2010 Kawasaki KLX110L Owners Manual

2010 Kawasaki KLX110L Manual

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  • 2010 Kawasaki KLX110L | Owners Manual - Page 1
  • 2010 Kawasaki KLX110L | Owners Manual - Page 2
  • 2010 Kawasaki KLX110L | 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.
  • 2010 Kawasaki KLX110L | Owners Manual - Page 4
    IMPORTANT INFORMATION vehicle is designed for the operator only, no passengers. • This This vehicle • highways. is an off-road motorcycle only and was not manufactured for use on public streets, roads or the environment and the rights of other people. • Respect Read owner's manual. •
  • 2010 Kawasaki KLX110L | Owners Manual - Page 5
  • 2010 Kawasaki KLX110L | Owners Manual - Page 6
    Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. DANGER DANGER
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    improperly conducted, this sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not occur. TO PROTECT THE FUTURE OF YOUR
  • 2010 Kawasaki KLX110L | Owners Manual - Page 8
    . Read and understand the owner's manual provided with the motorcycle. Review all instructions and warnings with your youngster. You riding the motorcycle. Also, familiarity with the motorcycle is important should a problem occur far from help. Do not allow your youngster to ride unsupervised.
  • 2010 Kawasaki KLX110L | Owners Manual - Page 9
    10. Encourage your youngster not to ride beyond his or her skill level or faster than conditions safely allow. Have them practice advanced riding maneuvers under controlled conditions. 11. Tell someone where you and your youngster are planning to ride and when you intend to return. Discuss the ride
  • 2010 Kawasaki KLX110L | Owners Manual - Page 10
    . 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
  • 2010 Kawasaki KLX110L | 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
  • 2010 Kawasaki KLX110L | Owners Manual - Page 12
    10 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height: KLX110C KLX110D Wheelbase Road Clearance: KLX110C KLX110D Curb Mass Fuel Tank Capacity ENGINE Type Bore × Stroke Displacement Compression Ratio Fuel System Starting System Ignition System Ignition Timing 4-
  • 2010 Kawasaki KLX110L | Owners Manual - Page 13
    SPECIFICATIONS 11 Lubrication System Spark Plug TRANSMISSION Transmission Type Clutch Type: KLX110C KLX110D Driving System Gear Ratio: 1st 2nd 3rd 4th Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio Engine Oil: Type Viscosity Capacity FRAME Type Steering Angle Backbone 45° to
  • 2010 Kawasaki KLX110L | Owners Manual - Page 14
    12 SPECIFICATIONS Caster: KLX110C KLX110D Trail: KLX110C KLX110D Tire Size/Type: Front Rear Rim Size: Front Rear Suspension: Front Rear Front Suspension Travel: KLX110C KLX110D Rear Wheel Travel: KLX110C KLX110D 110 mm (4.3 in.) 132 mm (5.2 in.) 110 mm (4.3 in.) 140 mm (5.5 in.) Telescopic fork
  • 2010 Kawasaki KLX110L | Owners Manual - Page 15
    SPECIFICATIONS 13 Front Fork Oil: Type Capacity (Per One Unit): KLX110C KLX110D BRAKES Type: Front Rear ELECTRICAL EQUIPMENT Battery 12 V 3 Ah Drum brake Drum brake 165 mL (5.6 US oz.) 182 mL (6.2 US oz.) SHOWA SS08 or equivalent SAE 10W-20 Specifications are subject to change without notice.
  • 2010 Kawasaki KLX110L | Owners Manual - Page 16
    14 GENERAL INFORMATION j GENERAL INFORMATION Location of Parts 1. Clutch Lever (KLX110D Model) 2. Engine Stop Switch 3. Front Brake Lever 4. Throttle Grip 5. Starter Button 6. Fuel Tank Cap
  • 2010 Kawasaki KLX110L | Owners Manual - Page 17
    GENERAL INFORMATION 15 j 7. Front Fork 8. Brake Cable 9. Choke Knob 10. Fuel Tap 11. Brake Cam Lever 12. Air Cleaner 13. Oil Filter Cap 14. Engine Oil Drain Bolt 15. Shift Pedal 16. Chain Slipper 17. Side Stand 18. Swingarm 19. Drive Chain
  • 2010 Kawasaki KLX110L | Owners Manual - Page 18
    16 GENERAL INFORMATION j 20. Muffler 21. Rear Shock Absorber 22. Seat 23. Fuel Tank 24. Throttle Limiting Screw 25. Kick Pedal 26. Rear Brake Pedal 27. Oil Level Gauge 28. Carburetor
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    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 0.4 L (0.11 US
  • 2010 Kawasaki KLX110L | 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. WARNING Practice operating the fuel tap with the motorcycle stopped. To prevent an
  • 2010 Kawasaki KLX110L | Owners Manual - Page 21
    standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or nonrecommended 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
  • 2010 Kawasaki KLX110L | Owners Manual - Page 22
    drain all fuel from the fuel system. See the Storage section in this manual. NOTICE Avoid using blends of unleaded gasoline and methanol (wood alcohol) gasohol" containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is
  • 2010 Kawasaki KLX110L | Owners Manual - Page 23
    GENERAL INFORMATION 21 j Throttle Limiting Screw A screw-type throttle limiting screw can be equipped to this motorcycle to decrease the maximum engine power for a novice rider. The limiting screws function by restricting the turning degree of the throttle grip so that it opens to either 3/8 or 1/2
  • 2010 Kawasaki KLX110L | 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 position for the motorcycle to operate. For the ordinary engine stoppage and, if some emergency requires stopping the engine, set the engine stop
  • 2010 Kawasaki KLX110L | Owners Manual - Page 25
    GENERAL INFORMATION 23 j Starter Button This motorcycle has the starter button. A. Engine Stop Switch B. Indicator Light (LED) A. Starter Button
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    24 GENERAL INFORMATION j Kick Pedal This motorcycle is equipped with a kick starting system. When using the kick pedal, make sure that the transmission is in neutral. Starting the Engine • Turn the fuel tap lever to the ON position. A. Fuel Tap B. ON Position A. Kick Pedal • Shift the
  • 2010 Kawasaki KLX110L | Owners Manual - Page 27
    GENERAL INFORMATION 25 • Check that the engine stop switch is in the position. j A. Choke Knob A. Engine Stop Switch Position B. NOTE żWhen the engine is already warm or on hot days, open the throttle part way instead of using the choke, and then start the engine. the throttle completely
  • 2010 Kawasaki KLX110L | Owners Manual - Page 28
    26 GENERAL INFORMATION j żFor KLX110D model; when using the kick pedal, make sure that the transmission is in neutral, and do not pull in the clutch lever. A. Starter Button NOTICE Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power
  • 2010 Kawasaki KLX110L | Owners Manual - Page 29
    GENERAL INFORMATION 27 NOTICE Do not let the engine idle longer than five minutes, or engine overheating and damage may occur. j A. Clutch Lever B. Starter Lockout Switch push the choke knob back a little at • Gradually a time as necessary to keep the engine running • properly during warm-up.
  • 2010 Kawasaki KLX110L | Owners Manual - Page 30
    28 GENERAL INFORMATION j Moving Off KLX110C Model Check that the side stand is up. Shift into 1st gear. Open the throttle slowly. Shifting Gears KLX110C Model Close the throttle completely. Shift into the next higher or lower gear. Open the throttle slowly. • • • KLX110D Model that the side stand
  • 2010 Kawasaki KLX110L | Owners Manual - Page 31
    GENERAL INFORMATION 29 pedal, gently release the clutch lever, then release the shift pedal. To shift up to the next gear, pull in the clutch lever, lift the shift pedal with your toes, gently release the clutch lever, and then release the shift pedal. To shift down to the next gear, pull in the
  • 2010 Kawasaki KLX110L | Owners Manual - Page 32
    30 GENERAL INFORMATION 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 (KLX110D model). Independent use of the front or rear brake may be advantageous in certain circumstances.
  • 2010 Kawasaki KLX110L | Owners Manual - Page 33
    GENERAL INFORMATION 31 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
  • 2010 Kawasaki KLX110L | Owners Manual - Page 34
    32 GENERAL INFORMATION 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
  • 2010 Kawasaki KLX110L | Owners Manual - Page 35
    GENERAL INFORMATION 33 Frame Tires ...Overall condition good No wear or damage 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 wear to
  • 2010 Kawasaki KLX110L | Owners Manual - Page 36
    34 MAINTENANCE AND ADJUSTMENT 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
  • 2010 Kawasaki KLX110L | Owners Manual - Page 37
    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
  • 2010 Kawasaki KLX110L | Owners Manual - Page 38
    36 MAINTENANCE AND ADJUSTMENT 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
  • 2010 Kawasaki KLX110L | Owners Manual - Page 39
    MAINTENANCE AND ADJUSTMENT 37 Periodic Maintenance Chart The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. 1. Periodic Inspection (Engine Related Item)
  • 2010 Kawasaki KLX110L | Owners Manual - Page 40
    lubricate Spoke tightness and rim runout - inspect † Drive chain - inspect and adjust Drive chain - lubricate Drive chain wear - inspect † Drive chain guide and slipper - inspect † Front fork - clean and inspect K Front fork oil - inspect † Nuts, bolts, fasteners - inspect † Steering play - inspect
  • 2010 Kawasaki KLX110L | Owners Manual - Page 41
    MAINTENANCE AND ADJUSTMENT 39 FREQUENCY OPERATION Battery - inspect † Battery terminal - inspect † General lubrication - perform Side stand - inspect † K Wheel bearing - inspect † K Swingarm pivots - inspect † K Rear shock absorber - inspect † Frame - inspect Wheels/tires - inspect Cable - inspect
  • 2010 Kawasaki KLX110L | Owners Manual - Page 42
    (1 month) Every 50 hours (6 months) 100 hours (12 months) See Page 42 42 - - j • • • Every 4 years • • • • †: 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
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    transmission seizure, accident, and injury. Check the oil level before each ride and change the oil according to the periodic maintenance chart in the owner's manual. NOTE żIf the oil level is too high, remove the excess oil using a syringe or other suitable device. żIf the oil level is too low
  • 2010 Kawasaki KLX110L | Owners Manual - Page 44
    42 MAINTENANCE AND ADJUSTMENT NOTE 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. Set the motorcycle up on its side stand. Stop the
  • 2010 Kawasaki KLX110L | Owners Manual - Page 45
    MAINTENANCE AND ADJUSTMENT 43 WARNING Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling. the oil filter is replaced, remove the engine • When guard and oil filter cap bolts and take off the cap with O-
  • 2010 Kawasaki KLX110L | Owners Manual - Page 46
    44 MAINTENANCE AND ADJUSTMENT the oil filter element with a new one. • Replace Install the oil filter element with the grommet to• ward the engine. the spring to the oil filter cap. • Install Install oil filter cap with the high-temperature • greasethe applied to a new O-ring and tighten its bolts
  • 2010 Kawasaki KLX110L | Owners Manual - Page 47
    MAINTENANCE AND ADJUSTMENT 45 Tightening Torque Engine Oil Drain Bolt: 29 N·m (3.0 kgf·m, 21 ft·lb) The oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. j NOTE żReplace the gasket and O-ring with a new one. the engine up to the high level line with
  • 2010 Kawasaki KLX110L | Owners Manual - Page 48
    46 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 CR6HSA 0.6 ~ 0.7 mm (0.024 ~ 0.
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    MAINTENANCE AND ADJUSTMENT 47 a suitable wrench to the spark plug. • Apply Loosen and remove the spark plug. • When reinstalling the spark plug, torque it to spec• ification. Tightening Torque Spark Plug: 13 N·m (1.3 kgf·m, 115 in·lb) the plug cap securely onto the spark plug, and • Fit pull the cap
  • 2010 Kawasaki KLX110L | Owners Manual - Page 50
    48 MAINTENANCE AND ADJUSTMENT Element Removal and Inspection j • • • Remove the bolts on the right and left sides. Clear the projections from the grommets and hook portions from the slots, and remove the side covers. Remove the seat backward. the screw and bolts on the right and left • Remove
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    MAINTENANCE AND ADJUSTMENT 49 • Remove the screws and air cleaner cover. • Take out the air cleaner element. j A. Screws B. Air Cleaner Cover A. Air Cleaner Element inside of the intake tract and carburetor for • Check dirt. If dirty, clean the intake tract and carburetor • • thoroughly.
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    50 MAINTENANCE AND ADJUSTMENT NOTICE A clogged air cleaner may allow dirt and dust to enter the engine, causing it to wear excessively or to become damaged. j Element Cleaning and Installation the element in a bath of a high-flash point • Clean solvent or hot soapy water. Rinse the element with
  • 2010 Kawasaki KLX110L | Owners Manual - Page 53
    MAINTENANCE AND ADJUSTMENT 51 cleaning, let the filter dry completely. Satu• After rate the element with a high-quality foam air filter oil and make sure that the oil is evenly applied throughout the element. Squeeze out the excess oil, but do not wring the element as this could cause tearing. In
  • 2010 Kawasaki KLX110L | Owners Manual - Page 54
    52 MAINTENANCE AND ADJUSTMENT the hook and projection into the slot and • Insert grommet. Oil Draining j the plug to see if any oil or water has run • Inspect down. A. B. C. D. Hook Projection Slot Grommet A. Plug there are any oil, remove the plug and drain the • If oil. WARNING Oil on
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    MAINTENANCE AND ADJUSTMENT 53 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 Maintenance Chart. Check that the throttle grip has 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of play
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    54 MAINTENANCE AND ADJUSTMENT the rubber boot. • Install If the free play cannot be set by adjusting the upper • cable adjuster, use the adjuster on the lower end if the throttle grip moves smoothly from full • Check open to close, and the throttle closes quickly and completely in all steering
  • 2010 Kawasaki KLX110L | Owners Manual - Page 57
    MAINTENANCE AND ADJUSTMENT 55 Carburetor The following procedure covers the idle adjustment, which should be performed whenever the idle speed is disturbed. j Idle Speed Adjustment • Thoroughly warm up the engine. DANGER Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas.
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    56 MAINTENANCE AND ADJUSTMENT Clutch KLX110C Model the engine and check the clutch by operating • Start the shift pedal. KLX110D Model j Clutch Adjustment Clutch Lever Adjustment Proper clutch lever free play is 2 ∼ 3 mm (0.08 ∼ 0.12 in.). Lever play increases with cable stretch and friction
  • 2010 Kawasaki KLX110L | Owners Manual - Page 59
    MAINTENANCE AND ADJUSTMENT 57 If the clutch lever free play cannot be adjusted at the clutch lever, make the adjustment further down the cable as follows. Turn the adjuster in all the way. Slide the dust cover at the clutch cable lower end out of place. Loosen the adjusting nuts at the lower end of
  • 2010 Kawasaki KLX110L | Owners Manual - Page 60
    58 MAINTENANCE AND ADJUSTMENT 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,
  • 2010 Kawasaki KLX110L | Owners Manual - Page 61
    MAINTENANCE AND ADJUSTMENT 59 the right side cover (see Air Cleaner sec• Remove tion). • Remove the screws and muffler cover. • Remove the bolts and pull the spark arrester. j A. Bolts B. Spark Arrester A. Screws B. Muffler Cover
  • 2010 Kawasaki KLX110L | Owners Manual - Page 62
    60 MAINTENANCE AND ADJUSTMENT a wire brush, remove the carbon off the inside • With of the spark arrester and muffler. Tightening Torque Muffler Cover Screws: 3.0 N·m (0.31 kgf·m, 27 in·lb) j • Install the removed parts. A. Spark Arrester the spark arrester into the rear end of the • Install
  • 2010 Kawasaki KLX110L | Owners Manual - Page 63
    MAINTENANCE AND ADJUSTMENT 61 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 or break. the drive chain if
  • 2010 Kawasaki KLX110L | Owners Manual - Page 64
    62 MAINTENANCE AND ADJUSTMENT j A. Torque Link Nut B. Cotter Pin the cotter pin from the rear axle nut. • Remove Loosen the • locknuts. rear axle nut and both chain adjuster both chain adjusting nuts evenly until the • Turn drive chain slack (measured between the chain and the swingarm) is within
  • 2010 Kawasaki KLX110L | Owners Manual - Page 65
    MAINTENANCE AND ADJUSTMENT 63 both chain adjuster locknuts. • Tighten Tighten the axle nut to the specified torque. • Tightening Torque Rear Axle Nut: 64 N·m (6.5 kgf·m, 47 ft·lb) the wheel, measure the chain slack again • Rotate at the tightest position, and readjust it if necessary. a new cotter
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    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
  • 2010 Kawasaki KLX110L | Owners Manual - Page 67
    the "U" pointing in the direction of chain rotation. j A. Weight B. Tape Measure Drive Chain 20-Link Length 254.0 ∼ 254.6 mm (10.00 ∼ 10.02 Standard in.) Service Limit 259 mm (10.2 in.) A. Master Link Clip B. Direction of Chain Rotation
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    66 MAINTENANCE AND ADJUSTMENT Chain Slipper Wear Inspection j • Sprocket Wear Inspection Visually inspect the chain slipper on the swingarm and replace it if worn or damaged. inspect the sprocket teeth and replace the • Visually sprocket if its teeth are worn or damaged. Sprocket Teeth Wear A.
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    MAINTENANCE AND ADJUSTMENT 67 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
  • 2010 Kawasaki KLX110L | Owners Manual - Page 70
    68 MAINTENANCE AND ADJUSTMENT the handlebar clamp bolts, front first, then • Tighten rear. If the handlebar clamps are correctly installed, there will be no gap at the front and an even gap at the rear of the clamps after the bolts torqued. Brakes Brake lining wear, drum wear, and cable stretch
  • 2010 Kawasaki KLX110L | Owners Manual - Page 71
    lining wear indicator does not point within the USABLE RANGE when the brake is fully applied, the brake shoe linings have worn past the service limit. In this case, the brake shoes must be replaced and the drum and other brake parts examined by an authorized Kawasaki dealer. j A. B. C. D. Front
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    70 MAINTENANCE AND ADJUSTMENT j A. Rear Brake Panel B. USABLE RANGE C. Brake Lining Wear Indicator A. Locknut B. Adjuster C. 4 ~ 5 mm (0.16 ~ 0.20 in.) Front Brake Lever Play Inspection the front brake lever dust cover back. • Slide Check that the brake lever has 4 ~ 5 mm (0.16 ~ • 0.20 in.) of
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    MAINTENANCE AND ADJUSTMENT 71 Front Brake Lever Play Adjustment the front brake lever dust cover back. • Slide Loosen the locknut at the front brake lever, screw • the adjuster fully in, and tighten the locknut. Loosen the nuts at the lower end of the front brake • cable. j A. 4 ~ 5 mm (0.16 ~
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    72 MAINTENANCE AND ADJUSTMENT Rear Brake Pedal Play Inspection j • WARNING An improperly adjusted brake could drag and cause the brake to overheat, damaging the brake assembly and possibly locking the wheel, resulting in loss of control. Always maintain the proper brake adjustment. The brake
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    MAINTENANCE AND ADJUSTMENT 73 Steering The steering should always be kept adjusted so that the handlebar will turn freely but not have excessive play. The steering play must be checked in accordance with the Periodic Maintenance Chart. j Steering Inspection check the steering adjustment, raise
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    74 MAINTENANCE AND ADJUSTMENT Steering Adjustment j Raise the front wheel off the ground using a jack (special tool: 57001-1238). Unlock the clamp of the number plate. Remove the bolt. Clear the holes and remove the number plate. the handlebar clamp bolts and take out • Remove the handlebar.
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    MAINTENANCE AND ADJUSTMENT 75 the steering stem head nut and left and • Loosen right front fork clamp bolts (upper). j A. Steering Stem Locknut B. Stem Nut Wrench (Special Tool: 57001-1100) A. Steering Stem Head Nut B. Front Fork Clamp Bolts (Upper) the specified torques to the steering stem •
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    , followed by subsequent straitening, can weaken the inner tube. j 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
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    MAINTENANCE AND ADJUSTMENT 77 Rear Suspension The rear shock absorber inspection should be done in accordance with the Periodic Maintenance Chart. Wheels Tire Air Pressure Tire air pressure affects traction, handling, and tire life. Adjust the tire air pressure to suit track conditions and rider
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    78 MAINTENANCE AND ADJUSTMENT Spokes and Rims The spokes on both wheels must all be securely and evenly tightened and not be allowed to loosen. Unevenly tightened or loose spokes will cause the rim to warp, the nipples and spokes to fatigue more quickly, and the spokes to break. Bead Protector
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    MAINTENANCE AND ADJUSTMENT 79 Rim Runout Set up a dial gauge on the side of the rim and rotate the wheel to measure its axial runout. The difference between the highest and lowest readings is the amount of runout. Set up the dial gauge on the inner circumference of the rim and rotate the wheel to
  • 2010 Kawasaki KLX110L | Owners Manual - Page 82
    80 MAINTENANCE AND ADJUSTMENT Hoses Inspection Check the fuel hose for cracks or deterioration, and the connections for looseness in accordance with the Periodic Maintenance Chart. Inspect the fuel hose and fittings for deterioration, cracks and signs of leakage by bending or twisting the hose. If
  • 2010 Kawasaki KLX110L | Owners Manual - Page 83
    or add distilled water. The sealing strip should not be pulled off once the specified electrolyte has been installed in the battery for initial service. However, in order to maximize battery life and ensure that it will provide the power needed to start the motorcycle you must properly maintain
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    battery in this motorcycle, or the electrical system cannot work properly. NOTE żIf you charge the sealed battery, never fail to observe the instructions shown in the label on the battery. WARNING Lead is a toxic substance. Battery posts, terminals and related accessories contain lead and lead
  • 2010 Kawasaki KLX110L | Owners Manual - Page 85
    MAINTENANCE AND ADJUSTMENT 83 Battery Removal Remove the side covers and seat (see Air Cleaner section). Remove the bolts and battery holder. Pull out the battery a little. Disconnect the cables from the battery, first from the (-) terminal and then the (+) terminal. Take the battery out. the
  • 2010 Kawasaki KLX110L | Owners Manual - Page 86
    84 MAINTENANCE AND ADJUSTMENT Fuse The fuse and spare fuse are mounted behind the left side cover. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage. j A. White/Red Cable B. Protective Cap • Reinstall
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    MAINTENANCE AND ADJUSTMENT 85 WARNING Substituting fuse can cause wiring to overheat, catch fire and/or fail. 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 fuse. j A. Normal B. Failed
  • 2010 Kawasaki KLX110L | Owners Manual - Page 88
    86 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. Front Fork Clamp Bolts 2.
  • 2010 Kawasaki KLX110L | Owners Manual - Page 89
    MAINTENANCE AND ADJUSTMENT 87 j 12. Rear Shock Absorber Nut (Lower) 13. Muffler Body Mounting Nut 14. Engine Mounting Nuts 15. Steering Stem Head Nut 16. 17. 18. 19. 20. Brake Cam Lever Bolt Rear Axle Nut Torque Link Nuts Brake Pedal Bolt Kick Pedal Bolt 21. 22. 23. 24. Footpeg Mounting Bolts
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    88 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
  • 2010 Kawasaki KLX110L | Owners Manual - Page 91
    MAINTENANCE AND ADJUSTMENT 89 Fastener Rear Shock Absorber Bolt and Nut (Upper) Rear Shock Absorber Nut (Lower) Swingarm Pivot Shaft Nut Torque Link Nuts Handlebar Clamp Bolts Steering Stem Head Nut Footpeg Mounting Bolts Side Stand Nut S: Follow the specified tightening sequence. N·m 39 39 78 25 25
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    90 MAINTENANCE AND ADJUSTMENT 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
  • 2010 Kawasaki KLX110L | Owners Manual - Page 93
    months or as conditions require. Avoid surfaces with "satin" or "flat" finishes. Always use non-abrasive products and apply them according to the instructions on the container. Leather, Vinyl, and Rubber If your motorcycle has leather accessories, special care must be taken. Use a leather cleaner
  • 2010 Kawasaki KLX110L | Owners Manual - Page 94
    92 MAINTENANCE AND ADJUSTMENT Lubrication Lubricate the areas shown in the illustrations of this section with either motor oil or regular grease, in accordance with the Periodic Maintenance Chart and whenever the vehicle has been operated under wet or rainy conditions, especially after using a high
  • 2010 Kawasaki KLX110L | Owners Manual - Page 95
    MAINTENANCE AND ADJUSTMENT 93 Pedal • Shift Side Stand • Apply an aerosol cable lubricant with a pressure lubricator on all cables: Clutch Cable (KLX110D Model) Throttle Cable Cable Lubrication • • j
  • 2010 Kawasaki KLX110L | Owners Manual - Page 96
    94 MAINTENANCE AND ADJUSTMENT j • • Apply grease to the following points: Clutch Inner Cable Upper End (KLX110D Model) Throttle Inner Cable Upper End Drive Chain Lubrication Lubricate the drive chain after riding through rain or on wet track, or any time that the chain appears dry. A heavy oil
  • 2010 Kawasaki KLX110L | Owners Manual - Page 97
    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 button not contacting Starter system wiring shorted or open Engine stop switch trouble 10 A fuse blown Engine does not turn over: Valve seized
  • 2010 Kawasaki KLX110L | Owners Manual - Page 98
    96 TROUBLESHOOTING GUIDE plug cap or high-tension wiring defective • Spark Spark cap not contacting properly • Spark plug plug type incorrect • Crankshaft sensor defective • Igniter defective • Ignition coil
  • 2010 Kawasaki KLX110L | Owners Manual - Page 99
    TROUBLESHOOTING GUIDE 97 not seating properly (valve bent, worn, or • Valve carbon accumulation Engine oil level too high • Engine oil viscosity too high • Ignition timing incorrect • Drive chain trouble • Poor or no high-speed performance Other: Fuel/air mixture incorrect: Main jet clogged or wrong
  • 2010 Kawasaki KLX110L | Owners Manual - Page 100
    98 TROUBLESHOOTING GUIDE Improper acceleration: Choke valve closed Carburetor fuel level too high or Clutch slipping Engine oil level too high Engine oil viscosity too high Drive chain trouble Lubrication inadequate: Knocking: Carbon built up in combustion chamber Fuel quality poor or type
  • 2010 Kawasaki KLX110L | Owners Manual - Page 101
    TROUBLESHOOTING GUIDE 99 release mechanism defective • Clutch Clutch hub or housing unevenly worn • groove worn • Gear Gear dogs and/or dog grooves worn • Shift drum groove worn •
  • 2010 Kawasaki KLX110L | Owners Manual - Page 102
    100 TROUBLESHOOTING GUIDE Other noise: Connecting rod small end clearance excessive Connecting rod 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
  • 2010 Kawasaki KLX110L | Owners Manual - Page 103
    TROUBLESHOOTING GUIDE 101 Exhaust smoke Excessively white: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high • Tire air pressure too low worn • Tire Swingarm bushing damaged • Rim warped out of balance • Front and/or or
  • 2010 Kawasaki KLX110L | Owners Manual - Page 104
    102 TROUBLESHOOTING GUIDE Shock absorption unsatisfactory (suspension too soft): Front fork oil level too low terminal voltage) Battery cable making poor contact Flywheel magneto trouble Wiring faulty Regulator trouble j Poor braking performance maladjusted (lever or pedal play excessive)
  • 2010 Kawasaki KLX110L | Owners Manual - Page 105
    STORAGE 103 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. the spark plug and spray
  • 2010 Kawasaki KLX110L | Owners Manual - Page 106
    104 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 • Checksall section. a lubrication procedure in the
  • 2010 Kawasaki KLX110L | Owners Manual - Page 107
    ENVIRONMENTAL PROTECTION 105 ENVIRONMENTAL PROTECTION To protect our environment, properly discard used 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 the proper disposal
  • 2010 Kawasaki KLX110L | Owners Manual - Page 108
    106 WIRING DIAGRAM WIRING DIAGRAM KLX110C Model
  • 2010 Kawasaki KLX110L | Owners Manual - Page 109
    WIRING DIAGRAM 107 KLX110D Model
  • 2010 Kawasaki KLX110L | Owners Manual - Page 110
    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
  • 2010 Kawasaki KLX110L | Owners Manual - Page 111
    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..
  • 2010 Kawasaki KLX110L | Owners Manual - Page 112
    110 MAINTENANCE RECORD 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 Traveled Distance Maintenance Performed
  • 2010 Kawasaki KLX110L | Owners Manual - Page 113
    MAINTENANCE RECORD 111 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2010 Kawasaki KLX110L | Owners Manual - Page 114
    112 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2010 Kawasaki KLX110L | Owners Manual - Page 115
    MAINTENANCE RECORD 113 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2010 Kawasaki KLX110L | Owners Manual - Page 116
    114 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2010 Kawasaki KLX110L | Owners Manual - Page 117
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