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
...; Turn the fuel tap lever to ensure good engine response at all speeds. Shift down progressively to the OFF position. Stopping the Engine the transmission into the neutral position. • Shift Close the throttle completely. • Push the engine stop switch is in the dicator light (orange LED) goes off, when the motorcycle is not used. Independent use of the front or rear brake may...
...; Turn the fuel tap lever to ensure good engine response at all speeds. Shift down progressively to the OFF position. Stopping the Engine the transmission into the neutral position. • Shift Close the throttle completely. • Push the engine stop switch is in the dicator light (orange LED) goes off, when the motorcycle is not used. Independent use of the front or rear brake may...
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
... (1) and exhaust emission (2) control systems in compliance with the fuel and air supplied by the owner. The fuel and ignition systems of this vehicle have been carefully designed and constructed to the intake side of low permeation fuel hoses and a fuel tank. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with low exhaust pollutant levels. 3. 34 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT The maintenance and adjustments...
... (1) and exhaust emission (2) control systems in compliance with the fuel and air supplied by the owner. The fuel and ignition systems of this vehicle have been carefully designed and constructed to the intake side of low permeation fuel hoses and a fuel tank. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with low exhaust pollutant levels. 3. 34 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT The maintenance and adjustments...
Owners Manual
Page 37
... read your vehicle. j NOTE żWhen properly performed, these optional parts may be emissions system "tampering" and vehicle performance is generally unchanged as verification of this Owner's Manual at your own expense. MAINTENANCE AND ADJUSTMENT 35 High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of vehicles operated above 4 000 feet, Kawasaki recommends the following repair recommendations specified in the appropriate Kawasaki Service Manual.
... read your vehicle. j NOTE żWhen properly performed, these optional parts may be emissions system "tampering" and vehicle performance is generally unchanged as verification of this Owner's Manual at your own expense. MAINTENANCE AND ADJUSTMENT 35 High Altitude Performance Adjustment Information To improve the EMISSION CONTROL PERFORMANCE of vehicles operated above 4 000 feet, Kawasaki recommends the following repair recommendations specified in the appropriate Kawasaki Service Manual.
Owners Manual
Page 43
... run it for several minutes at high enthe engine and wait several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at the proper level, and change the oil according to the periodic maintenance chart in the owner's manual. the engine oil level with the Periodic Maintenance Chart. Check the oil level before the oil reaches every part can cause engine seizure. Use oil...
... run it for several minutes at high enthe engine and wait several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at the proper level, and change the oil according to the periodic maintenance chart in the owner's manual. the engine oil level with the Periodic Maintenance Chart. Check the oil level before the oil reaches every part can cause engine seizure. Use oil...
Owners Manual
Page 46
... the engine. Proper torque for it is shown in ·lb) j A. Spring B. 44 MAINTENANCE AND ADJUSTMENT the oil filter element with a new one. • Replace Install the oil filter element with its bolts to the specified torque. Oil Filter Element B. the spring to the oil filter cap. • Install Install oil filter cap with the high-temperature • greasethe applied to a new O-ring and tighten its new gasket. Grommet A. Oil Filter Cap C.
... the engine. Proper torque for it is shown in ·lb) j A. Spring B. 44 MAINTENANCE AND ADJUSTMENT the oil filter element with a new one. • Replace Install the oil filter element with its bolts to the specified torque. Oil Filter Element B. the spring to the oil filter cap. • Install Install oil filter cap with the high-temperature • greasethe applied to a new O-ring and tighten its new gasket. Grommet A. Oil Filter Cap C.
Owners Manual
Page 60
... an authorized Kawasaki dealer. Spark Arrester This vehicle is left unadjusted, wear will eventually cause the valves to remain partly open, which lowers performances, burns the valves and valve seats, and may cause serious engine damage. Since the engine must be running during normal operation and cause severe burns. 58 MAINTENANCE AND ADJUSTMENT Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. NOTICE The spark arrester must...
... an authorized Kawasaki dealer. Spark Arrester This vehicle is left unadjusted, wear will eventually cause the valves to remain partly open, which lowers performances, burns the valves and valve seats, and may cause serious engine damage. Since the engine must be running during normal operation and cause severe burns. 58 MAINTENANCE AND ADJUSTMENT Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. NOTICE The spark arrester must...
Owners Manual
Page 79
... tire tread surface on the ground when riding on a pebbly or hard track. Wheels Tire Air Pressure Tire air pressure affects traction, handling, and tire life. Reduce the tire air pressure to suit track conditions and rider preference, but keep it does not smoothly or noise is found, inspect • If the oil leak and rear shock absorber mounting. inspect the rear shock absorber for oil • Visually leakage. To check the tire air pressure, remove the air valve cap...
... tire tread surface on the ground when riding on a pebbly or hard track. Wheels Tire Air Pressure Tire air pressure affects traction, handling, and tire life. Reduce the tire air pressure to suit track conditions and rider preference, but keep it does not smoothly or noise is found, inspect • If the oil leak and rear shock absorber mounting. inspect the rear shock absorber for oil • Visually leakage. To check the tire air pressure, remove the air valve cap...
Owners Manual
Page 87
j A. Normal B. Replace the blown fuse with a new one of the correct capacity, as specified on the fuse. Failed Do not use any substitute for the standard fuse. MAINTENANCE AND ADJUSTMENT 85 WARNING Substituting fuse can cause wiring to overheat, catch fire and/or fail.
j A. Normal B. Replace the blown fuse with a new one of the correct capacity, as specified on the fuse. Failed Do not use any substitute for the standard fuse. MAINTENANCE AND ADJUSTMENT 85 WARNING Substituting fuse can cause wiring to overheat, catch fire and/or fail.
Owners Manual
Page 90
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 44 64 4.0 34 7.0 8.8 30 20 kgf·m 2.2 1.9 3.0 0.53 0.90 0.53...
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 44 64 4.0 34 7.0 8.8 30 20 kgf·m 2.2 1.9 3.0 0.53 0.90 0.53...
Owners Manual
Page 92
... air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. Always use non-abrasive wax and cleaner/polisher. The heat from the engine will help dry moist areas. water can easily be scratched. Use care when washing the plastic parts as in an area where the roads are cool before washing. Do not let the water air dry as ammonia-based window...
... air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. Always use non-abrasive wax and cleaner/polisher. The heat from the engine will help dry moist areas. water can easily be scratched. Use care when washing the plastic parts as in an area where the roads are cool before washing. Do not let the water air dry as ammonia-based window...
Owners Manual
Page 97
...: 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 Starting failure...
...: 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 Starting failure...
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
... rough Clutch hub spline damaged Gear shifting faulty Transmission does not go into gear; 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 or piston worn Connecting rod bent Piston pin or piston pin holes worn Valve noise: • clearance incorrect • Valve Valve spring broken or weak • Camshaft bearing...
... rough Clutch hub spline damaged Gear shifting faulty Transmission does not go into gear; 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 or piston worn Connecting rod bent Piston pin or piston pin holes worn Valve noise: • clearance incorrect • Valve Valve spring broken or weak • Camshaft bearing...
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
.... • • j WARNING Motor oil is well-ventilated and free from entering. Install the spark plug. WARNING Gasoline is a toxic substance. Turn the engine over the muffler to prevent rusting. Avoid getting oil on rubber parts and on all the cables. the spark plug and spray fogging oil di• Remove rectly into the cylinder. Tie a plastic bag over several times with a pilot light. Contact your local...
.... • • j WARNING Motor oil is well-ventilated and free from entering. Install the spark plug. WARNING Gasoline is a toxic substance. Turn the engine over the muffler to prevent rusting. Avoid getting oil on rubber parts and on all the cables. the spark plug and spray fogging oil di• Remove rectly into the cylinder. Tie a plastic bag over several times with a pilot light. Contact your local...