Owners Manual
Page 11
... ...Engine Oil...Spark Plug...Air Cleaner ...Throttle Cable...Carburetor ...10 14 14 17 17 18 21 22 23 24 24 28 28 30 30 31 32 34 34 37 41 46 48 53 55 Clutch ...Valve Clearance ...Spark Arrester ...Drive Chain...Handlebar...Brakes ...Steering ...Front Suspension ...Rear Suspension ...Wheels ...Hoses Inspection ...Battery ...Fuse ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...STORAGE ...Before Storage ...After Storage ...ENVIRONMENTAL PROTECTION ...WIRING DIAGRAM ...YOUR WARRANTY/OWNER...
... ...Engine Oil...Spark Plug...Air Cleaner ...Throttle Cable...Carburetor ...10 14 14 17 17 18 21 22 23 24 24 28 28 30 30 31 32 34 34 37 41 46 48 53 55 Clutch ...Valve Clearance ...Spark Arrester ...Drive Chain...Handlebar...Brakes ...Steering ...Front Suspension ...Rear Suspension ...Wheels ...Hoses Inspection ...Battery ...Fuse ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...STORAGE ...Before Storage ...After Storage ...ENVIRONMENTAL PROTECTION ...WIRING DIAGRAM ...YOUR WARRANTY/OWNER...
Owners Manual
Page 12
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-stroke, SOHC, single-cylinder, air-cooled 53.0 × 50.6 mm (2.1 × 2.0 in.) 112 cm³ (6.8 cu in.) 9.5:1 Carburetor KEIHIN PB18 Electric starter and kick starter SHINDENGEN CDI 10° BTDC @1 300 r/min (rpm) a 31°...
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-stroke, SOHC, single-cylinder, air-cooled 53.0 × 50.6 mm (2.1 × 2.0 in.) 112 cm³ (6.8 cu in.) 9.5:1 Carburetor KEIHIN PB18 Electric starter and kick starter SHINDENGEN CDI 10° BTDC @1 300 r/min (rpm) a 31°...
Owners Manual
Page 21
... reduce exhaust emissions. If gasoline is spilled on service station pumps in the U.S.A. The Antiknock Index is posted on the fuel tank, wipe it can be covered under certain conditions, creating the potential for use a different brand of gasoline of low quality or not meeting standard industry specifications may cause the fuel to severe engine damage. The octane rating of fuel oxygenates approved...
... reduce exhaust emissions. If gasoline is spilled on service station pumps in the U.S.A. The Antiknock Index is posted on the fuel tank, wipe it can be covered under certain conditions, creating the potential for use a different brand of gasoline of low quality or not meeting standard industry specifications may cause the fuel to severe engine damage. The octane rating of fuel oxygenates approved...
Owners Manual
Page 32
... off, when the motorcycle is not used. Pull in the clutch lever as the motorcycle comes to ensure good engine response at all speeds. Engine Stop Switch Position B. • Turn the fuel tap lever to the • A. 30 GENERAL INFORMATION j Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Push the engine stop (KLX110D model).
... off, when the motorcycle is not used. Pull in the clutch lever as the motorcycle comes to ensure good engine response at all speeds. Engine Stop Switch Position B. • Turn the fuel tap lever to the • A. 30 GENERAL INFORMATION j Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Push the engine stop (KLX110D model).
Owners Manual
Page 34
... damage Engine Engine Oil ...No leakage Level correct Spark Plug ...Correctly torqued Clutch ...Functions properly Carburetor ...Properly adjusted Air Cleaner ...Clean Apply oil to a safe operating condition. Inhaling carbon monoxide can cause serious brain injury or death. Operate only in enclosed areas. 32 GENERAL INFORMATION j Daily Pre-Ride Checks Check the following items each day before operation. DANGER Exhaust gas contains...
... damage Engine Engine Oil ...No leakage Level correct Spark Plug ...Correctly torqued Clutch ...Functions properly Carburetor ...Properly adjusted Air Cleaner ...Clean Apply oil to a safe operating condition. Inhaling carbon monoxide can cause serious brain injury or death. Operate only in enclosed areas. 32 GENERAL INFORMATION j Daily Pre-Ride Checks Check the following items each day before operation. DANGER Exhaust gas contains...
Owners Manual
Page 35
... Air valve cap installed Spokes ...No looseness Drive Chain ...Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ...Function properly Lever and pedal play correct No wear to brake lining Throttle ...Functions properly Throttle grip returns smoothly Steering ...Smooth but not loose from lock to lock No binding due to control cables Front Fork ...Functions properly No oil leakage Rear Shock Absorber ...Functions properly No oil leakage Fuel Tank ...Mounted...
... Air valve cap installed Spokes ...No looseness Drive Chain ...Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ...Function properly Lever and pedal play correct No wear to brake lining Throttle ...Functions properly Throttle grip returns smoothly Steering ...Smooth but not loose from lock to lock No binding due to control cables Front Fork ...Functions properly No oil leakage Rear Shock Absorber ...Functions properly No oil leakage Fuel Tank ...Mounted...
Owners Manual
Page 36
..., maintenance, and repair work should be able to keep the vehicle in accordance with the fuel and air supplied by the exhaust of the United States Environmental Protection Agency. 1. Instead, the vapors are burned along with the Periodic Maintenance Chart to carry out many of the engine. Crankcase Emission Control System This system eliminates the release of low permeation fuel hoses and a fuel tank. While...
..., maintenance, and repair work should be able to keep the vehicle in accordance with the fuel and air supplied by the exhaust of the United States Environmental Protection Agency. 1. Instead, the vapors are burned along with the Periodic Maintenance Chart to carry out many of the engine. Crankcase Emission Control System This system eliminates the release of low permeation fuel hoses and a fuel tank. While...
Owners Manual
Page 37
... retain copies of maintenance work orders, receipts, etc., as verification of this Owner's Manual at your own expense. 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 new vehicle for your vehicle. To obtain warranty service, the Kawasaki Limited Emission Control Systems Warranty requires that...
... retain copies of maintenance work orders, receipts, etc., as verification of this Owner's Manual at your own expense. 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 new vehicle for your vehicle. To obtain warranty service, the Kawasaki Limited Emission Control Systems Warranty requires that...
Owners Manual
Page 43
... window. Do not run it for several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at high en- Not only do dirt and metal particles collect in accordance with the Periodic Maintenance Chart. Check the engine oil level with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in the Owner's Manual. j • • WARNING...
... window. Do not run it for several minutes for the engine, transmission and clutch to function properly, maintain the engine oil at high en- Not only do dirt and metal particles collect in accordance with the Periodic Maintenance Chart. Check the engine oil level with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in the Owner's Manual. j • • WARNING...
Owners Manual
Page 46
... and tighten its new gasket. 44 MAINTENANCE AND ADJUSTMENT the oil filter element with a new one. • Replace Install the oil filter element with the grommet to the specified torque. Tightening Torque Oil Filter Cap Bolts: 5.2 N·m (0.53 kgf·m, 46 in the table. Oil Filter Element B. Oil Filter Cap C. Grommet A. Spring B. the spring to the oil filter cap. • Install Install oil filter cap with its bolts to • ward the engine. Proper torque for...
... and tighten its new gasket. 44 MAINTENANCE AND ADJUSTMENT the oil filter element with a new one. • Replace Install the oil filter element with the grommet to the specified torque. Tightening Torque Oil Filter Cap Bolts: 5.2 N·m (0.53 kgf·m, 46 in the table. Oil Filter Element B. Oil Filter Cap C. Grommet A. Spring B. the spring to the oil filter cap. • Install Install oil filter cap with its bolts to • ward the engine. Proper torque for...
Owners Manual
Page 79
...) NOTE żTire air pressure should be checked when the tires are cold, before you ride the motorcycle. Wheels Tire Air Pressure Tire air pressure affects traction, handling, and tire life. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. Increase the tire air pressure to suit track conditions and rider preference, but keep it does not smoothly or noise is found, inspect • If the oil leak and rear shock absorber mounting.
...) NOTE żTire air pressure should be checked when the tires are cold, before you ride the motorcycle. Wheels Tire Air Pressure Tire air pressure affects traction, handling, and tire life. necessary, repair or replace by 4 or 5 times, and • Pump inspect the smooth stroke. Increase the tire air pressure to suit track conditions and rider preference, but keep it does not smoothly or noise is found, inspect • If the oil leak and rear shock absorber mounting.
Owners Manual
Page 89
..., possibly resulting in ·lb 22 15 R R R, S R Remarks S j Fastener Cylinder Head Nuts Clutch Adjusting Screw Locknut (KLX110C Model) Engine Oil Drain Bolt Oil Filter Cap Bolts Kick Pedal Bolt Shift Pedal Bolt Spark Plug Exhaust Pipe Holder Nuts Muffler Body Mounting Bolt Muffler Body Mounting Nut Engine Mounting Nuts Front Axle Nut Rear Axle Nut Spoke Nipples Rear Sprocket Nuts Brake Cam Lever Bolt Brake Pedal Bolt Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) N·m 22 19 29 5.2 8.8 5.2 13 16 9.8 30 54 44...
..., possibly resulting in ·lb 22 15 R R R, S R Remarks S j Fastener Cylinder Head Nuts Clutch Adjusting Screw Locknut (KLX110C Model) Engine Oil Drain Bolt Oil Filter Cap Bolts Kick Pedal Bolt Shift Pedal Bolt Spark Plug Exhaust Pipe Holder Nuts Muffler Body Mounting Bolt Muffler Body Mounting Nut Engine Mounting Nuts Front Axle Nut Rear Axle Nut Spoke Nipples Rear Sprocket Nuts Brake Cam Lever Bolt Brake Pedal Bolt Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) N·m 22 19 29 5.2 8.8 5.2 13 16 9.8 30 54 44...
Owners Manual
Page 91
j WARNING Build-up of debris or flammable material in air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. Avoid wire brushes, steel wool, and all harsh chemicals, solvents, detergents, • Avoid and household cleaning products such as they can penetrate seals and electrical components and damage your Kawasaki motorcycle will enhance its appearance, optimize overall performance, and extend its surfaces...
j WARNING Build-up of debris or flammable material in air intakes, carburetor, brake components, electrical components, muffler outlets, and fuel tank openings. Avoid wire brushes, steel wool, and all harsh chemicals, solvents, detergents, • Avoid and household cleaning products such as they can penetrate seals and electrical components and damage your Kawasaki motorcycle will enhance its appearance, optimize overall performance, and extend its surfaces...
Owners Manual
Page 96
Starter motor does not rotating: Engine stop switch not position Starter lockout switch (KLX110D model only) or gear position switch trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Starter system wiring shorted or open Engine stop switch turned off • Fuel tank cap air vent obstructed • Fuel tap clogged • Fuel line clogged • Float valve clogged • level too high • Fuel Float valve worn or stuck open...
Starter motor does not rotating: Engine stop switch not position Starter lockout switch (KLX110D model only) or gear position switch trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Starter system wiring shorted or open Engine stop switch turned off • Fuel tank cap air vent obstructed • Fuel tap clogged • Fuel line clogged • Float valve clogged • level too high • Fuel Float valve worn or stuck open...
Owners Manual
Page 97
...; Engine stop switch wiring defective • Flywheel magneto damaged • Gear position switch defective • Wiring shorted or interrupted • Poor low-speed performance Spark weak: Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap shorted or not contacting properly Spark plug type incorrect Igniter defective Ignition coil defective Crankshaft sensor defective Flywheel magneto defective Wiring connector not in good contact • • • Fuel/air mixture...
...; Engine stop switch wiring defective • Flywheel magneto damaged • Gear position switch defective • Wiring shorted or interrupted • Poor low-speed performance Spark weak: Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap shorted or not contacting properly Spark plug type incorrect Igniter defective Ignition coil defective Crankshaft sensor defective Flywheel magneto defective Wiring connector not in good contact • • • Fuel/air mixture...
Owners Manual
Page 98
...; Ignition timing incorrect • Drive chain trouble • Poor or no high-speed performance Other: Fuel/air mixture incorrect: Main jet clogged or wrong size Jet needle or needle jet worn Jet needle clip in wrong position Carburetor fuel level too high or too low Air cleaner element clogged, poorly sealed, or not installed Choke valve closed Fuel contaminated with water or foreign matter Fuel tank cap air...
...; Ignition timing incorrect • Drive chain trouble • Poor or no high-speed performance Other: Fuel/air mixture incorrect: Main jet clogged or wrong size Jet needle or needle jet worn Jet needle clip in wrong position Carburetor fuel level too high or too low Air cleaner element clogged, poorly sealed, or not installed Choke valve closed Fuel contaminated with water or foreign matter Fuel tank cap air...
Owners Manual
Page 99
... warped Clutch spring broken or weak Clutch release maladjusted (KLX110C Model) TROUBLESHOOTING GUIDE 97 Improper acceleration: Choke valve closed Carburetor fuel level too high or too low Main jet clogged Throttle valve does not fully open Air cleaner element clogged Muffler clogged Fuel contaminated with water or foreign matter Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Crankshaft bearing worn or damaged Ignition timing incorrect Crankshaft sensor defective Fuel/air mixture...
... warped Clutch spring broken or weak Clutch release maladjusted (KLX110C Model) TROUBLESHOOTING GUIDE 97 Improper acceleration: Choke valve closed Carburetor fuel level too high or too low Main jet clogged Throttle valve does not fully open Air cleaner element clogged Muffler clogged Fuel contaminated with water or foreign matter Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Crankshaft bearing worn or damaged Ignition timing incorrect Crankshaft sensor defective Fuel/air mixture...
Owners Manual
Page 100
... Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating Igniter defective Piston slap: Piston clearance excessive Cylinder or piston worn Connecting rod bent Piston pin or piston pin holes worn Valve noise: • clearance incorrect • Valve Valve spring broken or weak • Camshaft bearing or cam face worn • shift pedal does not return: Clutch not disengaging Shift fork bent or seized Gear...
... Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating Igniter defective Piston slap: Piston clearance excessive Cylinder or piston worn Connecting rod bent Piston pin or piston pin holes worn Valve noise: • clearance incorrect • Valve Valve spring broken or weak • Camshaft bearing or cam face worn • shift pedal does not return: Clutch not disengaging Shift fork bent or seized Gear...
Owners Manual
Page 101
... Cylinder head gasket leaking Exhaust pipe leaking at cylinder head Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain, sprocket, chain guide worn Flywheel magneto loose Drive chain noise: Drive chain slack improperly adjusted Drive chain worn Rear and/or engine sprocket(s) worn Drive chain inefficiently lubrified Rear wheel misaligned j Frame noise abnormal - • • Front fork noise: Oil level or viscosity too low Spring broken or weak Rear shock absorber noise: Shock absorber damaged Brake noise: Brake...
... Cylinder head gasket leaking Exhaust pipe leaking at cylinder head Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain, sprocket, chain guide worn Flywheel magneto loose Drive chain noise: Drive chain slack improperly adjusted Drive chain worn Rear and/or engine sprocket(s) worn Drive chain inefficiently lubrified Rear wheel misaligned j Frame noise abnormal - • • Front fork noise: Oil level or viscosity too low Spring broken or weak Rear shock absorber noise: Shock absorber damaged Brake noise: Brake...
Owners Manual
Page 104
.... Turn the engine over the muffler to warm the oil, then stop switch to keep dampness away from the tire rubber.). this cannot be done, put boards under the front and rear wheels to be stored for serious burns. Contact your local authorities for a long time.). Clean the entire vehicle thoroughly. Move the enposition. Gasoline is a toxic substance. j • • WARNING Engine oil...
.... Turn the engine over the muffler to warm the oil, then stop switch to keep dampness away from the tire rubber.). this cannot be done, put boards under the front and rear wheels to be stored for serious burns. Contact your local authorities for a long time.). Clean the entire vehicle thoroughly. Move the enposition. Gasoline is a toxic substance. j • • WARNING Engine oil...