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
... the Engine the transmission into the neutral position. • Shift Close the throttle completely. • position. Push the engine stop switch to ensure good engine response at all speeds. NOTE Shift down progressively to the • A. Engine Stop Switch Position B. • Turn the fuel tap lever to a stop switch is not used. Independent use of the front or rear brake may be advantageous in the ange indicator light...
... the Engine the transmission into the neutral position. • Shift Close the throttle completely. • position. Push the engine stop switch to ensure good engine response at all speeds. NOTE Shift down progressively to the • A. Engine Stop Switch Position B. • Turn the fuel tap lever to a stop switch is not used. Independent use of the front or rear brake may be advantageous in the ange indicator light...
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
... live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in good running condition. The initial maintenance is operating, the vapors are routed through an oil separator to keep the vehicle in compliance with the Periodic Maintenance Chart to the intake side of low permeation fuel hoses and a fuel tank. While the engine is vitally important and must be completed by the owner. j EMISSION CONTROL INFORMATION...
... live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in good running condition. The initial maintenance is operating, the vapors are routed through an oil separator to keep the vehicle in compliance with the Periodic Maintenance Chart to the intake side of low permeation fuel hoses and a fuel tank. While the engine is vitally important and must be completed by the owner. j EMISSION CONTROL INFORMATION...
Owners Manual
Page 40
... internal parts Magneto ignition system Spark plug Air cleaner element j • • • • You should keep it contains. WARRANTY This vehicle is in use, or (2) the use of the vehicle after such device or element of sale. To obtain warranty service, the Kawasaki Limited Emission Control Systems Warranty requires that your vehicle comply with certain emissions regulation during a portion of its sale or delivery to...
... internal parts Magneto ignition system Spark plug Air cleaner element j • • • • You should keep it contains. WARRANTY This vehicle is in use, or (2) the use of the vehicle after such device or element of sale. To obtain warranty service, the Kawasaki Limited Emission Control Systems Warranty requires that your vehicle comply with certain emissions regulation during a portion of its sale or delivery to...
Owners Manual
Page 46
... the correct amount of the engine. the engine and run the engine at high enthe engine and wait several minutes at the proper level, and change the oil according to the oil level inspection window. 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. MAINTENANCE AND ADJUSTMENT 45 Engine Oil In order for the...
... the correct amount of the engine. the engine and run the engine at high enthe engine and wait several minutes at the proper level, and change the oil according to the oil level inspection window. 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. MAINTENANCE AND ADJUSTMENT 45 Engine Oil In order for the...
Owners Manual
Page 49
...; Install ward the engine. Proper torque for it is shown in ·lb) j A. 48 MAINTENANCE AND ADJUSTMENT the oil filter element with a new one. • Replace the oil filter element with its bolts to the specified torque. Oil Filter Element B. Tightening Torque Oil Filter Cap Bolts: 5.2 N·m (0.53 kgf·m, 46 in the table. the spring to the oil filter cap. • Install the oil filter cap with the high-temperature...
...; Install ward the engine. Proper torque for it is shown in ·lb) j A. 48 MAINTENANCE AND ADJUSTMENT the oil filter element with a new one. • Replace the oil filter element with its bolts to the specified torque. Oil Filter Element B. Tightening Torque Oil Filter Cap Bolts: 5.2 N·m (0.53 kgf·m, 46 in the table. the spring to the oil filter cap. • Install the oil filter cap with the high-temperature...
Owners Manual
Page 50
... changed to extend the life of your Kawasaki. Consistent use of these products meets or exceeds warranty and service requirements and can help to accommodate atmospheric conditions in the table. NOTE the engine up to the oil. Recommended Engine Oil Type: Kawasaki Performance 4-Stroke Motorcycle Oil* Kawasaki Performance 4-Stroke Semi-Synthetic Oil* Kawasaki Performance 4-Stroke Full Synthetic Oil* or other 4-stroke oils with good • Fill quality engine oil specified in your vehicle...
... changed to extend the life of your Kawasaki. Consistent use of these products meets or exceeds warranty and service requirements and can help to accommodate atmospheric conditions in the table. NOTE the engine up to the oil. Recommended Engine Oil Type: Kawasaki Performance 4-Stroke Motorcycle Oil* Kawasaki Performance 4-Stroke Semi-Synthetic Oil* Kawasaki Performance 4-Stroke Full Synthetic Oil* or other 4-stroke oils with good • Fill quality engine oil specified in your vehicle...
Owners Manual
Page 72
...time the chain appears dry with the punch mark on the clamp face to install the handlebar clamps correctly. j • • • • A. C. D. Align the gap at the rear with a high quality lubricant for drive chains. Handlebar Clamps Arrow Marks Punch Mark Gap Mount... the handlebar clamps so that it is necessary after riding in the rain or mud, or any excess lubricant. B. Chain Lubrication Handlebar To keep the handlebar ...
...time the chain appears dry with the punch mark on the clamp face to install the handlebar clamps correctly. j • • • • A. C. D. Align the gap at the rear with a high quality lubricant for drive chains. Handlebar Clamps Arrow Marks Punch Mark Gap Mount... the handlebar clamps so that it is necessary after riding in the rain or mud, or any excess lubricant. B. Chain Lubrication Handlebar To keep the handlebar ...
Owners Manual
Page 82
... or noise is found, inspect • If the oil leak and rear shock absorber mounting. Clean the sliding surface after checking the tire pressure. Adjust the tire air pressure to increase the tire tread surface on the ground when riding on a pebbly or hard track. Wheels Tire air pressure affects traction, handling, and tire life. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. inspect the rear shock absorber for oil...
... or noise is found, inspect • If the oil leak and rear shock absorber mounting. Clean the sliding surface after checking the tire pressure. Adjust the tire air pressure to increase the tire tread surface on the ground when riding on a pebbly or hard track. Wheels Tire air pressure affects traction, handling, and tire life. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. inspect the rear shock absorber for oil...
Owners Manual
Page 92
...bolt may become damaged or fall out. 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... an accurate torque wrench. An overtightened nut or bolt may become damaged, broken, or fall out, possibly resulting in ·lb 22 15 R...
...bolt may become damaged or fall out. 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... an accurate torque wrench. An overtightened nut or bolt may become damaged, broken, or fall out, possibly resulting in ·lb 22 15 R...
Owners Manual
Page 94
..., park the vehicle outside and stop the engine. sure the engine and exhaust are cool before • Be washing. • Avoid applying degreaser to cool, then remove any oil or grease which build up of fire. Use care when washing the plastic parts as in air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. Washing Your Motorcycle your bike with clean water to...
..., park the vehicle outside and stop the engine. sure the engine and exhaust are cool before • Be washing. • Avoid applying degreaser to cool, then remove any oil or grease which build up of fire. Use care when washing the plastic parts as in air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. Washing Your Motorcycle your bike with clean water to...
Owners Manual
Page 100
... troubleshooting for some of the more air 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 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 to assist you in tank Fuel tap turned off Fuel tank cap air vent obstructed Fuel...
... troubleshooting for some of the more air 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 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 to assist you in tank Fuel tap turned off Fuel tank cap air vent obstructed Fuel...
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
... light. Spray oil on the brakes. Run the engine for about five minutes to warm the oil, then stop switch to the smoke. the spark plug and spray fogging oil di• Remove rectly into the cylinder. Move the enposition. Turn the engine over the muffler to prevent moisture from any source of flame or sparks; the oil drain bolt and fill in fresh engine oil. • Install the fuel tank and...
... light. Spray oil on the brakes. Run the engine for about five minutes to warm the oil, then stop switch to the smoke. the spark plug and spray fogging oil di• Remove rectly into the cylinder. Move the enposition. Turn the engine over the muffler to prevent moisture from any source of flame or sparks; the oil drain bolt and fill in fresh engine oil. • Install the fuel tank and...