2012 Kawasaki KLX140L Owners Manual

2012 Kawasaki KLX140L Manual

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  • 2012 Kawasaki KLX140L | Owners Manual - Page 1
  • 2012 Kawasaki KLX140L | Owners Manual - Page 2
  • 2012 Kawasaki KLX140L | 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.
  • 2012 Kawasaki KLX140L | 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. •
  • 2012 Kawasaki KLX140L | Owners Manual - Page 5
    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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 6
    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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 7
    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.
  • 2012 Kawasaki KLX140L | Owners Manual - Page 8
    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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 9
  • 2012 Kawasaki KLX140L | 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 11
    Inspection ...75 Battery ...76 Fuse ...80 Tightening Torques of Nuts and Bolts...81 Cleaning Your Motorcycle...86 Lubrication...89 TROUBLESHOOTING GUIDE...92 STORAGE ...94 Before Storage ...94 After Storage ...95 ENVIRONMENTAL PROTECTION ...96 WIRING DIAGRAM ...97 YOUR WARRANTY/OWNER SATISFACTION
  • 2012 Kawasaki KLX140L | Owners Manual - Page 12
    10 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall length Overall width Overall height Wheelbase Road clearance Curb Mass Fuel tank capacity ENGINE Type Bore × stroke Displacement Compression ratio Carburetor Starting system Ignition system Ignition timing Lubrication system Spark plug Spark plug
  • 2012 Kawasaki KLX140L | 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 Viscosity FRAME Type Steering angle Castor Trail Tubular, semi-double
  • 2012 Kawasaki KLX140L | Owners Manual - Page 14
    12 SPECIFICATIONS 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) BRAKES Type (Front & Rear) ELECTRICAL EQUIPMENT Battery B: KLX140B Specifications are subject to change without notice. 12
  • 2012 Kawasaki KLX140L | Owners Manual - Page 15
    GENERAL INFORMATION 13 GENERAL INFORMATION Location of Parts j 1. Clutch Lever 2. Engine Stop Switch 3. Choke Knob 4. Front Brake Fluid Reservoir 5. Front Brake Lever 6. Throttle Grip 7. Starter Button 8. Fuel Tank Cap
  • 2012 Kawasaki KLX140L | Owners Manual - Page 16
    14 GENERAL INFORMATION j 9. Front Fork 10. Fuel Tank 11. Fuel Tap 12. Carburetor 13. Seat 14. Air Cleaner Element 15. Brake Disc 16. Brake Caliper 17. Engine Oil Drain Plug 18. Side Stand 19. Drive Chain 20. Swingarm 21. Chain Guide 22. Rear Shock Absorber
  • 2012 Kawasaki KLX140L | Owners Manual - Page 17
    GENERAL INFORMATION 15 j 23. Muffler 24. Fuse 25. Battery 26. Rear Axle Nut 27. Chain Adjuster 28. Rear Brake Fluid Reservoir 29. Oil Filler Cap/Dipstick 30. Rear Brake Pedal
  • 2012 Kawasaki KLX140L | Owners Manual - Page 18
    16 GENERAL INFORMATION 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 approximately 1.1
  • 2012 Kawasaki KLX140L | Owners Manual - Page 19
    GENERAL INFORMATION 17 NOTE j Fuel The required of fuel is specified under "Fuel Requirements". The capacity of the fuel tank is 5.8 L (1.5 US gal). To open the fuel tank cap, pull out the breather hose from the hole in the steering shaft and turn the tank cap counterclockwise. Avoid filling the
  • 2012 Kawasaki KLX140L | Owners Manual - Page 20
    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 meeting standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or non-recommended
  • 2012 Kawasaki KLX140L | Owners Manual - Page 21
    drain all fuel from the fuel system. See the Storage section in this manual. j NOTICE 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 22
    20 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 position for the motorcycle to operate. Move position to stop the engine. the switch to the Starter Button This motorcycle has the starter button.
  • 2012 Kawasaki KLX140L | Owners Manual - Page 23
    GENERAL INFORMATION 21 Starting the Engine that the engine stop switch is in the • Check position. j • Turn the fuel tap lever to the ON position. A. ON Position A. Engine Stop Switch Position B. • Shift the transmission into neutral. NOTE WARNING Riding with the side stand in the down
  • 2012 Kawasaki KLX140L | Owners Manual - Page 24
    22 GENERAL INFORMATION j NOTICE Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the battery power recover. When engine is cold: Pull
  • 2012 Kawasaki KLX140L | Owners Manual - Page 25
    GENERAL INFORMATION 23 NOTICE Do not let the engine idle longer than five minutes, or engine overheating and damage may occur. j Moving Off that the side stand is up. • Check Shift into gear. • Open the 1st throttle slowly. •
  • 2012 Kawasaki KLX140L | Owners Manual - Page 26
    24 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 27
    GENERAL INFORMATION 25 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 28
    26 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 29
    GENERAL INFORMATION 27 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 30
    28 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 31
    MAINTENANCE AND ADJUSTMENT 29 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 32
    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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 33
    MAINTENANCE AND ADJUSTMENT 31 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 34
    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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 35
    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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 36
    34 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 37
    MAINTENANCE AND ADJUSTMENT 35 3. Periodic Replacement (Engine and Chassis Related Item) Initial FREQUENCY OPERATION Engine oil - change Oil filter - replace (K) Brake hose - replace (K) Fuel hose - replace (K) Brake fluid - change (K) Brake master cylinder cup and dust seal - replace (K) Brake
  • 2012 Kawasaki KLX140L | Owners Manual - Page 38
    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. Oil Level Inspection the motorcycle so that it is perpendicular • Situate to the ground. the oil has just been changed, start the engine • If
  • 2012 Kawasaki KLX140L | Owners Manual - Page 39
    MAINTENANCE AND ADJUSTMENT 37 NOTICE Be careful not to allow any dirt or foreign materials to enter the engine. out the cap and check the oil level by the dip• Pull stick on the cap. The oil level should be between the "H" (High) and "L" (Low) lines on the dipstick. NOTE żDo not pinch the O-ring
  • 2012 Kawasaki KLX140L | Owners Manual - Page 40
    38 MAINTENANCE AND ADJUSTMENT 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 oil filter • When cover and take off the cover with O-ring. j the oil
  • 2012 Kawasaki KLX140L | Owners Manual - Page 41
    filler cap/dipstick. *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki.
  • 2012 Kawasaki KLX140L | Owners Manual - Page 42
    40 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.
  • 2012 Kawasaki KLX140L | Owners Manual - Page 43
    MAINTENANCE AND ADJUSTMENT 41 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 44
    42 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 45
    MAINTENANCE AND ADJUSTMENT 43 the wing bolt, and take out the air cleaner • Remove element. WARNING A clogged air cleaner may allow dirt and dust to enter the carburetor and the throttle may stick resulting in a hazardous operating condition. Clean the air filter according to the periodic
  • 2012 Kawasaki KLX140L | Owners Manual - Page 46
    44 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. NOTICE Do not twist,
  • 2012 Kawasaki KLX140L | Owners Manual - Page 47
    MAINTENANCE AND ADJUSTMENT 45 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 the towel from the carburetor. • Remove the element onto its frame, and
  • 2012 Kawasaki KLX140L | Owners Manual - Page 48
    46 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 49
    MAINTENANCE AND ADJUSTMENT 47 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 50
    48 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 51
    MAINTENANCE AND ADJUSTMENT 49 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 52
    50 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 53
    MAINTENANCE AND ADJUSTMENT 51 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 54
    52 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 55
    MAINTENANCE AND ADJUSTMENT 53 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,
  • 2012 Kawasaki KLX140L | Owners Manual - Page 56
    54 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 57
    MAINTENANCE AND ADJUSTMENT 55 • 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 58
    56 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 59
    MAINTENANCE AND ADJUSTMENT 57 both chain adjuster locknuts. • Tighten Torque the axle nut to the specified torque. • 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 60
    a straight part of • Measure 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 61
    MAINTENANCE AND ADJUSTMENT 59 Chain Guide Wear Inspection • Chain Slipper Wear Inspection aged. Visually inspect the drive chain guide and replace it if excessively worn or damaged. inspect the front end of the chain slippers • Visually on the swingarm and replace them if worn
  • 2012 Kawasaki KLX140L | Owners Manual - Page 62
    60 MAINTENANCE AND ADJUSTMENT Sprocket Wear Inspection j • 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 63
    MAINTENANCE AND ADJUSTMENT 61 Handlebar To suit various riding positions, the handlebar can be adjusted by turning the handlebar holders around. Remove the handlebar clamp bolts, the clamps and the handlebar. Check the handlebar for bent or crack. the handlebar holder nuts, turn the han• Loosen
  • 2012 Kawasaki KLX140L | Owners Manual - Page 64
    62 MAINTENANCE AND ADJUSTMENT the gap at the rear with the punch mark on • Align the handlebar. NOTE j żTighten the two clamp bolts alternately two times to ensure even tightening torque. the front brake for the proper brake effect, • Check or no brake drag. A. B. C. D. Front Handlebar Clamps
  • 2012 Kawasaki KLX140L | Owners Manual - Page 65
    MAINTENANCE AND ADJUSTMENT 63 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 position. the braking power and check that there is no • Test brake drag.
  • 2012 Kawasaki KLX140L | Owners Manual - Page 66
    64 MAINTENANCE AND ADJUSTMENT NOTICE 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 system fittings. Check for brake hose damage. j Brake Fluid Level
  • 2012 Kawasaki KLX140L | Owners Manual - Page 67
    MAINTENANCE AND ADJUSTMENT 65 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 68
    66 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 69
    MAINTENANCE AND ADJUSTMENT 67 Steering Adjustment Raise the front wheel off the ground using a jack (special tool). Remove the handlebar. Loosen the left and right front fork upper clamp bolts. Remove the steering stem head nut, and raise the front fork upper clamp. the steering stem locknut
  • 2012 Kawasaki KLX140L | Owners Manual - Page 70
    Bolts Tightening Torque 25 N·m (2.5 kgf·m, 18 ft·lb) 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 71
    MAINTENANCE AND ADJUSTMENT 69 NOTICE If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straitening, can weaken the inner tube. Rear Suspension Rear Shock Absorber Inspection the seat down and up by 4 or 5 times, and • Pump inspect the smooth stroke.
  • 2012 Kawasaki KLX140L | Owners Manual - Page 72
    70 MAINTENANCE AND ADJUSTMENT Rebound ONLY) Damping Adjustment (KLX140B Rebound Damping Adjuster Settings j To adjust the rear shock absorber rebound damping, turn the rebound damping adjuster at the bottom of the rear shock absorber with a flat-head screwdriver. A. Seated Position (Adjuster
  • 2012 Kawasaki KLX140L | Owners Manual - Page 73
    MAINTENANCE AND ADJUSTMENT 71 NOTICE Do not force the rebound and compression damping force adjusters beyond the fully seated position, or the adjusting mechanism may be damaged. Compression Damping Adjuster Setting The compression damping adjuster is a 4-stage adjustable. j Compression Damping
  • 2012 Kawasaki KLX140L | Owners Manual - Page 74
    72 MAINTENANCE AND ADJUSTMENT 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 soft or too stiff, have it adjusted by an authorized Kawasaki dealer. Wheels Tire Air Pressure
  • 2012 Kawasaki KLX140L | Owners Manual - Page 75
    MAINTENANCE AND ADJUSTMENT 73 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 76
    74 MAINTENANCE AND ADJUSTMENT 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 77
    MAINTENANCE AND ADJUSTMENT 75 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 78
    76 MAINTENANCE AND ADJUSTMENT Battery The battery installed in this motorcycle is a sealed type, so it is not necessary to check the battery electrolyte level or add distilled water. However, in order to maximize battery life and ensure that it will provide the power needed to start the motorcycle
  • 2012 Kawasaki KLX140L | Owners Manual - Page 79
    , never fail to obWARNING Lead is a toxic substance. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. serve the instructions shown in the label on the battery.
  • 2012 Kawasaki KLX140L | Owners Manual - Page 80
    78 MAINTENANCE AND ADJUSTMENT Battery Removal j • Remove the bolt and remove the side cover. • Remove the bolt and remove the seat. A. Bolt B. Side Cover A. Bolt B. Seat
  • 2012 Kawasaki KLX140L | Owners Manual - Page 81
    MAINTENANCE AND ADJUSTMENT 79 the cables from the battery, first from • Disconnect the (-) terminal and then the (+) terminal. Battery Installation the battery in the battery case. • Place Install the battery holder and tighten the bolts. • Connect the red cable to the (+) terminal, and then •
  • 2012 Kawasaki KLX140L | Owners Manual - Page 82
    80 MAINTENANCE AND ADJUSTMENT Fuse The main fuse (10 A) is mounted on the starter relay under the seat. 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. WARNING Substituting fuses can cause wiring to
  • 2012 Kawasaki KLX140L | Owners Manual - Page 83
    MAINTENANCE AND ADJUSTMENT 81 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. 7. 8. 9.
  • 2012 Kawasaki KLX140L | Owners Manual - Page 84
    82 MAINTENANCE AND ADJUSTMENT j 18. 19. 20. 21. 22. 23. 24. 25. Spark Plug Cylinder Head Bolts Muffler End Mounting Bolts Spark Arrester Mounting Bolts Rear Master Cylinder Mounting Bolts Steering Head Nut Front Master Cylinder Mounting Bolts Rear Brake Disk Mounting Bolts 26. 27. 28. 29. 30. 31
  • 2012 Kawasaki KLX140L | Owners Manual - Page 85
    MAINTENANCE AND ADJUSTMENT 83 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 86
    84 MAINTENANCE AND ADJUSTMENT 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 Side Stand Bolt Side Stand Nut Swingarm Pivot Shaft Nut Rear Axle Nut Rear Brake Pedal Pivot Bolt Rear Frame
  • 2012 Kawasaki KLX140L | Owners Manual - Page 87
    MAINTENANCE AND ADJUSTMENT 85 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 88
    86 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 89
    MAINTENANCE AND ADJUSTMENT 87 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 90
    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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 91
    MAINTENANCE AND ADJUSTMENT 89 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 92
    90 MAINTENANCE AND ADJUSTMENT 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 Cable Lubrication j • • •
  • 2012 Kawasaki KLX140L | Owners Manual - Page 93
    MAINTENANCE AND ADJUSTMENT 91 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 appears
  • 2012 Kawasaki KLX140L | Owners Manual - Page 94
    92 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE NOTE żThis troubleshooting guide is not exhaustive and j 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 95
    TROUBLESHOOTING GUIDE 93 Clutch not operating smoothly - Clutch slipping Friction plate worn Clutch springs weak Shock absorption too hard Tire air pressure too high • • Clutch doesn't disengaging
  • 2012 Kawasaki KLX140L | Owners Manual - Page 96
    94 STORAGE 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 97
    STORAGE 95 the motorcycle to keep dust and dirt away • Cover from it. 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-
  • 2012 Kawasaki KLX140L | Owners Manual - Page 98
    96 ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION Kawasaki subscribes to the guidelines of Tread Lightly! a program dedicated to protecting the great outdoors through education and fostering responsible enjoyment of public lands. When using your Kawasaki motorcycle, please follow these Tread
  • 2012 Kawasaki KLX140L | Owners Manual - Page 99
    WIRING DIAGRAM 97 WIRING DIAGRAM
  • 2012 Kawasaki KLX140L | Owners Manual - Page 100
    Am I Responsible For? You are responsible for maintaining your vehicle according to the maintenance schedule shown in this owner's manual. You are responsible for notifying your dealer immediately if there is a problem, and you, as the owner, will need to authorize the dealer to inspect the unit.
  • 2012 Kawasaki KLX140L | Owners Manual - Page 101
    , be sure to record your service in the Maintenance Record section of this Owner's Manual. Keep all receipts for the service and/or items necessary to perform vehicle if there is a failure, investigating the cause of the problem, and getting any needed authorization from Kawasaki if the repair is
  • 2012 Kawasaki KLX140L | Owners Manual - Page 102
    by a Kawasaki dealer. What if I am not Satisfied With My Warranty Service? If you aren't satisfied with your dealership's repair work or operations, dealership and work with it in resolving your problem. Want to Contact Kawasaki? This owner's manual should answer most of your questions about your
  • 2012 Kawasaki KLX140L | Owners Manual - Page 103
    YOUR WARRANTY/OWNER SATISFACTION 101 Please send your correspondence to: Consumer Services Kawasaki Motors Corp., U.S.A. P.O. Box 25252 Santa Ana, CA 92799-5252 (949) 460-5688
  • 2012 Kawasaki KLX140L | 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.
  • 2012 Kawasaki KLX140L | 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
  • 2012 Kawasaki KLX140L | Owners Manual - Page 106
    104 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2012 Kawasaki KLX140L | Owners Manual - Page 107
    MAINTENANCE RECORD 105 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2012 Kawasaki KLX140L | Owners Manual - Page 108
    106 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2012 Kawasaki KLX140L | Owners Manual - Page 109
    MAINTENANCE RECORD 107 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2012 Kawasaki KLX140L | Owners Manual - Page 110
    108 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2012 Kawasaki KLX140L | Owners Manual - Page 111
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