2008 Kawasaki KLX140 Owners Manual

2008 Kawasaki KLX140 Manual

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  • 2008 Kawasaki KLX140 | Owners Manual - Page 1
  • 2008 Kawasaki KLX140 | Owners Manual - Page 2
  • 2008 Kawasaki KLX140 | Owners Manual - Page 3
    Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION MAINTENANCE AND ADJUSTMENT TROUBLESHOOTING GUIDE STORAGE j j j j A Table of Contents is included after the Foreword.
  • 2008 Kawasaki KLX140 | Owners Manual - Page 4
    IMPORTANT INFORMATION KLX models are designed for the operator only, no passengers. • Kawasaki This motorcycle designed for competition only on a closed course. • Not intended for is use on public streets. • Read your owner's manual, it contains important information. •
  • 2008 Kawasaki KLX140 | Owners Manual - Page 5
    result in injury or death. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in conducted, this sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road
  • 2008 Kawasaki KLX140 | Owners Manual - Page 6
    techniques. Read and understand the owner's manual provided with the motorcycle. Review all instructions and warnings with your child. You riding the motorcycle. Also, familiarity with the motorcycle is important should a problem occur far from help. Do not allow your child to ride unsupervised.
  • 2008 Kawasaki KLX140 | Owners Manual - Page 7
    10. Encourage your child not to ride beyond his or her skill lever or faster than conditions safely allow. Have them practice advanced riding maneuvers under controlled conditions. 11. Tell someone where you and your child are planning to ride and when you Intend to return. Discuss the ride with
  • 2008 Kawasaki KLX140 | Owners Manual - Page 8
  • 2008 Kawasaki KLX140 | Owners Manual - Page 9
    . By giving your motorcycle the proper care and maintenance outlined in this manual, you will be helping to ensure it a long, trouble-free life. Before starting to ride your motorcycle, please read this manual thoroughly in order to know your motorcycle's capabilities, its limitations, and above
  • 2008 Kawasaki KLX140 | Owners Manual - Page 10
  • 2008 Kawasaki KLX140 | Owners Manual - Page 11
    ...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 SATISFACTION ...REPORTING SAFETY DEFECTS
  • 2008 Kawasaki KLX140 | Owners Manual - Page 12
    10 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall length Overall width Overall height Wheelbase Road clearance Dry weight Fuel tank capacity ENGINE Type Bore × stroke Displacement Compression ratio Carburetor Starting system Ignition system Ignition timing Lubrication system Spark plug Spark plug
  • 2008 Kawasaki KLX140 | Owners Manual - Page 13
    SPECIFICATIONS 11 TRANSMISSION Transmission type Clutch type Drive system Gear ratios: 1st gear 2nd gear 3rd gear 4th gear 5th gear Primary reduction ratio Final reduction ratio Overall ratio (top gear) Engine oil: Capacity Type 1.1 L (1.2 US qt) API SE, SF or SG API SH, SJ or SL with JASO MA SAE
  • 2008 Kawasaki KLX140 | Owners Manual - Page 14
    12 SPECIFICATIONS FRAME Type Steering angle Castor Trail Tire size, type: Front Rear Rim size: Front Rear Suspension: Front Rear Front suspension travel Rear wheel travel Front fork oil: Type Capacity (per fork leg) SHOWA SS8GO or equivalent 296 mL (10.0 US oz) B: 290 mL (9.8 US oz) Telescopic fork
  • 2008 Kawasaki KLX140 | Owners Manual - Page 15
    SPECIFICATIONS 13 BRAKES Type (Front & Rear) ELECTRICAL EQUIPMENT Battery 12 V 6 Ah Disc Specifications are subject to change without notice.
  • 2008 Kawasaki KLX140 | Owners Manual - Page 16
    14 GENERAL INFORMATION j GENERAL INFORMATION Location of Parts 1. Clutch Lever 2. Engine Stop Button 3. Ignition Button 4. Choke Knob 5. Front Brake Fluid Reservoir 6. Front Brake Lever 7. Throttle Grip 8. Starter Button 9. Fuel Tank Cap
  • 2008 Kawasaki KLX140 | Owners Manual - Page 17
    GENERAL INFORMATION 15 j 10. Front Fork 11. Fuel Tank 12. Fuel Tap 13. Carburetor 14. Seat 15. Air Cleaner Element 16. Brake Disc 17. Brake Caliper 18. Engine Oil Drain Plug 19. Side Stand 20. Drive Chain 21. Swingarm 22. Chain Guide 23. Rear Shock Absorber
  • 2008 Kawasaki KLX140 | Owners Manual - Page 18
    16 GENERAL INFORMATION j 24. Muffler 25. Fuse 26. Battery 27. Rear Axle Nut 28. Chain Adjuster 29. Rear Brake Fluid Reservoir 30. Oil Filler Cap/Dipstick 31. Rear Brake Pedal
  • 2008 Kawasaki KLX140 | Owners Manual - Page 19
    GENERAL INFORMATION 17 j Side Stand The motorcycle is equipped with a side stand. Fuel Tap The fuel tap has three position: OFF, ON, and RES (reserve). For normal operation, turn the fuel tap lever to the ON position, If the fuel runs out with the tap in the ON position, the last 1.1 L (0.29 US
  • 2008 Kawasaki KLX140 | Owners Manual - Page 20
    18 GENERAL INFORMATION NOTE j żSince riding distance is limited when on RES, refuel at the earliest opportunity. żMake certain that the fuel tap lever is turned to ON (not RES), after filling up the fuel tank. Fuel The required of fuel is specified under "Fuel Requirements". The capacity of the
  • 2008 Kawasaki KLX140 | Owners Manual - Page 21
    with a minimum Antiknock Index of 87. The Antiknock Index is posted on service station pumps in the U.S.A. The octane rating of a gasoline is a standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or non-recommended
  • 2008 Kawasaki KLX140 | Owners Manual - Page 22
    drain all fuel from the fuel system. See the Storage section in this manual. CAUTION Avoid using blends of unleaded gasoline and methanol (wood alcohol) " containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is
  • 2008 Kawasaki KLX140 | Owners Manual - Page 23
    GENERAL INFORMATION 21 Ignition Button The ignition button is a two-stage switch. To close (OFF: red light off) or open (ON: red light on) the electric circuits, push the button. WARNING Never operate the ignition switch, while driving the motorcycle. If you turn the ignition switch to the "OFF"
  • 2008 Kawasaki KLX140 | Owners Manual - Page 24
    22 GENERAL INFORMATION j Engine Stop Switch The engine stop switch is located on the left side of the handlebar. The engine stop switch must be in the RUN position (RUN button pushed in) for the motorcycle to operate. For ordinary engine stoppage and, if some emergency requires stopping the engine,
  • 2008 Kawasaki KLX140 | Owners Manual - Page 25
    GENERAL INFORMATION 23 Starting the Engine that the engine stop switch is in the RUN • Check position (RUN switch pushed in). j • Turn the fuel tap lever to the ON position. A. Engine Stop Switch B. RUN Position A. ON Position • Shift the transmission into neutral. NOTE żThis motorcycle is
  • 2008 Kawasaki KLX140 | Owners Manual - Page 26
    24 GENERAL INFORMATION in the ignition button to the ON position (red • Push light is lit). When engine is cold: Pull out the choke knob. j • A. Ignition Button A. Choke Knob WARNING Do not start the engine or attempt to ride the motorcycle when the side stand is installed. the throttle
  • 2008 Kawasaki KLX140 | Owners Manual - Page 27
    GENERAL INFORMATION 25 j Moving Off that the side stand is up. • Check Shift into gear. • Open the 1st throttle slowly. • A. Starter Button after the engine has started, do not push • Even back immediately the choke knob until the engine is thoroughly warmed up. NOTE żWhen the engine is already
  • 2008 Kawasaki KLX140 | Owners Manual - Page 28
    26 GENERAL INFORMATION j Shifting Gears This motorcycle is equipped with a 5-speed "return shift" transmission. The neutral is located halfway between 1st and 2nd gear. "Return shift" means that when shifting up or down, each gear must be engaged before the next higher or lower gear may be selected
  • 2008 Kawasaki KLX140 | Owners Manual - Page 29
    GENERAL INFORMATION 27 j Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Pull in the clutch lever as the motorcycle comes to a stop. Independent use of the front or rear brake may be advantageous in certain circumstances. Shift down
  • 2008 Kawasaki KLX140 | Owners Manual - Page 30
    28 GENERAL INFORMATION j Break-In The first one hour that the motorcycle is ridden is designed as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a "broken down" instead of a "broken in" motorcycle after the long use. Do not start
  • 2008 Kawasaki KLX140 | Owners Manual - Page 31
    GENERAL INFORMATION 29 j Daily Pre-Ride Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure a safe, reliable ride. If any irregularities are found during these checks, refer to the appropriate section and
  • 2008 Kawasaki KLX140 | Owners Manual - Page 32
    30 GENERAL INFORMATION Frame Tires ...Overall condition good No wear or damage Air pressure correct 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
  • 2008 Kawasaki KLX140 | Owners Manual - Page 33
    MAINTENANCE AND ADJUSTMENT 31 MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must be carried out in accordance with the Periodic Maintenance Chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be
  • 2008 Kawasaki KLX140 | Owners Manual - Page 34
    following repair recommendations specified in the appropriate Kawasaki Service Manual. MAINTENANCE Proper maintenance is necessary to ensure that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. You should keep a maintenance record
  • 2008 Kawasaki KLX140 | Owners Manual - Page 35
    MAINTENANCE AND ADJUSTMENT 33 TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED: Federal regulations and California State law prohibit the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of
  • 2008 Kawasaki KLX140 | Owners Manual - Page 36
    the motorcycle in good running condition. † : Replace, add, adjust, clean or torque if necessary. (K) : Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer. ż : Emission-related Item 1. Periodic Inspection (Engine Related Item) FREQUENCY OPERATION Initial 5 hours
  • 2008 Kawasaki KLX140 | Owners Manual - Page 37
    and rim runout - check † C H A S S I S (K) Drive chain wear - check † Drive chain - inspect and adjust † Drive chain - lubricate Drive chain guide and slipper - inspect † Front fork - inspect and clean † Nuts, bolts, fasteners - inspect † Steering play - inspect † (K) Steering stem bearing - grease
  • 2008 Kawasaki KLX140 | Owners Manual - Page 38
    36 MAINTENANCE AND ADJUSTMENT FREQUENCY OPERATION Battery - inspect † Battery terminal - inspect † Chassis parts - lubricate Side stand - inspect † C H A S S I S (K) Wheel bearing - check † (K) Swingarm and Uni-track linkage pivot - inspect (K) Swingarm and Uni-track linkage pivot - grease (K) Rear
  • 2008 Kawasaki KLX140 | Owners Manual - Page 39
    MAINTENANCE AND ADJUSTMENT 37 3. Periodic Replacement (Engine and Chassis Related Item) FREQUENCY Initial OPERATION Engine oil Oil filter (K) Brake hose (K) Fuel hose (K) Brake fluid (K) Brake master cylinder cup and dust seal (K) Brake caliper piston seal and dust seal (K) Front fork oil (K) Rear
  • 2008 Kawasaki KLX140 | Owners Manual - Page 40
    38 MAINTENANCE AND ADJUSTMENT Engine Oil In order for the engine, transmission and clutch to function properly, maintain the engine oil at the proper level, and change the oil and oil filter periodically. Not only do dirt and metal particles collect in the oil, but the oil itself loses its
  • 2008 Kawasaki KLX140 | Owners Manual - Page 41
    MAINTENANCE AND ADJUSTMENT 39 Oil and/or Oil Filter Change The engine oil and/or oil filter should be changed periodically to ensure long engine life. Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily. Stop the engine, and place a container beneath it. Remove
  • 2008 Kawasaki KLX140 | Owners Manual - Page 42
    40 MAINTENANCE AND ADJUSTMENT the oil filter is replaced, remove the oil filter • When cover and take off the cover with O-ring. the oil filter element with a new one. • Replace Apply the oil to the grommet. • Install the grease oil filter • ward the engine. element with the grommet to- j A. Oil
  • 2008 Kawasaki KLX140 | Owners Manual - Page 43
    MAINTENANCE AND ADJUSTMENT 41 Oil Filter Cover Tightening Torque 8.8 N·m (0.9 kgf·m, 78 in·lb) the oil has completely drained out, install the • After drain plug with its new gasket. Proper torque for it is shown in the table. Engine Oil Drain Plug Tightening Torque 18 N·m (1.8 kgf·m, 13 ft·lb)
  • 2008 Kawasaki KLX140 | Owners Manual - Page 44
    42 MAINTENANCE AND ADJUSTMENT Spark Plug The spark plug should be taken out periodically for inspection and regapping. Measure the gap with a wire-type thickness gauge. If incorrect, adjust the gap to the specified value by bending the outer electrode. Spark Plug Gap CR7HSA 0.6 ~ 0.7 mm (0.024 ~ 0.
  • 2008 Kawasaki KLX140 | Owners Manual - Page 45
    MAINTENANCE AND ADJUSTMENT 43 the plug cap securely onto the spark plug, and • Fit pull the cap lightly to make sure that it is properly Air Cleaner A clogged air cleaner restricts the air intake, increases fuel consumption, reduces engine power, and can cause spark plug fouling. Inspect the air
  • 2008 Kawasaki KLX140 | Owners Manual - Page 46
    44 MAINTENANCE AND ADJUSTMENT Element Removal and Inspection j • Remove the screw and remove the left side cover. the bolts and remove the air cleaner • Remove cover. A. Left Side Cover B. Bolt A. Air Cleaner Cover B. Bolts
  • 2008 Kawasaki KLX140 | Owners Manual - Page 47
    MAINTENANCE AND ADJUSTMENT 45 the wing bolt, and take out the air cleaner • Remove element. the element. If it is dirty, clean it. Also • Inspect check if the element is in good condition (no tears, hardening or shrinkage). If damaged, replace the element or it will allow dirt into the carburetor.
  • 2008 Kawasaki KLX140 | Owners Manual - Page 48
    46 MAINTENANCE AND ADJUSTMENT Element Cleaning and Installation the element in a bath of a high flash point • Clean solvent or hot soapy water. Rinse the element with j • clear water to remove all traces of the cleaning solution. Squeeze the element dry in a clean towel. CAUTION Do not twist,
  • 2008 Kawasaki KLX140 | Owners Manual - Page 49
    MAINTENANCE AND ADJUSTMENT 47 installation, check the element for damage • Before such as tears, hardening, or shrinkage. If damgrease to all mating surfaces and to the • Apply screw hole in the air cleaner housing and intake aged, replace the element. an air cleaner element with its pointing end •
  • 2008 Kawasaki KLX140 | Owners Manual - Page 50
    48 MAINTENANCE AND ADJUSTMENT Oil Draining the hose or plug to see if any oil or water • Inspect has run down. Throttle Cable Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle cable in accordance with the Periodic
  • 2008 Kawasaki KLX140 | Owners Manual - Page 51
    MAINTENANCE AND ADJUSTMENT 49 there is improper play, adjust it. • If Pull the rubber boot off the upper end of the throttle • cable. the locknut on the upper end of the throttle • Loosen cable and turn the adjuster to obtain the specified the rubber boot. • Install If the free play cannot be set by
  • 2008 Kawasaki KLX140 | Owners Manual - Page 52
    50 MAINTENANCE AND ADJUSTMENT the rubber boot off the top of the carburetor • Pull and make the necessary free play adjustment with the adjuster on the lower end of the cable. Then, tighten the locknut and reinstall the rubber boot. if the throttle grip moves smoothly from full • Check open to close
  • 2008 Kawasaki KLX140 | Owners Manual - Page 53
    MAINTENANCE AND ADJUSTMENT 51 Choke Knob Choke Knob Adjustment the choke knob fully up and set it where the • Pull knob stops. j • Take out the number plate by removing the bolt. A. Choke Knob A. Bolt B. Number Plate
  • 2008 Kawasaki KLX140 | Owners Manual - Page 54
    52 MAINTENANCE AND ADJUSTMENT the rubber boot off the adjuster, and adjust • Pull with the adjuster so that the knob can be pushed back with a finger. The following procedure covers the idling adjustment, which should be performed whenever the idle speed is disturbed. Idle Speed j Idling
  • 2008 Kawasaki KLX140 | Owners Manual - Page 55
    MAINTENANCE AND ADJUSTMENT 53 the idling speed 1 350 ∼ 1 450 r/min (rpm) • Adjust by turning the idling adjusting screw. Clutch Clutch Lever Adjustment Proper clutch lever play is 2 ∼ 3 mm (0.08 ∼ 0.12 in.). Lever play increases with cable stretch and friction plate wear, requiring periodic
  • 2008 Kawasaki KLX140 | Owners Manual - Page 56
    54 MAINTENANCE AND ADJUSTMENT If the clutch lever play cannot be adjusted at the clutch lever, make the adjustment further down the cable as follows. Loosen the locknut at the clutch lever. Turn the adjuster in all the way, then tighten the locknut. Loosen the locknut at the lower end of the clutch
  • 2008 Kawasaki KLX140 | Owners Manual - Page 57
    MAINTENANCE AND ADJUSTMENT 55 Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. Spark Arrester This vehicle is equipped with a spark arrester. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart,
  • 2008 Kawasaki KLX140 | Owners Manual - Page 58
    56 MAINTENANCE AND ADJUSTMENT • Remove the muffler end mounting bolts. • Take off the spark arrester mounting bolts. j A. Muffler End Mounting Bolts B. Muffler End A. Spark Arrester Mounting Bolts
  • 2008 Kawasaki KLX140 | Owners Manual - Page 59
    MAINTENANCE AND ADJUSTMENT 57 • Remove the spark arrester. Drive Chain For safety and to prevent excessive wear, the drive chain must be checked, adjusted, and lubricated before riding. If the chain becomes badly worn or maladjusted - either too loose or too tight - it could jump off the sprockets
  • 2008 Kawasaki KLX140 | Owners Manual - Page 60
    58 MAINTENANCE AND ADJUSTMENT Chain Slack Inspection j • • Raise the rear wheel off the ground, then rotate the rear wheel to find the place where the chain is tightest (because it wears unevenly). Push up the drive chain in the middle of the upper chain run to measure the chain slack. The
  • 2008 Kawasaki KLX140 | Owners Manual - Page 61
    MAINTENANCE AND ADJUSTMENT 59 Rear Axle Nut Tightening Torque 79 N·m (8.1 kgf·m, 58 ft·lb) the wheel, measure the chain slack again • Rotate at the tightest position, and readjust it if necessary. a new cotter pin through the axle, and • Install spread its ends. j WARNING If the axle nut is not
  • 2008 Kawasaki KLX140 | Owners Manual - Page 62
    on a straight part of the chain from the center of the 1st pin to the center of the 21st pin. If the length exceeds the service limit, the chain should be replaced. Since overworn sprockets will cause a new chain to wear faster, inspect both the engine and rear sprockets whenever the
  • 2008 Kawasaki KLX140 | Owners Manual - Page 63
    MAINTENANCE AND ADJUSTMENT 61 NOTE Chain Guide Wear Inspection żThe drive system was designed for use with a DAIDO D.I.D 428H (KLX140A: 122- the "U" pointing in the direction of chain rotation. inspect the drive chain guide and replace • Visually it if excessively worn or damaged. j A. Chain
  • 2008 Kawasaki KLX140 | Owners Manual - Page 64
    62 MAINTENANCE AND ADJUSTMENT Chain Slipper Wear Inspection j • Sprocket Wear Inspection Visually inspect the front end of the chain slippers on the swingarm and replace them if worn or damaged. inspect the sprocket teeth and replace the • Visually sprocket if its teeth are worn or damaged.
  • 2008 Kawasaki KLX140 | Owners Manual - Page 65
    MAINTENANCE AND ADJUSTMENT 63 Chain Lubrication Lubrication of the drive chain is necessary after riding in the rain or mud, or any time the chain appears dry. A heavy oil such as SAE90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. Apply oil
  • 2008 Kawasaki KLX140 | Owners Manual - Page 66
    64 MAINTENANCE AND ADJUSTMENT the handlebar holder nuts, turn the han• Loosen dlebar holders 180°, and securely tighten the nuts. the handlebar on the handlebar holders. • Put Mount the handlebar clamps. • Align the gap at the rear with the punch mark on • the handlebar. j A. Handlebar Holders B.
  • 2008 Kawasaki KLX140 | Owners Manual - Page 67
    MAINTENANCE AND ADJUSTMENT 65 Handlebar Clamp Bolts Tightening Torque 25 N·m (2.5 kgf·m, 18 ft·lb) Brakes Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action. There are no parts on the brakes that require adjustment except brake lever
  • 2008 Kawasaki KLX140 | Owners Manual - Page 68
    66 MAINTENANCE AND ADJUSTMENT the braking power and check that there is no • Test brake drag. CAUTION Do not spill brake fluid onto any painted surface. Do not use fluid from a container that has been left open or that has been unsealed for a long time. Check for fluid leakage around the brake
  • 2008 Kawasaki KLX140 | Owners Manual - Page 69
    MAINTENANCE AND ADJUSTMENT 67 the brake fluid in the front or rear reservoir is be• If low the minimum level line, check for fluid leaks in the brake line and fill the reservoir to the maximum level line. (The step inside the front and rear reservoirs indicate the maximum level.) j A. Rear
  • 2008 Kawasaki KLX140 | Owners Manual - Page 70
    68 MAINTENANCE AND ADJUSTMENT Brake Pad Wear Inspection Inspect the brake pads for wear in accordance with the Periodic Maintenance chart. If the thickness of any pad in any (front or rear) brake caliper is less than 1 mm (0.04 in.), have both pads in the caliper replaced as a set. Pad replacement
  • 2008 Kawasaki KLX140 | Owners Manual - Page 71
    MAINTENANCE AND ADJUSTMENT 69 Steering The steering should always be kept adjusted so that the handlebar will turn freely but not have excessive play. Steering Adjustment Steering Inspection check the steering adjustment, raise the front • To wheel off the ground using a jack (special tool). the
  • 2008 Kawasaki KLX140 | Owners Manual - Page 72
    70 MAINTENANCE AND ADJUSTMENT the steering stem locknut with a stem nut • Turn wrench (special tool) to obtain the proper adjustment. • Install the handlebar. NOTE j żTighten the two clamp bolts alternately two times to ensure even tightening torque. the handlebar and apply the specified •
  • 2008 Kawasaki KLX140 | Owners Manual - Page 73
    MAINTENANCE AND ADJUSTMENT 71 Front Suspension Front Fork Inspection the brake lever, pump the front fork back • Holding and forth manually to check for smooth operation. inspect the front fork for oil leakage, scor• Visually ing or scratches on the outer surface of the inner necessary,
  • 2008 Kawasaki KLX140 | Owners Manual - Page 74
    72 MAINTENANCE AND ADJUSTMENT Rear Suspension Rear Shock Absorber Inspection the seat down and up by 4 or 5 times, and • Pump inspect the smooth stroke. 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 •
  • 2008 Kawasaki KLX140 | Owners Manual - Page 75
    MAINTENANCE AND ADJUSTMENT 73 Rebound Damping Adjuster Settings CAUTION Do not force the rebound and compression damping force adjusters beyond the fully seated position, or the adjusting mechanism may be damaged. j Compression Damping Adjustment (KLX140B ONLY) To adjust the rear shock absorber
  • 2008 Kawasaki KLX140 | Owners Manual - Page 76
    74 MAINTENANCE AND ADJUSTMENT Compression Damping Adjuster Setting The compression damping adjuster is a 4-stage adjustable. Spring Preload Adjustment The rear shock absorber can be adjusted by changing the spring preload for various riding and loading conditions. If the spring action feels too
  • 2008 Kawasaki KLX140 | Owners Manual - Page 77
    MAINTENANCE AND ADJUSTMENT 75 Wheels Tire Air Pressure Tire air pressure affects traction, handling, and tire life. Adjust the tire air pressure to suit track conditions and rider preference, but keep it close within the recommended range. To check the tire air pressure, remove the air valve cap,
  • 2008 Kawasaki KLX140 | Owners Manual - Page 78
    76 MAINTENANCE AND ADJUSTMENT Bead Protector There is a bead protector on the both wheels. The bead protector prevents the tire and tube from slipping on the rim and damaging the valve stem. Valve stem damage may cause the tube to leak, necessitating tube replacement. In order to keep the tire and
  • 2008 Kawasaki KLX140 | Owners Manual - Page 79
    MAINTENANCE AND ADJUSTMENT 77 Rim Runout j A. Axial Rim Runout Measurement A. Rim B. Radial Runout C. Axial Runout Rim Runout Maximum Limit Axial 2.0 mm (0.08 in.) Radial A. Radial Rim Runout Measurement
  • 2008 Kawasaki KLX140 | Owners Manual - Page 80
    78 MAINTENANCE AND ADJUSTMENT Hoses Inspection Check the brake and fuel hoses for cracks or deterioration, and the connections for looseness in accordance with the Periodic Maintenance Chart. Inspect the brake hose and fittings for deterioration, cracks and signs of leakage by bending or twisting
  • 2008 Kawasaki KLX140 | Owners Manual - Page 81
    MAINTENANCE AND ADJUSTMENT 79 Self-discharge Approx. Number of Days from 100% charged to 100% discharged Lead-Antimony Lead-Calcium Battery 40°C (104°F) 25°C (77°F) 0°C (32°F) 100 Days 200 Days 550 Days Current Drain Discharging Ampere 7 mA 10 mA 15 mA 20 mA 30 mA Days from 100% charged to 50%
  • 2008 Kawasaki KLX140 | Owners Manual - Page 82
    in this motorcycle, or the electrical system cannot work properly. A. Bolt B. Side Cover NOTE żIf you charge the sealed battery, never fail to observe the instructions shown in the label on the battery.
  • 2008 Kawasaki KLX140 | Owners Manual - Page 83
    MAINTENANCE AND ADJUSTMENT 81 • Remove the bolt and remove the seat. the wire from the battery, first from the • Disconnect (-) terminal and then the (+) terminal. j A. Bolt B. Seat A. B. C. D. (+) Terminal (-) Terminal Battery Holder Bolt out battery holder by removing the bolt. • Take Take
  • 2008 Kawasaki KLX140 | Owners Manual - Page 84
    82 MAINTENANCE AND ADJUSTMENT Battery Installation the battery in the battery case. • Place Install the battery holder and tighten the bolts. • Connect the red wire to the (+) terminal, and then • connect the black wire to the (-) terminal. Fuse The main fuse is mounted on the starter relay under
  • 2008 Kawasaki KLX140 | Owners Manual - Page 85
    MAINTENANCE AND ADJUSTMENT 83 WARNING Do not use any substitute for the standard fuse. Replace the blown fuse with a new one of the correct capacity, as specified on the junction box and main fuse. j
  • 2008 Kawasaki KLX140 | Owners Manual - Page 86
    84 MAINTENANCE AND ADJUSTMENT Tightening Torques of Nuts and Bolts Location of nuts and bolts Before the first ride of each day of operation, check the tightness of the nuts and bolts shown below. Check also that all cotter pins are in place and in good condition. j 1. 2. 3. 4. 5. 6. Front Fork
  • 2008 Kawasaki KLX140 | Owners Manual - Page 87
    MAINTENANCE AND ADJUSTMENT 85 j 16. 17. 18. 19. Spark Plug Cylinder Head Bolts Muffler End Mounting Bolts Spark Arrester Mounting Bolts 20. Rear Master Cylinder Mounting Bolts 21. Steering Head Nut 22. Front Master Cylinder Mounting Bolts 23. Rear Brake Disk Mounting Bolts 24. Rear Axle Nut 25.
  • 2008 Kawasaki KLX140 | Owners Manual - Page 88
    86 MAINTENANCE AND ADJUSTMENT Torque table Tighten all nuts and bolts to the proper torque using an accurate torque wrench. An insufficiently tightened nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider. An overtightened nut or bolt may
  • 2008 Kawasaki KLX140 | Owners Manual - Page 89
    MAINTENANCE AND ADJUSTMENT 87 Part Name Brake Caliper Bolts Brake Disc Mounting Bolts Engine Bracket Nut/Bolt Engine Mounting Bolts Front Axle Nut Front Fork Clamp Bolts Handlebar Clamp Bolts Swingarm Pivot Shaft Nut Rear Axle Nut Rear Brake Pedal Pivot Bolt Rear Frame Bolts Rear Shock Absorber
  • 2008 Kawasaki KLX140 | Owners Manual - Page 90
    88 MAINTENANCE AND ADJUSTMENT Part Name Rear Shock Absorber Lower Nut Rear Shock Absorbor Lower Bolt Spokes Steering Stem Head Nut Steering Stem Locknut UNI-TRAK® Arm Bolt UNI-TRAK® Rod Bolts Rear Sprocket Nuts Front Brake Master Cylinder Clamp Bolts Rear Brake Master Cylinder Mounting Bolts N·m 29
  • 2008 Kawasaki KLX140 | Owners Manual - Page 91
    MAINTENANCE AND ADJUSTMENT 89 Cleaning Your Motorcycle General Precautions Frequent and proper care of your Kawasaki motorcycle will enhance its appearance, optimize overall performance, and extend its useful life. Covering your motorcycle with a high quality, breathable motorcycle cover will help
  • 2008 Kawasaki KLX140 | Owners Manual - Page 92
    90 MAINTENANCE AND ADJUSTMENT cleaning your motorcycle, check the rubber • After boot covering the shift pedal ball joint for correct installation. Be sure the sealing lip of the rubber boot fits into the groove of the ball joint. the boot is damaged, replace it with a new one. • If If the boot is
  • 2008 Kawasaki KLX140 | Owners Manual - Page 93
    or as conditions require. Avoid surfaces with "satin" or "flat" finishes. Always use nonabrasive products and apply them according to the instructions on the container. Chrome and Aluminum Chrome and uncoated aluminum parts can be treated with a chrome/aluminum polish. Coated aluminum should be
  • 2008 Kawasaki KLX140 | Owners Manual - Page 94
    92 MAINTENANCE AND ADJUSTMENT Leather, Vinyl, and Rubber If your motorcycle has leather accessories, special care must be taken. Use a leather cleaner/treatment to clean and care for leather accessories. Washing leather parts with detergent and water will damage them, shortening their life. Vinyl
  • 2008 Kawasaki KLX140 | Owners Manual - Page 95
    MAINTENANCE AND ADJUSTMENT 93 brake pedal • Rear Rear brake • Foot peg rod joints • Apply an aerosol cable lubricant with a pressure lubricator on all cables: Clutch cable Throttle cable Hot starter cable • • • j Cable Lubrication
  • 2008 Kawasaki KLX140 | Owners Manual - Page 96
    94 MAINTENANCE AND ADJUSTMENT j Apply grease to the following points: Upper end of clutch cable Upper end of throttle cable Upper end of hot starter cable Shift pedal Drive Chain Lubrication Lubricate the drive chain after riding through rain or on wet track, or any time that the chain
  • 2008 Kawasaki KLX140 | Owners Manual - Page 97
    TROUBLESHOOTING GUIDE 95 TROUBLESHOOTING GUIDE NOTE żThis troubleshooting guide is not exhaustive and does not give every possible cause for each problem listed. It is meant simply as a quick guide to assist you in troubleshooting for some of the more common difficulties. Fuel-air mixture
  • 2008 Kawasaki KLX140 | Owners Manual - Page 98
    96 TROUBLESHOOTING GUIDE Clutch not operating smoothly - Clutch slipping Friction plate worn Clutch springs weak Shock absorption too hard Tire air pressure too high j • • Clutch doesn't disengaging properly
  • 2008 Kawasaki KLX140 | Owners Manual - Page 99
    STORAGE 97 STORAGE Before Storage When the motorcycle is to be stored for any length of time, it should be prepared for storage as follows. Clean the entire vehicle thoroughly. Run the engine for about five minutes to warm the oil, then stop it and drain the engine oil. WARNING Gasoline is
  • 2008 Kawasaki KLX140 | Owners Manual - Page 100
    98 STORAGE After Storage the plastic bag from the muffler. • Remove Make sure the spark plug is tight. • NOTE żFit the plug cap securely onto the spark plug, and the fuel tank with fuel. • Fill Check the points listed in the Daily pre-ride • checks all section. • Perform a General Lubrication
  • 2008 Kawasaki KLX140 | Owners Manual - Page 101
    ENVIRONMENTAL PROTECTION 99 ENVIRONMENTAL PROTECTION To protect our environment, properly discard used batteries, tires, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper
  • 2008 Kawasaki KLX140 | Owners Manual - Page 102
    100 WIRING DIAGRAM WIRING DIAGRAM
  • 2008 Kawasaki KLX140 | Owners Manual - Page 103
    receipt of your correspondence we will contact the dealership and work with them in resolving your problem. In order to provide a permanent record, all warranty and service resolutions take place only through written correspondence. Please send your correspondence to: CONSUMER RELATIONS KAWASAKI
  • 2008 Kawasaki KLX140 | Owners Manual - Page 104
    it finds that a safety defect exists in a group of vehicles, if may order a recall and remedy campaign. However, the CPSC cannot become involved in individual problems between you, your dealer, or Kawasaki Motors Corporation, U.S.A.
  • 2008 Kawasaki KLX140 | Owners Manual - Page 105
    MAINTENANCE RECORD 103 MAINTENANCE RECORD Owner Name...Address ...Phone Number ...Engine Number ...Vehicle Number...Selling Dealer Name ...Address ...Phone Number ...Warranty Start Date ...Note: Keep this information and a spare key in a secure location. Date Odometer Reading Maintenance Performed
  • 2008 Kawasaki KLX140 | Owners Manual - Page 106
    104 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2008 Kawasaki KLX140 | Owners Manual - Page 107
    MAINTENANCE RECORD 105 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2008 Kawasaki KLX140 | Owners Manual - Page 108
    106 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2008 Kawasaki KLX140 | Owners Manual - Page 109
    MAINTENANCE RECORD 107 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2008 Kawasaki KLX140 | Owners Manual - Page 110
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