removal). • Visually inspect the primary clutch shoe linings [A] for un- even wear, discoloration, missing friction material, cracks or other damage. If any of the linings are damaged, replace the primary clutch hub.
  • Page 130: Clutch Plate Wear And Damage Inspection

    5-14 CLUTCH Clutches ○ Check that the rollers [A] in the one-way clutch is installed as shown when viewed from the right side of the engine. Clutch Plate Wear and Damage Inspection • Visually inspect the friction and steel plates for uneven wear, discoloration, missing friction material, cracks, or other damage.
  • Page 131: Secondary Clutch Hub Spline Damage Inspection

    Measure the spring free length [A]. If measurement is less than the service limit, replace it. Clutch Spring Free Length Standard: KLX110-A1 24.00 mm (0.94 in.) KLX110-A2 ∼ 22.04 mm (0.87 in.) Service Limit: KLX110-A1 23.00 mm (0.91 in.) KLX110-A2 ∼...
  • Page 132: Kickstarter

    5-16 CLUTCH Kickstarter Kickstarter Removal • Remove the clutch cover. • Remove the return spring [A] with pliers. • Remove: Spring Guide [B] • Remove the kick shaft assembly [C], twisting it counter- clockwise. • There is a thrust washer between the kick shaft end and the crankcase.
  • Page 133: Kickstarter Inspection

    CLUTCH 5-17 Kickstarter Kickstarter Inspection • Visually inspect the parts and portion listed below. Kick shaft return spring [A] Ratchet gear spring [B] Ratchet portion [C] of the kick gear [D] and ratchet gear If there is any kind of damage, replace the damaged part. •...
  • Page 134: External Shift Mechanism

    5-18 CLUTCH External Shift Mechanism External Shift Mechanism Removal • Remove: Clutch Cover (see Clutch Cover Removal) Primary Clutch (see Clutch Removal) Secondary Clutch (see Clutch Removal) Shift Pedal Clamp Bolt [A] Shift Pedal [B] • Move the shift mechanism arm out of its position on the end of the shift drum and pull out the shift shaft [A].
  • Page 135 CLUTCH 5-19 External Shift Mechanism • Install the shift pedal [A] to the shift shaft so that the pedal upper surface [B] is level with the footpeg upper surface [C].
  • Page 137 ENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Exploded View........................Specifications ......................... Engine Oil Flow Chart......................Engine Oil ..........................Oil Level Inspection......................Oil Changing ........................Oil Filter Element/Oil Screen ....................Oil Filter Element Replacement ..................Oil Screen Cleaning ......................Engine Oil Pump........................
  • Page 138: Exploded View

    6-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 139 ENGINE LUBRICATION SYSTEM 6-3 Exploded View 1. Oil Pump 2. Oil Screen 3. Oil Pipe 4. Copper Washer 5. Crankcase Breather Tube 6. Oil Filter 7. Drain Plug T1: 5.2 N·m (0.53 kgf·m, 46 in·lb) T2: 15 N·m (1.5 kgf·m, 11 ft·lb) T3: 29 N·m (3.0 kgf·m, 21 ft·lb) G: Apply grease.
  • Page 140: Specifications

    Engine Oil Grade API SE, SF or SG – – – API SH or SJ with JASO MA, MA1 or MA2 (KLX110-A1 ∼ A6F) API SH, SJ or SL with JASO MA, MA1 or MA2 (KLX110A7F ∼) Viscosity SAE 10W-40 –...
  • Page 141: Engine Oil Flow Chart

    ENGINE LUBRICATION SYSTEM 6-5 Engine Oil Flow Chart 1. Camshaft 11. Oil Passage (Cylinder Head) 2. Oil Pipe 12. Oil Passage (Camshaft) 3. Cylinder Head 13. Oil Passage (Right Engine Cover) 4. Primary Clutch Housing 14. Oil Passage (Crankshaft) 5. Clutch Cover 15.
  • Page 142: Engine Oil

    6-6 ENGINE LUBRICATION SYSTEM Engine Oil Oil Level Inspection • Refer to the Oil Level Inspection in the Periodic Mainte- nance chapter. Oil Changing • Refer to the Oil Changing in the Periodic Maintenance chapter.
  • Page 143: Oil Filter Element/oil Screen

    ENGINE LUBRICATION SYSTEM 6-7 Oil Filter Element/Oil Screen Oil Filter Element Replacement • Refer to the Oil Filter Element Replacement in the Peri- odic Maintenance chapter. Oil Screen Cleaning • Drain the engine oil. • Remove the clutch cover (see Clutch chapter). •...
  • Page 144: Engine Oil Pump

    6-8 ENGINE LUBRICATION SYSTEM Engine Oil Pump Engine Oil Pump Removal • Remove the clutch cover (see Clutch chapter). • Remove the primary and secondary clutch assemblies (see Clutch chapter). • Turn the crankshaft so that the engine oil pump screws [A] can be removed through the pump gear holes, and remove the screws and oil pump [B].
  • Page 145: Oil Pipe

    ENGINE LUBRICATION SYSTEM 6-9 Oil Pipe Oil Pipe Removal • Remove the banjo bolts [A] and oil pipe clamp screw [B]. Oil Pipe Installation • Before installation, flush out the pipe with a high-flash -point solvent. • Discard the used copper washers and install new washers on each side of the pipe fittings.
  • Page 146: Oil Pressure Measurement

    6-10 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove the oil filter cap (see Oil Filter Element Replace- ment in the Periodic Maintenance chapter), and attach the oil pressure cap [A], adapter [B] and gauge [C]. Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Oil Pressure Gauge Adapter, M10 ×...
  • Page 147 ENGINE REMOVAL/INSTALLATION 7-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 148: Exploded View

    7-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 149 ENGINE REMOVAL/INSTALLATION 7-3 Exploded View 1. Footpeg Mounting Bolts G. Apply grease. T1: 54 N·m (5.5 kgf·m, 40 ft·lb) T2: 23 N·m (2.3 kgf·m, 17 ft·lb)
  • Page 150: Engine Removal/installation

    7-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Drain the engine oil (see Engine Lubrication chapter). • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 151 ENGINE REMOVAL/INSTALLATION 7-5 Engine Removal/Installation • Remove the bolts [A] and the engine guard [B]. • Remove the brake pedal return spring [A]. • Support the rear part of the frame on the jack [A]. • Support the engine with a suitable stand [A]. •...
  • Page 152: Engine Installation

    7-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the three engine mounting bolts [A] and dis- mount the engine. Engine Installation • Support the engine with a suitable stand and set it at the correct position. • Install the lower [A], middle [B] and upper [C] engine mounting bolts from left side of the engine.
  • Page 153 CRANKSHAFT / TRANSMISSION 8-1 Crankshaft / Transmission Table of Contents Exploded View........................Specifications ......................... Crankcase Splitting......................... Crankcase Splitting ......................Crankcase Assembly ......................Crankshaft, Connecting Rod ....................Crankshaft Disassembly and Assembly................Disassembly........................Assembly .......................... Connecting Rod Big End Seizure Inspection ..............Connecting Rod Big End Radial Clearance Inspection.............
  • Page 154: Exploded View

    8-2 CRANKSHAFT / TRANSMISSION Exploded View...
  • Page 155 T3: 15 N·m (1.5 kgf·m, 11 ft·lb) T4: 22 N·m (2.2 kgf·m, 16 ft·lb) T5: 29 N·m (3.0 kgf·m, 22 ft·lb) T6: 42 N·m (4.3 kgf·m, 31 ft·lb): KLX110-A1 54 N·m (5.5 kgf·m, 40 ft·lb): KLX110-A2 ∼ T7: 72 N·m (7.3 kgf·m, 53 ft·lb) EO: Apply engine oil.
  • Page 156: Specifications

    5.05 ∼ 5.20 mm (0.199 ∼ 0.205 in.) Shift Drum Groove Width 5.3 mm (0.21 in.) Special Tools - Outside Circlip Pliers: 57001-144 Bearing Puller: 57001-158 Crankcase Splitting Tool Assembly: 57001-1098 Bearing Driver Set: 57001-1129 Crankshaft Jig: 57001-1174 Sealant - Kawasaki Bond (Liquid Gasket-Black): 92104-1003...
  • Page 157: Crankcase Splitting

    CRANKSHAFT / TRANSMISSION 8-5 Crankcase Splitting Crankcase Splitting • Remove the engine (see 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 Engine Top End chapter) Cylinder (see Engine Top End chapter) Piston (see Engine Top End chapter) Clutch Cover (see Clutch chapter)
  • Page 158 8-6 CRANKSHAFT / TRANSMISSION Crankcase Splitting WARNING Clean the engine parts in a well-ventilated area, and take care that there are no sparks or flame any- where near the working area; this includes any ap- pliance with a pilot light. Do not use gasoline or a low-flash-point solvent to clean parts.
  • Page 159 • Apply liquid gasket to the mating surface of the left crankcase half as shown. Sealant - Kawasaki Bond (Liquid Gasket-Black): 92104 -1003 • Check that two dowel pins [A], O-rings [B] and drive shaft spacer [C] in place.
  • Page 160: Crankshaft, Connecting Rod

    • Remove the camshaft chain drive sprocket, oil pump gear and bearings, using the bearing puller. (KLX110-A2 ∼ ) • Use a press to remove the crankpin. •...
  • Page 161: Connecting Rod Big End Seizure Inspection

    Connecting Rod Big End Radial Clearance Standard: 0.009 ∼ 0.023 mm (0.0004 ∼ 0.0009 in.) KLX110-A1 KLX110-A2 ∼ 0.006 ∼ 0.020 mm(0.002 ∼ 0.0008 in.) Service Limit: 0.07 mm (0.0028 in.) Connecting Rod Big End Side Clearance Inspection •...
  • Page 162: Crankshaft Runout Inspection

    Less than 0.03 mm (0.001 in.) TIR Service Limit: 0.08 mm (0.003 in.) TIR KLX110-A2 ∼ Crankshaft Alignment Inspection If the runout at either point exceeds the service limit, align the flywheels so that the runout falls within the service limit.
  • Page 163: Crankshaft Main Bearing Wear Inspection

    CRANKSHAFT / TRANSMISSION 8-11 Crankshaft, Connecting Rod • In the case of both horizontal and vertical misalignment, correct the horizontal misalignment first. • Recheck big end side clearance after aligning crankshaft (see Connecting Rod Big End Side Clearance). NOTE ○ If crankshaft alignment cannot be corrected by the above method, replace the crankpin or crank halves as required.
  • Page 164: Transmission

    1st Gear [D] Circlip [E] Shim [F] Apply Engine Oil [G] Bushing [H]: KLX110-A2 ∼ ○ The output shaft gears can be identified by size; the largest diameter gear is 1st gear, and the smallest is 4th (not working). 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 165: Transmission And Shift Mechanism Installation

    CRANKSHAFT / TRANSMISSION 8-13 Transmission Apply Engine Oil [G] ○ Always install circlips so that the opening is aligned with a spline groove. To install a circlip without damage, first fit the circlip onto the shaft expanding it just enough to install it, and then use a suitable gear to push the circlip into place.
  • Page 166: Shift Fork Bending Inspection

    8-14 CRANKSHAFT / TRANSMISSION Transmission Shift Fork Bending Inspection • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. [A] 90°...
  • Page 167: Gear Dog/gear Dog Hole Damage Inspection

    CRANKSHAFT / TRANSMISSION 8-15 Transmission Gear Dog/Gear Dog Hole Damage Inspection • Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes. Ball and Needle Bearing Wear Inspection CAUTION Do not remove the bearings for inspection.
  • Page 169 WHEELS/TIRES 9-1 Wheels/Tires Table of Contents Exploded View........................Specifications ......................... Wheels (Rims) ........................Front Wheel Removal ....................... Front Wheel Installation ....................Rear Wheel Removal......................Rear Wheel Installation..................... Axle Inspection........................Tires............................Air Pressure Inspection/Adjustment.................. Tires Inspection......................... Tire Removal........................Tire Installation........................9-10 Hub Bearing..........................
  • Page 170: Exploded View

    9-2 WHEELS/TIRES Exploded View...
  • Page 171 WHEELS/TIRES 9-3 Exploded View 1. Nipple 2. Spoke 3. Front Tire 4. Rim 5. Front Axle 6. Rear Tire 7. Rear Axle T1: 44 N·m (4.5 kgf·m, 32 ft·lb) T2: 64 N·m (6.5 kgf·m, 47 ft·lb) T3: 1.2 N·m (0.12 kgf·m, 10 in·lb) T4: 25 N·m (2.5 kgf·m, 18 ft·lb) G: Apply high-temperature grease.
  • Page 172: Specifications

    Axle Runout/100 mm (Rear: 110 mm) TIR 0.1 mm (0.004 in.) TIR 2 mm (0.08 in.) Tires Standard Tire: – – – Front: Size 2.50-14 4PR – – – 2.50-14 M/C 4PR (KLX110-A2 ∼ ) Make CHENG SHIN – – – Type C803 – – – Rear: Size 3.00-12 4PR...
  • Page 173: Front Wheel Removal

    WHEELS/TIRES 9-5 Wheels (Rims) Front Wheel Removal • Remove: Cotter Pin [A] Front Axle Nut [B] • Using a jack, raise the front wheel off the ground. • Remove: Front Brake Cable End [C] Front Axle [D] Front Wheel Front Brake Panel Collar Front Wheel Installation •...
  • Page 174: Rear Wheel Installation

    9-6 WHEELS/TIRES Wheels (Rims) • Remove: Adjusting Nut [A] Cotter Pin [B] Rear Torque Link Nut [C] Rear Torque Link Bolt [D] Cotter Pin [E] Rear Axle Nut [F] CAUTION Do not depress the brake pedal deeply with the brake rod inserted into the brake cam lever joint, this may elongate the spring beyond its allowable spring extension.
  • Page 175: Axle Inspection

    WHEELS/TIRES 9-7 Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axel, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 176: Tires

    NOTE ○ Check and balance the wheel when a tire is replaced with a new one. Standard Tire Front: Size: 2.50-14 4PR 2.50-14 M/C 4PR (KLX110-A2 ∼ ) Make: CHENG SHIN Type: C803 Rear: Size: 3.00-12 4PR 3.00-12 M/C 4PR (KLX110-A2 ∼ )
  • Page 177: Tire Removal

    WHEELS/TIRES 9-9 Tires Tire Removal • Remove the wheel from the motorcycle (see Wheels Re- moval). • 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 178: Tire Installation

    9-10 WHEELS/TIRES Tires Tire Installation • Inspect the rim and tire, and replace them if necessary. • Install the tube. • Apply a soap and water solution, or rubber lubricant to the rim flange and tire beads. • Position the tire on the rim so that the valve [A] is at the tire balance mark [B] (the chalk mark made during removal, or the yellow paint mark on a new tire.
  • Page 179: Hub Bearing

    WHEELS/TIRES 9-11 Hub Bearing 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 180: Bearing Lubrication

    9-12 WHEELS/TIRES Hub Bearing 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. • Spin each bearings by hand to check its condition.
  • Page 181 FINAL DRIVE 10-1 Final Drive Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Drive Chain..........................10-5 Chain Slack Inspection ..................... 10-5 Chain Slack Adjustment....................10-5 Drive Chain Removal ......................10-5 Drive Chain Installation ..................... 10-5 Chain Wear Inspection...................... 10-5 Chain Lubrication ......................
  • Page 182: Exploded View

    10-2 FINAL DRIVE Exploded View...
  • Page 183 FINAL DRIVE 10-3 Exploded View 1. Engine Sprocket Cover 2. Engine Sprocket 3. Swingarm 4. Chain Slipper 5. Chain Guide 6. Locknut 7. Adjusting Nut 8. Chain Adjuster 9. Drive Chain 10. Coupling Damper 11. Rear Axle 12. Chain Tension Guide 13.
  • Page 184: Specifications

    Item Standard Service Limit Drive Chain Make/Type – – – (KLX110-A1) DID 420MBK1 (KLX110-A2 ∼ A4/A6F ∼) DID 420DX Link (KLX110-A1) 88 links Link (KLX110-A2 ∼) 86 links 0 ∼ 5 mm (0 ∼ 0.2 in.) Drive Chain Slack – – –...
  • Page 185: Drive Chain

    FINAL DRIVE 10-5 Drive Chain Chain Slack Inspection • Refer to the Chain Slack Inspection in the Periodic Main- tenance chapter. Chain Slack Adjustment • Refer to the Chain Slack Adjustment in the Periodic Main- tenance chapter. Drive Chain Removal •...
  • Page 186: Sprockets, Coupling

    10-6 FINAL DRIVE Sprockets, Coupling Engine Sprocket Removal • Remove: Bolts [A] Engine Sprocket Cover [B] • Remove the circlip [A] and take off the sprocket [B] with drive chain [C]. • Pull the collar and O-ring off the output shaft. Special Tool - Outside Circlip Pliers: 57001-144 Engine Sprocket Installation •...
  • Page 187: Rear Sprocket Removal

    FINAL DRIVE 10-7 Sprockets, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheels/Tires chapter). • Unscrew the rear sprocket bolts [A], and remove the rear sprocket [B]. Rear Sprocket Installation • Install the rear sprocket facing the tooth number making [A] outward.
  • Page 188: Coupling Bearing Installation

    10-8 FINAL DRIVE Sprockets, Coupling Coupling Bearing Installation • Inspect the bearing, and replace it if necessary. • Press in the bearing so that the marked side faces out until it is bottomed. • Replace the oil seal with a new one. •...
  • Page 189 BRAKES 11-1 Brakes Table of Contents Exploded View........................11-2 Specifications ......................... 11-6 Brake Lever, Brake Pedal....................... 11-7 Brake Lever, Brake Pedal Free Play Inspection ............... 11-7 Front Brake Free Play Adjustment..................11-7 Brake Pedal Free Play Adjustment ................... 11-7 Brake Cable Removal ....................... 11-7 Brake Cable Installation ....................
  • Page 190: Exploded View

    11-2 BRAKES Exploded View...
  • Page 191 BRAKES 11-3 Exploded View 1. Brake Lever 2. Brake Cable 3. Cam Lever 4. Brake Panel 5. Brake Shoe 6. Camshaft 7. Brake Lever Pivot Nut 8. Front Brake Adjuster T1: 44 N·m (4.5 kgf·m, 32 ft·lb) C: Apply cable lubricant. G: Apply grease.
  • Page 192 11-4 BRAKES Exploded View...
  • Page 193 BRAKES 11-5 Exploded View 1. Brake Pedal 2. Brake Rod 3. Adjusting Nut 4. Brake Shoe 5. Camshaft 6. Cam Lever T1: 8.8 N·m (0.9 kgf·m, 78 in·lb) T2: 64 N·m (6.5 kgf·m, 47 ft·lb) T3: 7 N·m (0.7 kgf·m, 60 in·lb) G: Apply grease.
  • Page 194: 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 195: Brake Lever, Brake Pedal

    BRAKES 11-7 Brake Lever, Brake Pedal Brake Lever, Brake Pedal Free Play Inspection • Refer to the Brake Lever, Brake Pedal Free Play Inspec- tion in the Periodic Maintenance chapter. Front Brake Free Play Adjustment • Refer to the Front Brake Lever Free Play Adjustment in the Periodic Maintenance chapter.
  • Page 196: Brake Pedal And Rod Installation

    11-8 BRAKES Brake Lever, Brake Pedal Brake Pedal Return Spring [A] Brake Pedal Mounting Bolt [B] Brake Pedal [C] with Rod [D] Cotter Pin and Washer [A] Rod [B] O-rings [C] Brake Pedal and Rod Installation • Brake pedal and rod installation is the reverse of removal. •...
  • Page 197: Brake Panel And Drum

    BRAKES 11-9 Brake Panel and Drum Brake Lining Wear Inspection • Refer to the Brake Lining Wear Inspection in the Periodic Maintenance chapter. Cam Lever Angle Adjustment • Refer to the Cam Lever Angle Adjustment in the Periodic Maintenance chapter. Brake Panel Removal •...
  • Page 198: Brake Panel Assembly

    11-10 BRAKES Brake Panel and Drum • Remove the wheel and separate the brake panel from the wheel. • Using a clean cloth around the linings to prevent grease or oil from getting on them, remove and install the brake shoes [A] by pulling up on the center of the linings.
  • Page 199: Brake Shoe Lining Wear Inspection

    BRAKES 11-11 Brake Panel and Drum Brake Shoe Lining Wear Inspection • Visually inspect the linings for uneven wear, and file or sand down any high spots. With a wire brush, remove any foreign particles imbedded in the lining surface. Wash off any oil or grease with a high-flash-point solvent.
  • Page 200: Brake Shoe Springs Inspection

    11-12 BRAKES Brake Panel and Drum Brake Shoe Springs Inspection • Visually inspect the brake shoe springs for breaks or dis- tortion. If the springs are damaged in any way, replace them. • Measure [A] the free length of the brake shoe springs. If either is stretched beyond the service limit, replace both springs.
  • Page 201 SUSPENSION 12-1 Suspension Table of Contents Exploded View........................12-2 Specifications ......................... 12-6 Front Fork ..........................12-7 Fork Oil Level Check (Simplify)..................12-7 Oil Change/Oil Level Adjustment (each fork leg) .............. 12-7 Front Fork Removal ......................12-8 Front Fork Installation ....................... 12-8 Front Fork Disassembly (each fork ).................
  • Page 202: Exploded View

    12-2 SUSPENSION Exploded View...
  • Page 203 SUSPENSION 12-3 Exploded View 1. Circlip 2. Top Plug 3. O-ring 4. Fork Spring 5. Cylinder Unit 6. Inner Tube 7. Dust Seal 8. Retaining Ring 9. Oil Seal 10. Outer Tube 11. Gasket 12. Allen Bolt 13. Steering Stem Head 14.
  • Page 204 12-4 SUSPENSION Exploded View...
  • Page 205 SUSPENSION 12-5 Exploded View 1. Pivot Shaft 2. Swingarm 3. Rear Shock Absober 4. Rubber Bushing 5. Flap: Note the installing direction. T1: 78 N·m (8.0 kgf·m, 58 ft·lb) T2: 25 N·m (2.5 kgf·m, 18 ft·lb) T3: 39 N·m (4.0 kgf·m, 29 ft·lb) G: Apply grease.
  • Page 206: Specifications

    12-6 SUSPENSION Specifications Item Standard Service Limit Front Fork Oil Viscosity SHOWA SS-8 or equivalent – – – Oil Capacity (Completely Dry) 163 ±2.5 mL (5.51 ±0.08 US oz) – – – Oil Level – – – (Fully Compressed, Spring Removed) 89 ±2 mm (3.50 ±0.08 in.) –...
  • Page 207: Front Fork

    SUSPENSION 12-7 Front Fork Fork Oil Level Check (Simplify) • Refer to the Fork Oil Level Adjustment (Simplify) in the Periodic Maintenance chapter. Oil Change/Oil Level Adjustment (each fork leg) • Remove the front fork (see this chapter). • Remove the following. Top Plug Fork Spring WARNING...
  • Page 208: Front Fork Removal

    12-8 SUSPENSION Front Fork Front Fork Removal • Remove the front brake cable clamp [A]. • Remove the front brake cable [B]. • Remove the front wheel (see Wheels/Tires chapter). • Remove the number plate. • Loosen the upper and lower fork clamp bolts [A]. •...
  • Page 209 SUSPENSION 12-9 Front Fork • Remove the cylinder unit [A] and spring [B] from the 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]. •...
  • Page 210: Front Fork Assembly (each Fork)

    12-10 SUSPENSION Front Fork Front Fork Assembly (each fork) • Assembly is the reverse of disassembly. • Replace the following parts removed with a new one. Retaining Ring Oil Seal Bottom Allen Bolt Washer • Inspect the following and replace them with new ones if damaged.
  • Page 211: Dust Seal/oil Seal Inspection

    SUSPENSION 12-11 Front Fork Dust Seal/Oil Seal Inspection • Inspect the dust seal [B] for any signs of deterioration or damage. Replace it if necessary. • Replace the oil seal [A] with a new one whenever it has been removed. Spring Tension Inspection •...
  • Page 212: Rear Shock Absorber

    12-12 SUSPENSION Rear Shock Absorber Removal • Using the jack under the frame, raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 • Remove the shock absorber mounting bolt [A], nut and pull off the shock absorber [B]. •...
  • Page 213: Swingarm

    SUSPENSION 12-13 Swingarm Swingarm Removal • Using the jack under the frame, raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 • Remove: Rear Wheel (see Wheels/Tires chapter) Left Side Cover (see Frame chapter) Drive Chain Rear Shock Absorber Lower End •...
  • Page 215 STEERING 13-1 Steering Table of Contents Exploded View........................13-2 Specifications ......................... 13-4 Steering ..........................13-5 Steering Inspection ......................13-5 Steering Adjustment......................13-5 Steering Stem Removal ....................13-5 Steering Stem Installation ....................13-5 Steering Stem Race Removal................... 13-6 Steering Stem Race Installation Notes ................13-7 Steering Stem Bearing Lubrication ...................
  • Page 216: Exploded View

    13-2 STEERING Exploded View...
  • Page 217 STEERING 13-3 Exploded View 1. Handlebar Holder 2. Handlebar 3. Steering Stem Head Nut 4. Steering Stem Head 5. Stem Locknut 6. Upper Steel Balls 7. Head Pipe 8. Lower Steel Balls 9. Steering Stem 10. Lower Inner Race 11. Lower Outer Race 12.
  • Page 218: Specifications

    13-4 STEERING Specifications Special Tools - Steering Stem Bearing Driver: 57001-137 Steering Stem Nut Wrench: 57001-1100 Jack: 57001-1238 Bearing Driver Set: 57001-1129 Bearing Puller: 57001-158 Bearing Puller Stud: 57001-1190 Bearing Puller Adapter: 57001-317...
  • Page 219: 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. Steering Stem Removal • Remove: Front Wheel (see Wheels/Tires chapter) Front Brake Cable Clamp Front Fender Handlebar (see Handlebar Removal)
  • Page 220: Steering Stem Race Removal

    13-6 STEERING Steering • Install the stem head and washer, and tighten the stem head nut lightly. • Settle the bearing in place as follows; ○ Tighten the stem locknut to 39 N·m (4.0 kgf·m, 29 ft·lb) of torque. (To tighten the steering stem locknut to the specified torque, hook the wrench [A] on the stem locknut, and pull the wrench at the hole by 22.2 kg force [B] in the direction shown).
  • Page 221: Steering Stem Race Installation Notes

    STEERING 13-7 Steering • Remove the lower inner race on the steering stem with a bearing puller [A]. Special Tools - Bearing Puller: 57001-158 Bearing Puller Stud: 57001-1190 [B] Bearing Puller Adapter: 57001-317 [C] Steering Stem Race Installation Notes • Apply engine oil to the outer races, and then drive them into the head pipe using the bearing driver set [A].
  • Page 222: Handlebar

    13-8 STEERING Handlebar Handlebar Removal • Remove: Engine Stop Switch [A] Throttle Grip Assembly [B] Brake Lever Holder [C] Handlebar Clamps [D] Handlebar [E] Handlebar Installation • Apply adhesive cement to the inside of the left handlebar grip [A]. • Mount the handlebar holders [B] so that the arrows [C] on the holder point at the front [A].
  • Page 223 STEERING 13-9 Handlebar • Install the engine stop switch. ○ Position the engine stop switch so that its edge [A] is aligned with the punch mark [B] on the handlebar.
  • Page 225 ELECTRICAL SYSTEM 14-1 Electrical System Table of Contents Exploded View........................14-2 Specifications ......................... 14-4 Wiring Diagram........................14-5 Precautions..........................14-6 Electrical Wiring........................14-7 Wiring Inspection ......................14-7 Magneto Flywheel ........................14-8 Magneto Cover Removal ....................14-8 Magneto Cover Installation ....................14-8 Magneto Cover Disassembly ....................
  • Page 226: Exploded View

    14-2 ELECTRICAL SYSTEM Exploded View...
  • Page 227: Electrical System

    T2: 5.2 N·m (0.53 kgf·m, 46 in·lb) T3: 13 N·m (1.3 kgf·m, 113 in·lb) T4: 2.9 N·m (0.3 kgf·m, 26 in·lb) T5: 5.2 N·m (0.53 kgf·m, 46 in·lb): KLX110-A1 ∼ A7F 8.8 N·m (0.9 kgf·m, 78 in·lb): KLX110A8F ∼ G: Apply grease.
  • Page 228: Specifications

    15 V or above – – – Special Tools - Spark Plug Wrench, Hex 16: 57001-1262 Hand Tester: 57001-1394 Flywheel Puller, M28 × 1.0: 57001-1471 Rotor Puller, M16/M18/M20/M22 × 1.5: 57001-1216 Flywheel Holder: 57001-1313 Peak Voltage Adapter: 57001-1415 Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 229: Wiring Diagram

    ELECTRICAL SYSTEM 14-5 Wiring Diagram...
  • Page 230: Precautions

    14-6 ELECTRICAL SYSTEM Precautions There are a number of important precautions that need to follow during 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 231: Electrical Wiring

    ELECTRICAL SYSTEM 14-7 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 232: Magneto Flywheel

    Engine Sprocket Cover (see Final Drive chapter) • Pull off the magneto connector [A]. • Remove: Magneto Cover Screws [A] (KLX110-A1 ∼ A7F) Magneto Cover Bolts [A] (KLX110A8F ∼) Magneto Cover [B] Magneto Cover Installation • Check that two dowel pins are in place in the left crankcase half.
  • Page 233: Magneto Cover Assembly

    Tighten the flywheel nut while holding the flywheel steadily with the flywheel holder. Torque - Magneto Flywheel Nut: 42 N·m (4.3 kgf·m, 31 ft·lb): KLX110-A1 (M10) 54 N·m (5.5 kgf·m, 40 ft·lb): KLX110-A2 ∼ (M12) Special Tool - Flywheel Holder: 57001-1313...
  • Page 234: Magneto Flywheels Inspection

    14-10 ELECTRICAL SYSTEM Magneto Flywheel Magneto Flywheels Inspection • There are three types of magneto problems: short, open (wire burned out), or loss in flywheel magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all.
  • Page 235: Ignition System

    ELECTRICAL SYSTEM 14-11 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the electrical connections while the engine is running.
  • Page 236: Ignition Coil Removal

    14-12 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal • Remove: Left Side Cover Spark Plug Cap • Disconnect the ignition coil leads [A]. • Unscrew the bolt [B] and remove the ignition coil [C]. Ignition Coil Installation • Installation is the reverse of removal. •...
  • Page 237: Spark Plug Removal/installation

    ELECTRICAL SYSTEM 14-13 Ignition System If the hand tester reads as specified, the ignition coil wind- ings are probably good. However, if the ignition system still does not perform as it should after all other com- ponents have been checked, replace the coil with one known to be good.
  • Page 238 14-14 ELECTRICAL SYSTEM Ignition System • Connect the peak voltage adapter [A] between the termi- nal of primary lead (black) and ground connection of the unit with the lead of the ignition coil [B] connected. Special Tools - Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Hand Tester: 57001-1394 Connection:...
  • Page 239 ELECTRICAL SYSTEM 14-15 Ignition System Exciter Coil Peak Voltage Check: • Disconnect the connector of the main harness from the igniter. • To check the peak voltage, do the following procedures. NOTE ○ Measure the voltage with each lead connected cor- rectly.
  • Page 240 14-16 ELECTRICAL SYSTEM Ignition System...
  • Page 241: Switches

    ELECTRICAL SYSTEM 14-17 Switches Switch Inspection • Using the hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). Special Tool - Hand Tester: 57001-1394 If the switch has an open or short, repair it or replace it with a new one.
  • Page 242: Gear Position Switch Inspection

    14-18 ELECTRICAL SYSTEM Switches Gear Position Switch Inspection: • Remove the gear position switch head and examine the contact points for presence of oxidation, oil or dirt, etc. Clean the contact points, and ensure that the switch finger is working correctly. •...
  • Page 243 TROUBLESHOOTING 15-1 Troubleshooting Table of Contents Troubleshooting Guide ......................15-2...
  • Page 244: Troubleshooting

    15-2 TROUBLESHOOTING Troubleshooting Guide NOTE Cylinder head not sufficiently tightened ○ This is not an exhaustive list, giving every down possible cause for each problem listed. It Cylinder head warped is meant simply as a rough guide to assist Spark plug loose the troubleshooting for some of the more No valve clearance common difficulties.
  • Page 245 TROUBLESHOOTING 15-3 Troubleshooting Guide Spark plug cap shorted or not in good con- Igniter trouble tact Fuel/air mixture incorrect: Spark plug incorrect Main jet clogged or wrong size Ignition coil trouble Fuel level too low Crankshaft sensorl trouble Carburetor holder loose Stator coil shorted or open Air cleaner clogged Igniter trouble...
  • Page 246 15-4 TROUBLESHOOTING Troubleshooting Guide Drive shaft, output shaft, and/or gear Abnormal Frame Noise: splines worn Front fork noise: Overshifts: Oil insufficient or too thin Shift drum set lever spring weak or broken Spring weak or broken Shift pawl spring weak or broken Rear shock absorber noise: Abnormal Engine Noise: Shock absorber damaged...
  • Page 247 TROUBLESHOOTING 15-5 Troubleshooting Guide Right/left front fork oil level uneven Rear shock absorber oil leaking Rear shock absorber and/or swingarm bent Tire air pressure too low Shock absorption unsatisfactory: Brake Doesn’t Hold: (Too hard) Drum Brake: Front fork oil excessive Front fork oil viscosity too high Brake not properly adjusted Front fork bent...
  • Page 248 MODEL APPLICATION Year Model Beginning Frame No. □ JKALXSA1 2A000001 or 2002 KLX110-A1 JKALX110AAA000001 □ JKALXSA1 3DA08133 or 2003 KLX110-A2 JKALX110AADA08133 □ 2004 KLX110-A3 JKALXSA1 4DA14318 □ JKALXSA1 5DA21001 or 2005 KLX110-A4 JKALX110AADA23033 □ JKALXSA1 6DA31790 or 2006 KLX110A6F JKALX110AADA33290 □...

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