Owners Manual
Page 11
... ...Engine Oil...Spark Plug ...Air Cleaner ...Throttle Cable...11 15 15 18 21 21 22 25 26 27 28 28 32 32 34 34 35 36 38 38 41 45 50 52 57 Carburetor ...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...11 15 15 18 21 21 22 25 26 27 28 28 32 32 34 34 35 36 38 38 41 45 50 52 57 Carburetor ...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 12
SPECIFICATIONS 11 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...
SPECIFICATIONS 11 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 35
... or rear brake may be advantageous in the clutch lever as the motorcycle comes to the • A. Shift down progressively to the OFF position. ○To avoid battery discharging, check that the enposition and the orgine stop (KLX110D model). Engine Stop Switch Position B. • Turn the fuel tap lever to ensure good engine response at all speeds. Stopping the Engine the transmission into the neutral...
... or rear brake may be advantageous in the clutch lever as the motorcycle comes to the • A. Shift down progressively to the OFF position. ○To avoid battery discharging, check that the enposition and the orgine stop (KLX110D model). Engine Stop Switch Position B. • Turn the fuel tap lever to ensure good engine response at all speeds. Stopping the Engine the transmission into the neutral...
Owners Manual
Page 38
... 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 39
... intake side of the maintenance items described in good running condition. If you should be neglected. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the United States Environmental Protection Agency. 1. The fuel and ignition systems of crankcase vapors into the atmosphere by the owner. Instead, the vapors are burned along with the fuel and air...
... intake side of the maintenance items described in good running condition. If you should be neglected. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the United States Environmental Protection Agency. 1. The fuel and ignition systems of crankcase vapors into the atmosphere by the owner. Instead, the vapors are burned along with the fuel and air...
Owners Manual
Page 40
... original emission related parts: Carburetor or internal parts Magneto ignition system Spark plug Air cleaner element j • • • • This Owner's Manual contains maintenance operations recommended for purposes of maintenance, repair, or replacement, of any device or element of this maintenance. As the owner of design incorporated into any person. WARRANTY This vehicle is necessary to constitute tampering are noted in material and...
... original emission related parts: Carburetor or internal parts Magneto ignition system Spark plug Air cleaner element j • • • • This Owner's Manual contains maintenance operations recommended for purposes of maintenance, repair, or replacement, of any device or element of this maintenance. As the owner of design incorporated into any person. WARRANTY This vehicle is necessary to constitute tampering are noted in material and...
Owners Manual
Page 46
... Engine Oil In order for the • Stop oil to settle. Oil Level Inspection the oil has just been changed, let the motorcycle • If sit a few minutes allowing the oil to the oil level inspection window. Do not run it for several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at • Start idle speed. the engine oil level with the Periodic Maintenance Chart. j WARNING...
... Engine Oil In order for the • Stop oil to settle. Oil Level Inspection the oil has just been changed, let the motorcycle • If sit a few minutes allowing the oil to the oil level inspection window. Do not run it for several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at • Start idle speed. the engine oil level with the Periodic Maintenance Chart. j WARNING...
Owners Manual
Page 49
.... Spring B. Oil Filter Cap C. O-ring the oil has completely drained out, install the • After drain bolt with the high-temperature • Install grease applied to a new O-ring and tighten its new gasket. Proper torque for it is shown in ·lb) j A. Grommet A. Oil Filter Element B. the spring to the oil filter cap. • Install the oil filter cap with its bolts to • Install ward the engine.
.... Spring B. Oil Filter Cap C. O-ring the oil has completely drained out, install the • After drain bolt with the high-temperature • Install grease applied to a new O-ring and tighten its new gasket. Proper torque for it is shown in ·lb) j A. Grommet A. Oil Filter Element B. the spring to the oil filter cap. • Install the oil filter cap with its bolts to • Install ward the engine.
Owners Manual
Page 50
... JASO MA, MA1, MA2 rating Viscosity: SAE 10W-40 *Kawasaki Performance Oils and Lubricants have been specifically engineered for both the engine and the clutch. • Start the engine. Consistent use of your vehicle. NOTE Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for your Kawasaki. the oil filler plug. • Tighten Install the engine guard and tighten the bolts. • Tightening Torque Footpeg...
... JASO MA, MA1, MA2 rating Viscosity: SAE 10W-40 *Kawasaki Performance Oils and Lubricants have been specifically engineered for both the engine and the clutch. • Start the engine. Consistent use of your vehicle. NOTE Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for your Kawasaki. the oil filler plug. • Tighten Install the engine guard and tighten the bolts. • Tightening Torque Footpeg...
Owners Manual
Page 72
... the rain or mud, or any excess lubricant. j • • • • A. Mount the handlebar clamps so that it is necessary to the front. Apply lubricant to the side of the drive chain is necessary after riding in place, it will penetrate to the rollers and bushings. Wipe off any time the chain appears dry with...
... the rain or mud, or any excess lubricant. j • • • • A. Mount the handlebar clamps so that it is necessary to the front. Apply lubricant to the side of the drive chain is necessary after riding in place, it will penetrate to the rollers and bushings. Wipe off any time the chain appears dry with...
Owners Manual
Page 82
.... necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. MAINTENANCE AND ADJUSTMENT 81 Rear Suspension The rear shock absorber inspection should be done in accordance with the Periodic Maintenance Chart. Wheels Tire air pressure affects traction, handling, and tire life. NOTE it close within the recommended range. Increase the tire air pressure to an oil leak. the seat down and up by an authorized • If Kawasaki dealer...
.... necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. MAINTENANCE AND ADJUSTMENT 81 Rear Suspension The rear shock absorber inspection should be done in accordance with the Periodic Maintenance Chart. Wheels Tire air pressure affects traction, handling, and tire life. NOTE it close within the recommended range. Increase the tire air pressure to an oil leak. the seat down and up by an authorized • If Kawasaki dealer...
Owners Manual
Page 92
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 64 4.0 44 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 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 64 4.0 44 7.0 8.8 30 20 kgf·m 2.2 1.9 3.0 0.53 0.90 0.53...
Owners Manual
Page 94
... applying degreaser to inspecting for motor• Mix cycles or automobiles) and water in and around the vehicle chassis, engine, and exhaust can penetrate seals and electrical components and damage your motorcycle. Use care when washing the plastic parts as in air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. When operating the vehicle in conditions that allow debris or flammable...
... applying degreaser to inspecting for motor• Mix cycles or automobiles) and water in and around the vehicle chassis, engine, and exhaust can penetrate seals and electrical components and damage your motorcycle. Use care when washing the plastic parts as in air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. When operating the vehicle in conditions that allow debris or flammable...
Owners Manual
Page 100
... valve clogged Engine flooded: Fuel level too high Float valve worn or stuck open Wrong starting technique (when the engine is meant simply as a quick guide to assist you in troubleshooting for each problem listed. It is flooded, kick with the throttle fully open to reach the engine.) Spark missing or weak: Starter motor rotating but engine does not turn over: Starter clutch trouble Starter idle gear trouble stop switch turned off • Engine Spark plug...
... valve clogged Engine flooded: Fuel level too high Float valve worn or stuck open Wrong starting technique (when the engine is meant simply as a quick guide to assist you in troubleshooting for each problem listed. It is flooded, kick with the throttle fully open to reach the engine.) Spark missing or weak: Starter motor rotating but engine does not turn over: Starter clutch trouble Starter idle gear trouble stop switch turned off • Engine Spark plug...
Owners Manual
Page 101
...; 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 102
...; Igniter Brake dragging • Clutch slipping • Engine over heating • Engine oil level too high • Engine oil viscosity too high • Ignition timing incorrect • Drive chain trouble • Poor or no high-speed performance plug dirty, broken, or gap improperly ad• Spark justed plug cap or high-tension wiring defective • Spark Spark plug shorted or not contacting properly • Spark plug cap type incorrect • Igniter defective • Ignition coil defective • Crankshaft sensor defective...
...; Igniter Brake dragging • Clutch slipping • Engine over heating • Engine oil level too high • Engine oil viscosity too high • Ignition timing incorrect • Drive chain trouble • Poor or no high-speed performance plug dirty, broken, or gap improperly ad• Spark justed plug cap or high-tension wiring defective • Spark Spark plug shorted or not contacting properly • Spark plug cap type incorrect • Igniter defective • Ignition coil defective • Crankshaft sensor defective...
Owners Manual
Page 103
... 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 104
... Engine oil level too high Clutch housing frozen on the shaft Shift mechanism arm spring broken 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: 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...
... Engine oil level too high Clutch housing frozen on the shaft Shift mechanism arm spring broken 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: 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...
Owners Manual
Page 105
... damaged 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 maladjusted...
... damaged 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 maladjusted...
Owners Manual
Page 108
... the drive chain and all unpainted metal surfaces to prevent rusting. Clean the entire vehicle thoroughly. Do not gine stop it and drain the engine oil. Install the spark plug. Gasoline is a toxic substance. Contact your local authorities for serious burns. Dispose of gasoline properly. eral times with a pilot light. the oil drain bolt and fill in fresh engine oil. • Install the fuel tank...
... the drive chain and all unpainted metal surfaces to prevent rusting. Clean the entire vehicle thoroughly. Do not gine stop it and drain the engine oil. Install the spark plug. Gasoline is a toxic substance. Contact your local authorities for serious burns. Dispose of gasoline properly. eral times with a pilot light. the oil drain bolt and fill in fresh engine oil. • Install the fuel tank...
