Owners Manual
Page 11
... Maintenance Chart ...Engine Oil...Spark Plug...Air Cleaner ...Throttle Cable...Carburetor ...10 14 14 17 17 18 21 22 23 24 24 28 28 30 30 31 32 34 34 37 41 46 47 53 55 Clutch ...Valve Clearance ...Spark Arrester ...Drive Chain...Handlebar...Brakes ...Steering ...Front Suspension ...Rear Suspension ...Wheels ...Hoses Inspection ...Battery ...Fuse ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...STORAGE ...Before Storage ...After Storage ...ENVIRONMENTAL PROTECTION ...WIRING DIAGRAM ...OWNER...
... Maintenance Chart ...Engine Oil...Spark Plug...Air Cleaner ...Throttle Cable...Carburetor ...10 14 14 17 17 18 21 22 23 24 24 28 28 30 30 31 32 34 34 37 41 46 47 53 55 Clutch ...Valve Clearance ...Spark Arrester ...Drive Chain...Handlebar...Brakes ...Steering ...Front Suspension ...Rear Suspension ...Wheels ...Hoses Inspection ...Battery ...Fuse ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...STORAGE ...Before Storage ...After Storage ...ENVIRONMENTAL PROTECTION ...WIRING DIAGRAM ...OWNER...
Owners Manual
Page 12
10 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height: KLX110C KLX110D Wheelbase Road Clearance: KLX110C KLX110D Curb Mass Fuel Tank Capacity ENGINE Type Bore × Stroke Displacement Compression Ratio Fuel System Starting System Ignition System Ignition Timing 4-stroke, SOHC, single-cylinder, air-cooled 53.0 × 50.6 mm (2.1 × 2.0 in.) 112 cm³ (6.8 cu in.) 9.5:1 Carburetor KEIHIN PB18 Electric starter and kick starter SHINDENGEN CDI 10° BTDC @1 300 r/min (rpm) ∼ 31...
10 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height: KLX110C KLX110D Wheelbase Road Clearance: KLX110C KLX110D Curb Mass Fuel Tank Capacity ENGINE Type Bore × Stroke Displacement Compression Ratio Fuel System Starting System Ignition System Ignition Timing 4-stroke, SOHC, single-cylinder, air-cooled 53.0 × 50.6 mm (2.1 × 2.0 in.) 112 cm³ (6.8 cu in.) 9.5:1 Carburetor KEIHIN PB18 Electric starter and kick starter SHINDENGEN CDI 10° BTDC @1 300 r/min (rpm) ∼ 31...
Owners Manual
Page 32
Engine Stop Switch Position B. • Turn the fuel tap lever to ensure good engine response at all speeds. Independent use of the front or rear brake may be advantageous in the clutch lever as the motorcycle comes to the position. • A. NOTE żTo avoid battery discharging, check that the enposition and the ingine stop switch to a stop (KLX110D model). Shift down progressively to...
Engine Stop Switch Position B. • Turn the fuel tap lever to ensure good engine response at all speeds. Independent use of the front or rear brake may be advantageous in the clutch lever as the motorcycle comes to the position. • A. NOTE żTo avoid battery discharging, check that the enposition and the ingine stop switch to a stop (KLX110D model). Shift down progressively to...
Owners Manual
Page 35
... 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 ...Functions properly Throttle grip returns smoothly Steering ...Smooth but not loose from lock to lock No binding due to control cables Front Fork ...Functions properly No oil leakage Rear Shock Absorber ...Functions properly No oil leakage Fuel Tank ...Mounted...
... 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 ...Functions properly Throttle grip returns smoothly Steering ...Smooth but not loose from lock to lock No binding due to control cables Front Fork ...Functions properly No oil leakage Rear Shock Absorber ...Functions properly No oil leakage Fuel Tank ...Mounted...
Owners Manual
Page 36
... air supplied by the owner. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in this chapter. While the engine is vitally important and must be carried out in accordance with the Periodic Maintenance Chart to keep the vehicle in compliance with low exhaust pollutant levels. 3. j EMISSION CONTROL INFORMATION To protect the environment in which we all adjustments, maintenance, and repair work...
... air supplied by the owner. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in this chapter. While the engine is vitally important and must be carried out in accordance with the Periodic Maintenance Chart to keep the vehicle in compliance with low exhaust pollutant levels. 3. j EMISSION CONTROL INFORMATION To protect the environment in which we all adjustments, maintenance, and repair work...
Owners Manual
Page 37
... applicable regulation of this vehicle, you return your own expense. MAINTENANCE Proper maintenance is free from defects in the Periodic Maintenance Chart. Please read your vehicle comply with applicable regulation. Installation of sale. MAINTENANCE AND ADJUSTMENT 35 High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of certain carburetor components. Maintenance operations necessary to ensure compliance with this Owner's Manual at the time of...
... applicable regulation of this vehicle, you return your own expense. MAINTENANCE Proper maintenance is free from defects in the Periodic Maintenance Chart. Please read your vehicle comply with applicable regulation. Installation of sale. MAINTENANCE AND ADJUSTMENT 35 High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of certain carburetor components. Maintenance operations necessary to ensure compliance with this Owner's Manual at the time of...
Owners Manual
Page 43
... level, and change the oil according to the gauge. the engine oil level with the Periodic Maintenance Chart. Oil Level Inspection the oil has just been changed, let the motorcycle • If sit a few minutes allowing the oil to settle. gine speed. Do not run it for several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at • Start idle speed. Use oil of the...
... level, and change the oil according to the gauge. the engine oil level with the Periodic Maintenance Chart. Oil Level Inspection the oil has just been changed, let the motorcycle • If sit a few minutes allowing the oil to settle. gine speed. Do not run it for several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at • Start idle speed. Use oil of the...
Owners Manual
Page 46
... torque. Oil Filter Element B. Tightening Torque Oil Filter Cap Bolts: 5.2 N·m (0.53 kgf·m, 46 in the table. Grommet A. O-ring the oil has completely drained out, install the • After drain bolt with the high-temperature • greasethe applied to a new O-ring and tighten its new gasket. the spring to the oil filter cap. • Install Install oil filter cap with its bolts to • ward the engine. Oil Filter Cap C. Spring B.
... torque. Oil Filter Element B. Tightening Torque Oil Filter Cap Bolts: 5.2 N·m (0.53 kgf·m, 46 in the table. Grommet A. O-ring the oil has completely drained out, install the • After drain bolt with the high-temperature • greasethe applied to a new O-ring and tighten its new gasket. the spring to the oil filter cap. • Install Install oil filter cap with its bolts to • ward the engine. Oil Filter Cap C. Spring B.
Owners Manual
Page 60
... valves and valve seats, and may cause serious engine damage. Since the engine must be running during normal operation and cause severe burns. Inspection and adjustment should be done by an authorized Kawasaki dealer. Spark Arrester Cleaning WARNING The muffler can become extremely hot during this procedure, wear heat-resistant gloves while cleaning the spark arrester. In accordance with the Periodic Maintenance Chart. Valve...
... valves and valve seats, and may cause serious engine damage. Since the engine must be running during normal operation and cause severe burns. Inspection and adjustment should be done by an authorized Kawasaki dealer. Spark Arrester Cleaning WARNING The muffler can become extremely hot during this procedure, wear heat-resistant gloves while cleaning the spark arrester. In accordance with the Periodic Maintenance Chart. Valve...
Owners Manual
Page 79
... smoothly or noise is found, inspect • If the oil leak and rear shock absorber mounting. inspect the rear shock absorber for oil • Visually leakage. Wheels Tire Air Pressure Tire air pressure affects traction, handling, and tire life. MAINTENANCE AND ADJUSTMENT 77 Rear Suspension The rear shock absorber inspection should be done in accordance with the Periodic Maintenance Chart. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. Adjust the tire air pressure to increase...
... smoothly or noise is found, inspect • If the oil leak and rear shock absorber mounting. inspect the rear shock absorber for oil • Visually leakage. Wheels Tire Air Pressure Tire air pressure affects traction, handling, and tire life. MAINTENANCE AND ADJUSTMENT 77 Rear Suspension The rear shock absorber inspection should be done in accordance with the Periodic Maintenance Chart. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. Adjust the tire air pressure to increase...
Owners Manual
Page 87
MAINTENANCE AND ADJUSTMENT 85 WARNING Substituting fuse can cause wiring to overheat, catch fire and/or fail. Replace the blown fuse with a new one of the correct capacity, as specified on the fuse. Normal B. Failed Do not use any substitute for the standard fuse. j A.
MAINTENANCE AND ADJUSTMENT 85 WARNING Substituting fuse can cause wiring to overheat, catch fire and/or fail. Replace the blown fuse with a new one of the correct capacity, as specified on the fuse. Normal B. Failed Do not use any substitute for the standard fuse. j A.
Owners Manual
Page 90
... out, possibly resulting in ·lb 22 15 S Remarks S j Fastener Cylinder Head Nuts Clutch Adjusting Screw Locknut (KLX110C Model) Engine Oil Drain Bolt Oil Filter Cap Bolts Kick Pedal Bolt Shift Pedal Bolt Spark Plug Exhaust Pipe Holder Nuts Muffler Body Mounting Nut Engine Mounting Nuts Front Axle Nut Rear Axle Nut Spoke Nipples Rear Sprocket Nuts Brake Cam Lever Bolt Brake Pedal Bolt Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) N·m 22 19 29 5.2 8.8 5.2 13 16 24 54...
... out, possibly resulting in ·lb 22 15 S Remarks S j Fastener Cylinder Head Nuts Clutch Adjusting Screw Locknut (KLX110C Model) Engine Oil Drain Bolt Oil Filter Cap Bolts Kick Pedal Bolt Shift Pedal Bolt Spark Plug Exhaust Pipe Holder Nuts Muffler Body Mounting Nut Engine Mounting Nuts Front Axle Nut Rear Axle Nut Spoke Nipples Rear Sprocket Nuts Brake Cam Lever Bolt Brake Pedal Bolt Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) N·m 22 19 29 5.2 8.8 5.2 13 16 24 54...
Owners Manual
Page 92
... • Avoid air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. If needed, use a mild degreaser to remove any oil or grease which build up. Start the engine and let it Always use warm water as it idle for several times. a mild neutral detergent (designed for motor• Mix cycles or automobiles) and water in an area where the roads are cool before washing...
... • Avoid air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. If needed, use a mild degreaser to remove any oil or grease which build up. Start the engine and let it Always use warm water as it idle for several times. a mild neutral detergent (designed for motor• Mix cycles or automobiles) and water in an area where the roads are cool before washing...
Owners Manual
Page 97
... rotating: Engine stop switch not position Starter lockout switch (KLX110D model only) or gear position switch trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Starter system wiring shorted or open Engine stop switch turned off • Engine plug dirty, broken, or gap improperly ad• Spark justed Spark missing or weak: Engine flooded: Fuel does not flow: Starter motor rotating but engine does not turn over : Starter clutch trouble Starter idle gear trouble...
... rotating: Engine stop switch not position Starter lockout switch (KLX110D model only) or gear position switch trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Starter system wiring shorted or open Engine stop switch turned off • Engine plug dirty, broken, or gap improperly ad• Spark justed Spark missing or weak: Engine flooded: Fuel does not flow: Starter motor rotating but engine does not turn over : Starter clutch trouble Starter idle gear trouble...
Owners Manual
Page 98
...; Engine stop switch wiring defective • Flywheel magneto damaged • Gear position switch defective • Wiring shorted or interrupted • Poor low-speed performance Spark weak: Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap shorted or not contacting properly Spark plug type incorrect Igniter defective Ignition coil defective Crankshaft sensor defective Flywheel magneto defective Wiring connector not in good contact j • • • Fuel/air mixture...
...; Engine stop switch wiring defective • Flywheel magneto damaged • Gear position switch defective • Wiring shorted or interrupted • Poor low-speed performance Spark weak: Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap shorted or not contacting properly Spark plug type incorrect Igniter defective Ignition coil defective Crankshaft sensor defective Flywheel magneto defective Wiring connector not in good contact j • • • Fuel/air mixture...
Owners Manual
Page 99
...; Ignition timing incorrect • Drive chain trouble • Poor or no high-speed performance Other: Fuel/air mixture incorrect: Main jet clogged or wrong size Jet needle or needle jet worn Jet needle clip in wrong position Carburetor fuel level too high or too low Air cleaner element clogged, poorly sealed, or not installed Choke valve closed Fuel contaminated with water or foreign matter Fuel tank cap air...
...; Ignition timing incorrect • Drive chain trouble • Poor or no high-speed performance Other: Fuel/air mixture incorrect: Main jet clogged or wrong size Jet needle or needle jet worn Jet needle clip in wrong position Carburetor fuel level too high or too low Air cleaner element clogged, poorly sealed, or not installed Choke valve closed Fuel contaminated with water or foreign matter Fuel tank cap air...
Owners Manual
Page 100
... TROUBLESHOOTING GUIDE Improper acceleration: Choke valve closed Carburetor fuel level too high or too low Main jet clogged Throttle valve does not fully open Air cleaner element clogged Muffler clogged Fuel contaminated with water or foreign matter Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Crankshaft bearing worn or damaged Ignition timing incorrect Crankshaft sensor defective j Fuel/air mixture incorrect: Main jet clogged or wrong size Carburetor fuel...
... TROUBLESHOOTING GUIDE Improper acceleration: Choke valve closed Carburetor fuel level too high or too low Main jet clogged Throttle valve does not fully open Air cleaner element clogged Muffler clogged Fuel contaminated with water or foreign matter Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Crankshaft bearing worn or damaged Ignition timing incorrect Crankshaft sensor defective j Fuel/air mixture incorrect: Main jet clogged or wrong size Carburetor fuel...
Owners Manual
Page 101
... Shift mechanism arm broken Shift return spring broken or weak Shift return spring pin loose Shift pawl broken Shift drum broken Transmission jumps out of gear: Shift fork worn j • • Transmission skips gears: Gear positioning lever spring broken or weak Shift mechanism arm spring broken or weak Engine noise abnormal - Knocking: Carbon built up in combustion chamber Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating Igniter defective Piston slap: Piston clearance excessive Cylinder...
... Shift mechanism arm broken Shift return spring broken or weak Shift return spring pin loose Shift pawl broken Shift drum broken Transmission jumps out of gear: Shift fork worn j • • Transmission skips gears: Gear positioning lever spring broken or weak Shift mechanism arm spring broken or weak Engine noise abnormal - Knocking: Carbon built up in combustion chamber Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating Igniter defective Piston slap: Piston clearance excessive Cylinder...
Owners Manual
Page 102
... Cylinder head gasket leaking Exhaust pipe leaking at cylinder head Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain, sprocket, chain guide worn Flywheel magneto loose j Drive chain noise: Drive chain slack improperly adjusted Drive chain worn Rear and/or engine sprocket(s) worn Drive chain inefficiently lubrified Rear wheel misaligned Frame noise abnormal - • • Front fork noise: Oil level or viscosity too low Spring broken or weak Rear shock absorber noise: Shock absorber damaged Brake noise: Brake...
... Cylinder head gasket leaking Exhaust pipe leaking at cylinder head Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain, sprocket, chain guide worn Flywheel magneto loose j Drive chain noise: Drive chain slack improperly adjusted Drive chain worn Rear and/or engine sprocket(s) worn Drive chain inefficiently lubrified Rear wheel misaligned Frame noise abnormal - • • Front fork noise: Oil level or viscosity too low Spring broken or weak Rear shock absorber noise: Shock absorber damaged Brake noise: Brake...
Owners Manual
Page 105
... spark plug and spray fogging oil di• Remove rectly into the cylinder. Lift the motorcycle on a box or stand so that both wheels are raised off the ground (If this includes any appliance with the starter button to keep dust and dirt away from it and drain the engine oil. the oil drain bolt and fill in fresh engine oil. • Install Empty the fuel tank...
... spark plug and spray fogging oil di• Remove rectly into the cylinder. Lift the motorcycle on a box or stand so that both wheels are raised off the ground (If this includes any appliance with the starter button to keep dust and dirt away from it and drain the engine oil. the oil drain bolt and fill in fresh engine oil. • Install Empty the fuel tank...