2013 Kawasaki KLX110 Owners Manual

2013 Kawasaki KLX110 Manual

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  • 2013 Kawasaki KLX110 | Owners Manual - Page 1
  • 2013 Kawasaki KLX110 | Owners Manual - Page 2
  • 2013 Kawasaki KLX110 | 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.
  • 2013 Kawasaki KLX110 | 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. •
  • 2013 Kawasaki KLX110 | Owners Manual - Page 5
  • 2013 Kawasaki KLX110 | Owners Manual - Page 6
    Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. NOTICE NOTICE is used to address practices not related to personal injury. DANGER DANGER indicates a hazardous situation which,
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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
  • 2013 Kawasaki KLX110 | 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.
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    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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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 ...YOUR WARRANTY/OWNER SATISFACTION MAINTENANCE RECORD
  • 2013 Kawasaki KLX110 | 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-
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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 Front Fork Oil: Type SHOWA SS8 110 mm (4.3 in.) 132 mm (5.2 in.) 110 mm (4.3 in.) 140 mm
  • 2013 Kawasaki KLX110 | Owners Manual - Page 15
    SPECIFICATIONS 13 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.) Specifications are subject to change without notice.
  • 2013 Kawasaki KLX110 | 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
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    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
  • 2013 Kawasaki KLX110 | 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 Inspection Window 28. Carburetor
  • 2013 Kawasaki KLX110 | 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 approximately 0.4
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    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
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    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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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 position for the motorcycle to operate. Move position to stop the engine. the switch to the NOTE żTo avoid battery discharging, check that the
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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.
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    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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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.
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 37
    make sure 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 for Owner's Manual carefully and keep it valid by complying with the owner's obligations it contains. To obtain warranty service,
  • 2013 Kawasaki KLX110 | Owners Manual - Page 38
    36 MAINTENANCE AND ADJUSTMENT TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits 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 any device or element of design
  • 2013 Kawasaki KLX110 | 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)
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    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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 42
    (1 month) Every 50 hours (6 months) 100 hours (12 months) See Page 42 42 - - j • • • Every 5 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 43
    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. gine speed. Stop the engine and wait several minutes for the oil to settle. Check the engine oil level with the motorcycle vertical through the
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 45
    MAINTENANCE AND ADJUSTMENT 43 WARNING Engine 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-
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 47
    MAINTENANCE AND ADJUSTMENT 45 Tightening Torque Engine Oil Drain Bolt: 29 N·m (3.0 kgf·m, 21 ft·lb) Engine Oil Capacity Capacity: 0.9 L (1.0 US qt) (When filter is not removed) 1.0 L (1.1 US qt) (When filter is removed) 1.1 L (1.2 US qt) (When engine is completely dry) The oil viscosity may need to
  • 2013 Kawasaki KLX110 | Owners Manual - Page 48
    . • *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. Spark Plug The spark plug should be taken out periodically for
  • 2013 Kawasaki KLX110 | Owners Manual - Page 49
    MAINTENANCE AND ADJUSTMENT 47 If the plug is oily or has carbon built up on it, clean it (preferably with a sandblaster) and then clean off any abrasive particles. The plug may also be cleaned using a high flash-point solvent and a wire brush or other suitable tool. If the spark plug electrodes are
  • 2013 Kawasaki KLX110 | Owners Manual - Page 50
    48 MAINTENANCE AND ADJUSTMENT 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 intake system, which includes the air filter and air duct to the carburetor, and the duct clamp and
  • 2013 Kawasaki KLX110 | Owners Manual - Page 51
    MAINTENANCE AND ADJUSTMENT 49 • Remove the screws and air cleaner cover. j A. B. C. D. Screw Bolts Fuel Tank Cap Shroud A. Screws B. Air Cleaner Cover • Install the fuel tank cap.
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    50 MAINTENANCE AND ADJUSTMENT • Take out the air cleaner element. j A. Air Cleaner Element A. Wire Screen B. Air Cleaner Cover inside of the intake tract and carburetor for • Check dirt. If dirty, clean the intake tract and carburetor the element. If it is dirty, clean it. Also • Inspect check
  • 2013 Kawasaki KLX110 | Owners Manual - Page 53
    MAINTENANCE AND ADJUSTMENT 51 NOTICE A clogged air cleaner may allow dirt and dust to enter the engine, causing it to wear excessively or to become damaged. 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 54
    52 MAINTENANCE AND ADJUSTMENT the air cleaner element in the housing, and • Install make sure the sealing surface of the element is the hook and projection into the slot and • Insert grommet. j • Install the air cleaner cover and tighten the screws. Tightening Torque Air Cleaner Cover Screws: 1.5
  • 2013 Kawasaki KLX110 | Owners Manual - Page 55
    MAINTENANCE AND ADJUSTMENT 53 Oil Draining the plug to see if any oil or water has run • Inspect 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 Maintenance
  • 2013 Kawasaki KLX110 | Owners Manual - Page 56
    54 MAINTENANCE AND ADJUSTMENT 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 57
    MAINTENANCE AND ADJUSTMENT 55 if the throttle grip moves smoothly from full • Check open to close, and the throttle closes quickly and completely in all steering positions by the return spring. If not, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle
  • 2013 Kawasaki KLX110 | Owners Manual - Page 58
    56 MAINTENANCE AND ADJUSTMENT Clutch KLX110C Model j Clutch Adjustment the locknut. • Loosen the clutch release adjusting screw counter• Turn clockwise until it becomes hard to turn, and then back it out a quarter turn. A. Idle Adjusting Screw and close the throttle a few times to make • Open
  • 2013 Kawasaki KLX110 | Owners Manual - Page 59
    MAINTENANCE AND ADJUSTMENT 57 the engine and check the clutch by operating • Start the shift pedal. KLX110D Model 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 60
    58 MAINTENANCE AND ADJUSTMENT the dust cover back into place. • Slide Start the check that the clutch does not • slip and itengine, releases properly. Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. j WARNING Too much cable play can prevent clutch
  • 2013 Kawasaki KLX110 | Owners Manual - Page 61
    MAINTENANCE AND ADJUSTMENT 59 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, clean the spark arrester. the right side cover (see Air Cleaner sec• Remove tion). • Remove the
  • 2013 Kawasaki KLX110 | Owners Manual - Page 62
    60 MAINTENANCE AND ADJUSTMENT • Remove the bolts and pull the spark arrester. a wire brush, remove the carbon off the inside • With of the spark arrester and muffler. j A. Bolts B. Spark Arrester A. Spark Arrester the spark arrester into the rear end of the • Install muffler. • Tighten the
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 67
    A. Weight B. Tape Measure A. Master Link Clip B. Direction of Chain Rotation Drive Chain 20-Link Length 254.0 a 254.6 mm (10.00 a 10.02 Standard in.) Service Limit 259 mm (10.2 in.) NOTE żThe drive system was designed for use with a DAIDO DID 420DX 90-links chain. For maximum stretch resistance
  • 2013 Kawasaki KLX110 | Owners Manual - Page 68
    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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 72
    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 ~
  • 2013 Kawasaki KLX110 | Owners Manual - Page 74
    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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 75
    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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 79
    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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 80
    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. Rim Runout Set up a
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    MAINTENANCE AND ADJUSTMENT 79 NOTE żThe welding spot of the rim may show excessive runout. Disregard this when measuring rim runout. Rim Runout j A. Axial Rim Runout Measurement A. Rim B. Axial Runout C. Radial Runout Rim Runout Maximum Limit Axial *TIR 2.0 mm (0.08 in.) Radial *: Total
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    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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 83
    MAINTENANCE AND ADJUSTMENT 81 Self-discharge Approx. number of days from 100% charged to 100% discharged Lead-Antimony 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% discharged 60 Days
  • 2013 Kawasaki KLX110 | Owners Manual - Page 84
    to reinstall the battery in the motorcycle (see Battery Installation). NOTE j 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
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    MAINTENANCE AND ADJUSTMENT 83 NOTICE Installing the (-) cable to the (+) terminal of the battery or the (+) cable to the (-) terminal of the battery can seriously damaged the electrical system. a light coat of grease on the terminals to pre• Put vent corrosion. • Cover the (+) terminal with its
  • 2013 Kawasaki KLX110 | 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. WARNING Substituting fuses can cause wiring to overheat
  • 2013 Kawasaki KLX110 | Owners Manual - Page 87
    MAINTENANCE AND ADJUSTMENT 85 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.
  • 2013 Kawasaki KLX110 | Owners Manual - Page 88
    86 MAINTENANCE AND ADJUSTMENT j 12. Rear Shock Absorber Nut (Lower) 13. Muffler Body Mounting Bolt and Nut 14. Engine Mounting Nuts 15. 16. 17. 18. 19. Steering Stem Head Nut Brake Cam Lever Bolt Rear Axle Nut Torque Link Nuts Brake Pedal Bolt 20. 21. 22. 23. 24. Kick Pedal Bolt Footpeg
  • 2013 Kawasaki KLX110 | Owners Manual - Page 89
    MAINTENANCE AND ADJUSTMENT 87 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 90
    88 MAINTENANCE AND ADJUSTMENT 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 Bolt Side Stand Nut R: Replacement Parts S: Follow the specified
  • 2013 Kawasaki KLX110 | Owners Manual - Page 91
    such as ammo- j WARNING Build-up of debris or flammable material in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of fire. When operating the vehicle in conditions that allow debris or flammable material to collect in and around the
  • 2013 Kawasaki KLX110 | Owners Manual - Page 92
    every three 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.
  • 2013 Kawasaki KLX110 | Owners Manual - Page 93
    MAINTENANCE AND ADJUSTMENT 91 Chrome and Aluminum Chrome and uncoated aluminum parts can be treated with a chrome/aluminum polish. Coated aluminum should be washed with a mild neutral detergent and finished with a spray polish. Aluminum wheels, both painted and unpainted can be cleaned with special
  • 2013 Kawasaki KLX110 | Owners Manual - Page 94
    92 MAINTENANCE AND ADJUSTMENT Brake Pedal • Rear Rear Brake • Kick Pedal Rod Joint • Footpeg • Pedal • Shift Side Stand • j
  • 2013 Kawasaki KLX110 | Owners Manual - Page 95
    MAINTENANCE AND ADJUSTMENT 93 Apply an aerosol cable lubricant with a pressure lubricator on all cables: Clutch Cable (KLX110D Model) Throttle Cable Cable Lubrication • • • • Apply grease to the following points: Clutch Inner Cable Upper End (KLX110D Model) Throttle Inner Cable Upper End j A.
  • 2013 Kawasaki KLX110 | Owners Manual - Page 96
    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 shorted or open Engine stop switch trouble 10 A fuse blown Engine
  • 2013 Kawasaki KLX110 | Owners Manual - Page 97
    TROUBLESHOOTING GUIDE 95 plug cap or high-tension wiring defective • Spark Spark cap not contacting properly • Spark plug plug type incorrect • Crankshaft sensor defective • Igniter defective • Ignition
  • 2013 Kawasaki KLX110 | Owners Manual - Page 98
    96 TROUBLESHOOTING GUIDE not seating properly (valve bent, worn, or • Valve carbon accumulation on 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 99
    TROUBLESHOOTING GUIDE 97 Improper acceleration: Choke valve closed Carburetor fuel level too high 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 100
    98 TROUBLESHOOTING GUIDE release mechanism defective • Clutch Clutch hub or housing unevenly worn • groove worn • Gear Gear dogs and/or dog grooves worn • Shift drum groove worn • Gear
  • 2013 Kawasaki KLX110 | Owners Manual - Page 101
    TROUBLESHOOTING GUIDE 99 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 Drive chain noise: Drive chain slack
  • 2013 Kawasaki KLX110 | Owners Manual - Page 102
    100 TROUBLESHOOTING GUIDE 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 103
    TROUBLESHOOTING GUIDE 101 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) •
  • 2013 Kawasaki KLX110 | Owners Manual - Page 104
    102 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 105
    STORAGE 103 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 pull the cap lightly to make sure that it is properly installed. the fuel tank with fuel. • Fill Check the points listed in the Daily
  • 2013 Kawasaki KLX110 | Owners Manual - Page 106
    104 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 107
    WIRING DIAGRAM 105 WIRING DIAGRAM KLX110C Model
  • 2013 Kawasaki KLX110 | Owners Manual - Page 108
    106 WIRING DIAGRAM KLX110D Model
  • 2013 Kawasaki KLX110 | Owners Manual - Page 109
    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.
  • 2013 Kawasaki KLX110 | Owners Manual - Page 110
    , 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 111
    YOUR WARRANTY/OWNER SATISFACTION 109 How Do I Get Warranty Service? If there is a problem with your vehicle within the limited warranty period, you will need to schedule a service appointment and provide any maintenance records to an authorized Kawasaki dealer for inspection and diagnosis. You can
  • 2013 Kawasaki KLX110 | Owners Manual - Page 112
    ? This owner's manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you. Please send your correspondence to: Consumer Services Kawasaki Motors Corp
  • 2013 Kawasaki KLX110 | Owners Manual - Page 113
    MAINTENANCE RECORD 111 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
  • 2013 Kawasaki KLX110 | Owners Manual - Page 114
    112 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2013 Kawasaki KLX110 | Owners Manual - Page 115
    MAINTENANCE RECORD 113 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2013 Kawasaki KLX110 | Owners Manual - Page 116
    114 MAINTENANCE RECORD Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2013 Kawasaki KLX110 | Owners Manual - Page 117
    MAINTENANCE RECORD 115 Date Traveled Distance Maintenance Performed Dealer Name Dealer Address
  • 2013 Kawasaki KLX110 | Owners Manual - Page 118
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