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 Digital DC-CDI 10° BTDC @1 300 r/min (rpm) ∼...
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 Digital DC-CDI 10° BTDC @1 300 r/min (rpm) ∼...
Owners Manual
Page 24
... 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 in the tank cap. If gasoline is posted on the fuel tank, wipe it can be covered under certain conditions, creating the potential for use a different brand of gasoline of flame or sparks; After refueling...
... 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 in the tank cap. If gasoline is posted on the fuel tank, wipe it can be covered under certain conditions, creating the potential for use a different brand of gasoline of flame or sparks; After refueling...
Owners Manual
Page 35
...; Turn the fuel tap lever to the OFF position. ○To avoid battery discharging, check that the enposition and the orgine stop switch to the • A. Pull in certain circumstances. Stopping the Engine the transmission into the neutral position. • Shift Close the throttle completely. • position. Independent use of the front or rear brake may be advantageous in the clutch lever...
...; Turn the fuel tap lever to the OFF position. ○To avoid battery discharging, check that the enposition and the orgine stop switch to the • A. Pull in certain circumstances. Stopping the Engine the transmission into the neutral position. • Shift Close the throttle completely. • position. Independent use of the front or rear brake may be advantageous in the clutch lever...
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
..., Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in this vehicle consists of crankcase vapors into the combustion chamber, where they are routed through an oil separator to keep the vehicle in which we all adjustments, maintenance, and repair work should be neglected. Crankcase Emission Control System This system eliminates the release of low permeation fuel hoses and a fuel tank. Evaporative Emission Control System...
..., Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in this vehicle consists of crankcase vapors into the combustion chamber, where they are routed through an oil separator to keep the vehicle in which we all adjustments, maintenance, and repair work should be neglected. Crankcase Emission Control System This system eliminates the release of low permeation fuel hoses and a fuel tank. Evaporative Emission Control System...
Owners Manual
Page 40
... regulation of the United States Environmental Protection Agency (EPA) at the time of sale. As the owner of this vehicle, you in keeping this record, we have the responsibility to the instructions in this Owner's Manual carefully and keep a maintenance record for remedy under warranty. Please read your Kawasaki Limited Emission Control Systems Warranty delivered with this Owner's Manual at the end of this maintenance...
... regulation of the United States Environmental Protection Agency (EPA) at the time of sale. As the owner of this vehicle, you in keeping this record, we have the responsibility to the instructions in this Owner's Manual carefully and keep a maintenance record for remedy under warranty. Please read your Kawasaki Limited Emission Control Systems Warranty delivered with this Owner's Manual at the end of this maintenance...
Owners Manual
Page 46
... change the oil according to settle. the engine oil level with the motorcycle ver• Check tical through the oil level inspection window on the lower right side of oil through the oil filler opening. j WARNING Motorcycle operation with the Periodic Maintenance Chart. Do not run it for several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at • Start idle speed. Check the oil...
... change the oil according to settle. the engine oil level with the motorcycle ver• Check tical through the oil level inspection window on the lower right side of oil through the oil filler opening. j WARNING Motorcycle operation with the Periodic Maintenance Chart. Do not run it for several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at • Start idle speed. Check the oil...
Owners Manual
Page 49
... tighten its new gasket. Oil Filter Element B. Oil Filter Cap C. 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 its bolts to • Install ward the engine. Spring B. Proper torque for it is shown in ·lb) j A. the spring to the oil filter cap. • Install the oil filter cap with the...
... tighten its new gasket. Oil Filter Element B. Oil Filter Cap C. 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 its bolts to • Install ward the engine. Spring B. Proper torque for it is shown in ·lb) j A. the spring to the oil filter cap. • Install the oil filter cap with the...
Owners Manual
Page 50
... 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 these products meets or exceeds warranty and service requirements and can help to extend the life of your riding area. the oil filler plug. • Tighten Install the engine guard and tighten the bolts. • Tightening Torque...
... 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 these products meets or exceeds warranty and service requirements and can help to extend the life of your riding area. the oil filler plug. • Tighten Install the engine guard and tighten the bolts. • Tightening Torque...
Owners Manual
Page 82
... the tire air pressure to tighten the cap securely after each ride. Wheels Tire air pressure affects traction, handling, and tire life. To check the tire air pressure, remove the air valve cap, and make sure to increase the tire tread surface on the ground when riding on a wet, muddy, sandy or slippery track. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. Adjust the tire air pressure to an oil leak. Tire Air Pressure j Rear Shock...
... the tire air pressure to tighten the cap securely after each ride. Wheels Tire air pressure affects traction, handling, and tire life. To check the tire air pressure, remove the air valve cap, and make sure to increase the tire tread surface on the ground when riding on a wet, muddy, sandy or slippery track. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. Adjust the tire air pressure to an oil leak. Tire Air Pressure j Rear Shock...
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
... rays, pollutants, and reduce the amount of your Kawasaki motorcycle will damage the • Gasoline, finish of your motorcycle). Use care when washing the plastic parts as in air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. Avoid spraying water in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. off immediately. Washing Your Motorcycle...
... rays, pollutants, and reduce the amount of your Kawasaki motorcycle will damage the • Gasoline, finish of your motorcycle). Use care when washing the plastic parts as in air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. Avoid spraying water in and around the vehicle, inspect the engine, electrical component and exhaust areas frequently. off immediately. Washing Your Motorcycle...
Owners Manual
Page 100
... Transmission gear or bearing seized Kick shaft return spring broken Kick ratchet gear not engaging j Fuel does not flow: No fuel in troubleshooting for each problem listed. NOTE Starter motor does not 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 Fuel tank cap air vent obstructed Fuel...
... Transmission gear or bearing seized Kick shaft return spring broken Kick ratchet gear not engaging j Fuel does not flow: No fuel in troubleshooting for each problem listed. NOTE Starter motor does not 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 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
... the drive chain and all unpainted metal surfaces to prevent rusting. Tie a plastic bag over sev- • • j WARNING Engine oil is a toxic substance. Make sure the area is well-ventilated and free from it and drain the engine oil. Dispose of used oil properly. Dispose of gasoline properly. eral times with a pilot light. Lift the motorcycle on the brakes. Run the engine for...
... the drive chain and all unpainted metal surfaces to prevent rusting. Tie a plastic bag over sev- • • j WARNING Engine oil is a toxic substance. Make sure the area is well-ventilated and free from it and drain the engine oil. Dispose of used oil properly. Dispose of gasoline properly. eral times with a pilot light. Lift the motorcycle on the brakes. Run the engine for...