Owners Manual
Page 10
... ...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 48 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 ...YOUR WARRANTY/OWNER...
... ...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 48 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 ...YOUR WARRANTY/OWNER...
Owners Manual
Page 11
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 20
... unsatisfactory performance. If the tank is an average of low quality or not meeting standard industry specifications may cause the fuel to severe engine damage. Octane Rating Method Antiknock Index (RON + MON) 2 Minimum Rating 87 j NOTICE If engine "knocking" or "pinging" occurs, use of flame or sparks; Gasoline quality is closed securely. and Canada which are required to reduce exhaust emissions...
... unsatisfactory performance. If the tank is an average of low quality or not meeting standard industry specifications may cause the fuel to severe engine damage. Octane Rating Method Antiknock Index (RON + MON) 2 Minimum Rating 87 j NOTICE If engine "knocking" or "pinging" occurs, use of flame or sparks; Gasoline quality is closed securely. and Canada which are required to reduce exhaust emissions...
Owners Manual
Page 31
... the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Shift down progressively to the position. • A. Stopping the Engine the transmission into the neutral position. • Shift Close the throttle completely. • Push the engine stop switch to ensure good engine response at all speeds. Engine Stop Switch Position B. • Turn the fuel tap lever to a stop switch is in certain circumstances.
... the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Shift down progressively to the position. • A. Stopping the Engine the transmission into the neutral position. • Shift Close the throttle completely. • Push the engine stop switch to ensure good engine response at all speeds. Engine Stop Switch Position B. • Turn the fuel tap lever to a stop switch is in certain circumstances.
Owners Manual
Page 33
.... Always perform daily safety checks before operation may result in serious damage or an accident. Operate only in enclosed areas. Engine Engine Oil ...No leakage Level correct Spark Plug ...Correctly torqued Clutch ...Functions properly Carburetor ...Properly adjusted Air Cleaner ...Clean Apply oil to a safe operating condition. If any irregularities are found during these checks will help ensure a safe, reliable ride. The time required...
.... Always perform daily safety checks before operation may result in serious damage or an accident. Operate only in enclosed areas. Engine Engine Oil ...No leakage Level correct Spark Plug ...Correctly torqued Clutch ...Functions properly Carburetor ...Properly adjusted Air Cleaner ...Clean Apply oil to a safe operating condition. If any irregularities are found during these checks will help ensure a safe, reliable ride. The time required...
Owners Manual
Page 34
... 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 35
... live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with the Periodic Maintenance Chart to ensure an efficient engine with applicable regulations of low permeation fuel hoses and a fuel tank. The fuel and ignition systems of the engine. j EMISSION CONTROL INFORMATION To protect the environment in which we all adjustments, maintenance, and repair work should be able to the intake side of this vehicle have...
... live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with the Periodic Maintenance Chart to ensure an efficient engine with applicable regulations of low permeation fuel hoses and a fuel tank. The fuel and ignition systems of the engine. j EMISSION CONTROL INFORMATION To protect the environment in which we all adjustments, maintenance, and repair work should be able to the intake side of this vehicle have...
Owners Manual
Page 36
... the time of sale. WARRANTY This vehicle is carried out according to an authorized Kawasaki dealer for remedy under warranty. 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. Installation Instructions: High altitude adjustment requires replacement of this manual where an authorized Kawasaki dealer...
... the time of sale. WARRANTY This vehicle is carried out according to an authorized Kawasaki dealer for remedy under warranty. 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. Installation Instructions: High altitude adjustment requires replacement of this manual where an authorized Kawasaki dealer...
Owners Manual
Page 42
... 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 oil level should come up between the high and low level lines next to settle. Check the oil level before the oil reaches every part can cause engine seizure. the engine and run the engine at • Start idle speed...
... 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 oil level should come up between the high and low level lines next to settle. Check the oil level before the oil reaches every part can cause engine seizure. the engine and run the engine at • Start idle speed...
Owners Manual
Page 45
... drain bolt with its bolts to • ward the engine. Proper torque for it is shown in ·lb) j A. Grommet A. Oil Filter Cap C. 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. Spring B. Oil Filter Element B. 44 MAINTENANCE AND ADJUSTMENT the oil filter element with a new one. • Replace Install the oil filter element...
... drain bolt with its bolts to • ward the engine. Proper torque for it is shown in ·lb) j A. Grommet A. Oil Filter Cap C. 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. Spring B. Oil Filter Element B. 44 MAINTENANCE AND ADJUSTMENT the oil filter element with a new one. • Replace Install the oil filter element...
Owners Manual
Page 78
... the tire pressure. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. Adjust the tire air pressure to increase the tire tread surface on the ground when riding on a pebbly or hard track. 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...
... the tire pressure. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. Adjust the tire air pressure to increase the tire tread surface on the ground when riding on a pebbly or hard track. 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...
Owners Manual
Page 88
..., possibly resulting in ·lb 22 15 R R R, S R 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 Bolt 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 9.8 30 54 44...
..., possibly resulting in ·lb 22 15 R R R, S R 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 Bolt 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 9.8 30 54 44...
Owners Manual
Page 90
... neutral detergent (designed for chips and scratches. j Washing Your Motorcycle your motorcycle. Covering your motorcycle with clean water to dry your motorcycle with cold water from harmful UV rays, pollutants, and reduce the amount of your motorcycle for motor• Mix cycles or automobiles) and water in • Avoid air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. The heat from...
... neutral detergent (designed for chips and scratches. j Washing Your Motorcycle your motorcycle. Covering your motorcycle with clean water to dry your motorcycle with cold water from harmful UV rays, pollutants, and reduce the amount of your motorcycle for motor• Mix cycles or automobiles) and water in • Avoid air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. The heat from...
Owners Manual
Page 95
... guide to assist you in .) 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 or difficulties - It is • flooded,starting kick with the throttle fully closed by pulling the hot starter lever in troubleshooting for each problem listed...
... guide to assist you in .) 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 or difficulties - It is • flooded,starting kick with the throttle fully closed by pulling the hot starter lever in troubleshooting for each problem listed...
Owners Manual
Page 96
...; 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 • • • 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 • • • Fuel/air mixture...
Owners Manual
Page 97
...; 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 98
TROUBLESHOOTING GUIDE 97 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 Fuel/air mixture incorrect: Main jet clogged or wrong size Carburetor...
TROUBLESHOOTING GUIDE 97 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 Fuel/air mixture incorrect: Main jet clogged or wrong size Carburetor...
Owners Manual
Page 99
... 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 or cam face worn • shift pedal does not return: Clutch not disengaging Shift fork bent or seized Gear...
... 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 or cam face worn • shift pedal does not return: Clutch not disengaging Shift fork bent or seized Gear...
Owners Manual
Page 100
... 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 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 j 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 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 j 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 103
... keep dampness away from it and drain the engine oil. Tie a plastic bag over sev- Cover the motorcycle to warm the oil, then stop switch to be done, put boards under certain conditions, creating the potential for storage as follows. Contact your local authorities for any length of flame or sparks; Run the engine for a long time.). Clean the entire vehicle thoroughly.
... keep dampness away from it and drain the engine oil. Tie a plastic bag over sev- Cover the motorcycle to warm the oil, then stop switch to be done, put boards under certain conditions, creating the potential for storage as follows. Contact your local authorities for any length of flame or sparks; Run the engine for a long time.). Clean the entire vehicle thoroughly.