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The correct value may not be obtained if disconnected.

1. eese Connecting Rod Big End Radial Clearance Inspechon Connecting Rod Big End Side Clearance Inspechon Crankshaft Runout Inspechon emnes Crankshaft Alignment Inspection ssssssssssseemm nennen Crankshaft Main Bearing Wear Inspection sssssseee e Transmission Transmission and Shift Mechanism Removal nennen Transmission DiSassembly ureegen Ee SE e e egen Transmission ASSEM le E Transmission and Shift Mechanism Installaton Shift Fork Bending eene eet Esp Shift Fork Ear Gear Shift Fork Groove Wear Inspechon Shift Fork Guide Pin Shift Drum Groove Wear Inspection Gear Dog Gear Dog Hole Damage Inspection ssssssseeeeeee Ball and Needle Bearing Wear Inspection cccceeceeeeeeeeeneneeeeeeeeeeeeeeeeeeeeeeeeeeeteeeennaaeees Oil Seal Inspection 8 2 8 4 8 5 8 10 8 10 8 11 8 12 8 12 8 12 8 12 8 13 8 14 8 14 8 14 8 15 8 15 8 15 8 2 CRANKSHAFT TRANSMISSION Exploded View CRANKSHAFT TRANSMISSION 8 3 Exploded View OONOARWN A Left Crankcase Half Right Crankcase Half Shift Fork Shift Rod Shift Drum Cam Shift Drum Gear Position Switch Drive Shaft Output Shaft Ball Bearing Bushing KLX110 A2 Woodruff Key KLX110 A1 2 9 N m 0 3 kgf m 26 in Ib 5 2 N m 0 53 kgf m 46 in Ib gt 15 N m 1 5 kgfm 11 ft lb 2
2. G113090BS1 C CRANKSHAFT TRANSMISSION 8 13 Transmission Apply Engine Oil G 68113379BSi C OAlways install circlips so that the opening is aligned with a spline groove To install a circlip without damage first A fit the circlip onto the shaft expanding it just enough to SV install it and then use a suitable gear to push the circlip 77 into place A Opening of Circlip B Groove of Shaft Spline zz 7 OG e Transmission and Shift Mechanism Installation e Fit the shift drum to the right crankcase half e Install the shift drum cam A aligning its hole B with the dowel pin C e Install the holder and tighten the Allen bolt Torque Shift Drum Allen Bolt 5 2 N m 0 53 kgf m 46 in Ib e Apply a clean engine oil to the transmission gears bear ings and shaft journal and fit the output A and drive shaft B assemblies as a set into the right crankcase half e Set the shift drum in neutral position e Apply a clean engine oil to the shift fork fingers and fit each shift fork into its gear groove so that the shift fork guide pin is in the proper shift drum groove NOTE OFingers of the 1st 3rd shift fork are longer than the fin gers of the 2nd 4th shift fork e Apply a clean engine oil to the shift rods A and insert each rod running it through each shift fork B e Set the shift drum in neutral position that is drive and output shaft turn free
3. 4 20 Muffler Installation 4 35 Valve Guide Installation 4 21 Spark Arrester Cleaning 4 35 4 2 ENGINE TOP END Exploded View Q N G a ec s Ww CO a3 969 9 it O ENGINE TOP END 4 3 Exploded View OONOARWN Intake Pipe Valve Adjusting Cover Valve Guide Rocker Arm Shaft Stopper Camshaft Sprocket Cover Cylinder Head Rocker Arm Rocker Arm Shaft Valve Adjusting Screw Valve Adjusting Screw Locknut Split Keepers Valve Spring Valve Spring Retainer Stem Oil Seal Spring Seat Valve Stem Camshaft Camshaft Sprocket Chain Guide Camshaft Chain Chain Guide KLX110 A2 Chain Guide KLX110 A1 Camshaft Chain Holder 5 2 N m 0 53 kgf m 46 in Ib 8 8 N m 0 9 kgf m 78 in Ib 12 Num 1 2 kgf m 104 in Ib 22 N m 2 2 kgf m 16 ft lb Apply engine oil Apply grease Apply a non permanent locking agent Apply molybdenum disulfide grease Replacement parts Follow the specific tightening sequence 4 4 ENGINE TOP END Exploded View GE02292885 C ENGINE TOP END 4 5 Exploded View NOORWN Camshaft Chain Tensioner Piston Piston Pin Cylinder Muffler Damper KLX110 A1 Exhaust Pipe Holder Nuts T1 T2 EO Apply non permanent locking agent Replacement parts 5 2 N m 0 53 kgf
4. c cceceeceeeeeneeeeeeeeeeeeseseceeneeseeeeenenseseneeeceeeeeeeessneeaeeees 11 9 Brake Panel Removal eec need en e cecec eiii i e rre cere does 11 9 Brake Panel Installation ssssssssssee mener 11 9 Brake Pane Disassembly EE 11 9 Brake Panel Assembly i esce titel er ott tbt beds tto de Veo atu oua tae cec eti edt pedo ri 11 10 Brake Drum Wear Inspechon mener 11 10 Brake Shoe Lining Wear Inspection eise e ero cete ei pieds uo Se Lose ds 11 11 Camshaft Wear Inspection 11 11 Brake Shoe Springs Inspechon mener 11 12 Brake Pariel E briCatlon ni er recorre ER ee e exar E Rp ee endure ive a E RR ee 11 12 11 2 BRAKES Exploded View BRAKES 11 3 Exploded View 4 A2ONOOARWN 000 Brake Lever Brake Cable Cam Lever Brake Panel Brake Shoe Camshaft Brake Lever Pivot Nut Front Brake Adjuster 44 N m 4 5 kgf m 32 ft lb Apply cable lubricant Apply grease Apply silicone grease 11 4 BRAKES Exploded View 6L02232885 C BRAKES 11 5 Exploded View OORUN Brake Pedal Brake Rod Adjusting Nut Brake Shoe Camshaft Cam Lever T1 T2 T3 Apply grease Replacement Parts 8 8 N m 0 9 kgf m 78 in Ib 64 N m 6 5 kgf m 47 ft lb 7 N m 0 7 kgf m 60 in Ib 11 6 BRAKES Specifications Item Standard Service Limit Brake Lever and Pedal Brake Lever Free Play Brake Ped
5. 7571129ST C Valve Spring Compressor Adapter 20 57001 1154 ST5711548T C Crankshaft Jig 57001 1174 ST5711748T C Oil Pressure Gauge Adapter M10 x 1 25 57001 1182 T5711828T Bearing Puller Stud 57001 1190 zd ST571190ST Valve Seat Cutter 45 22 57001 1205 7571205ST C Valve Seat Cutter 32 022 57001 1206 7571206ST C Valve Seat Cutter 67 5 622 57001 1207 7571207ST C Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 7571216ST C 1 14 GENERAL INFORMATION Special Tools and Sealants Valve Adjusting Screw Holder 57001 1217 7571217ST C a Bearing Remover Head 10 x 12 57001 1266 Front Fork Oil Seal Driver 57001 1219 T5712198T Jack 57001 1238 7571238ST C Spark Plug Wrench Hex 16 57001 1262 75712628ST C N Bearing Remover Shaft 9 57001 1265 7571265ST C 7571266ST C Fork Oil Level Gauge 57001 1290 7571290ST C Flywheel Holder 57001 1313 K ST5713138T Compression Gauge Adapter M10 x 1 0 57001 1317 7571317ST C Valve Seat Cutter Holder 4 5 57001 1330 7571330ST C Special Tools and Sealants GENERAL INFORMATION 1 15 Valve Guide Arbor 4 5 57001 1331 7T571331ST C Valve Guide Reamer 4 5 57001 1333
6. NC L___ yo LImg dois oulsug GPO5025BW5 C 14 6 ELECTRICAL SYSTEM Precautions There are a number of important precautions that need to follow during servicing electrical systems Learn and ob serve all the rules below OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine leads for signs of burning fraying etc Poor leads and bad connections will affect electrical system operation OMeasure coil and winding resistance when the part is cold at room temperature OColor Codes BK Black GY Gray R Red BL Blue LB Light blue SB Sky Blue BR Brown LG Light green W White CH Chooolate O Orange Y Yellow DG Dark green P Pink G Green PU Purple ELECTRICAL SYSTEM 14 7 Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc lf any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage lf the connector is corroded or dirty clean it ca
7. Steering Stem Bearing Lubrication e Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter Steering Stem Bearing Inspection e Using a high flash point solvent wipe the bearings clean of grease and dirt e Check the races and balls xIf the balls or races are worn or if either race is dented replace both races and all the balls for that bearing as a set Steering Stem Warp Inspection e Whenever the steering stem is removed or if the steering cannot be adjusted for smooth action check the steering stem for straightness xIf the steering stem shaft A is bent replace the steering stem 6N04010381 13 8 STEERING Handlebar Handlebar Removal e Remove Engine Stop Switch A Throttle Grip Assembly B Brake Lever Holder C Handlebar Clamps D Handlebar E Handlebar Installation e Apply adhesive cement to the inside of the left handlebar grip A GNO86050151 C e Mount the handlebar holders B so that the arrows C on the holder point at the front A OAlign the punch mark D on the handlebar to the mating surface of each holders of handlebar e Tighten the holder bolts front first and then the rear If the handlebar holder is correctly installed there will be no gap at the front and a gap E at the rear after tightening e Torque the handlebar holder bolts Torque Handlebar Holder Bolts 25 N m 2 5 kgf m 18 ft Ib e Apply grease t
8. Air Cleaner e Stuff a clean lint free towel into the carburetor so that no dirt is allowed to enter the carburetor e Wipe out the inside of the air cleaner housing A and the wire screen B with a clean damp towel CAUTION Check inside of the inlet tract and carburetor for dirt If dirt is present clean the intake tract and car buretor thoroughly You may also need to replace the element and seal the housing and inlet tract Element Installation e When installing the element coat the lip of the element with a thick layer of all purpose grease A to assure a complete seal against the air cleaner element base Also coat the base and wire screen where the lip of the element fits Element Cleaning and Inspection e Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter Oil Draining e Inspect the transparent plug A under the air cleaner housing B to see if any oil has run down from the air cleaner housing If there is any oil in the plug remove the plug and drain the oil 3 18 FUEL SYSTEM Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Shrouds Seat e Turn the fuel tap to t
9. 2 7 Brake Panel Lubrication 2 20 Idle Speed Adjustment 2 7 Suspension ee ee eee cece eeeee eee eeeeeeees 2 21 Air Cleaner Element Cleaning and Fork Oil Level Adjustment INSPOCUON aote 2 7 Simplity iris 2 21 Engine Top End 2 8 Front Fork Inner Tube Inspection 2 22 Valve Clearance Inspection 2 8 Rear Shock Absorber Inspection 2 22 Valve Clearance Adjustment 2 9 Swingarm Pivot Inspection 2 23 Spark Arrester Cleaning 2 9 Swingarm Rubber Bushing GIUtCDE er te t ere ee 2 10 Inspechon eenean eener 2 23 Clutch Adjustment 2 10 Steering EE 2 24 Engine Lubrication System 2 10 Steering Inspection 2 24 Oil Level Inspection 2 11 Steering Adjustment 2 24 Oil Charge estet 2 11 Steering Stem Bearing Oil Filter Element Replacement 2 12 Lubrication 2 25 Wheels Tires nssnnesnnnnnnnnere rrenen 2 12 Side Stand ssssssssssss 2 25 Wheels Inspection 2 12 Side Stand Inspection 2 25 Spoke Tightness Inspection 2 12 Electrical System 2 25 Wheel Bearing Inspection 2 13 Spark Plug Gap 2 25 Rim Runout Inspection 2 13 Spark Plug Cleaning and Final Drive 2 14 Insp
10. 5 18 CLUTCH External Shift Mechanism External Shift Mechanism Removal e Remove Clutch Cover see Clutch Cover Removal Primary Clutch see Clutch Removal Secondary Clutch see Clutch Removal Shift Pedal Clamp Bolt A Shift Pedal B e Move the shift mechanism arm out of its position on the end of the shift drum and pull out the shift shaft A e Remove the screw A and pivot bolt B e Remove the gear positioning plate C gear positioning lever D and its spring E as a set External Shift Mechanism Installation e Apply a non permanent locking agent to the lever pivot bolt e Install the gear positioning lever plate and spring OCheck that the return spring pin A is not loose OCheck that the return spring B and shift arm spring C are properly fitted on the mechanism Torque Shift Drum Positioning Lever Pivot Bolt 5 2 N m 0 53 kgf m 46 in Ib Shift Drum Position Plate Screw 5 2 N m 0 53 kgf m 46 in Ib e Apply high temperature grease to the oil seal lips e Install the shift shaft e Install the removed parts Torque Return Spring Pin 22 N m 2 2 kgf m 16 ft Ib CLUTCH 5 19 External Shift Mechanism e Install the shift pedal A to the shift shaft so that the pedal upper surface B is level with the footpeg upper surface C 61i16001BSi C ENGINE LUBRICATION SYSTEM 6 1 Engine Lubrication System Table of Contents leie e WAT eet Le Engine Oil e de M
11. 7571333ST C Hand Tester 57001 1394 7571394ST C Peak Voltage Adapter 57001 1415 ST5714158T C Flywheel Puller M28 x 1 0 57001 1471 ST5714718T C Clutch Holder 1 57001 1507 N 7571507ST C Clutch Holder 2 57001 1508 7571508ST C Oil Pressure Cap 57001 1651 cA ST571651ST C Pilot Screw Adjuster 57001 1665 E S Kawasaki Bond Silicone Sealant 56019 120 ST560120ST ST571665ST C 1 16 GENERAL INFORMATION Special Tools and Sealants Kawasaki Bond Liquid Gasket Black 92104 1003 up 7921003ST GENERAL INFORMATION 1 17 Cable Wire and Hose Routing Dummy Page 1 18 GENERAL INFORMATION Cable Wire and Hose Routing THROTTLE CABLE AND SWITCH LEAD ROUTING Viewed From Left GENERAL INFORMATION 1 19 Cable Wire and Hose Routing Throttle Cable Engine Stop Switch Lead Band Handlebar Frame Carburetor Clamp Air Vent Hose Regulator Rectifier 10 Igniter 11 Crankcase Breather Hose 12 Magneto Leads 13 Gear Position Switch Leads 14 Main Harness 15 Choke Knob 16 Ignition Coil 17 Ground Lead 18 Brake Cable 19 Bend the clamp as shown 20 Approx 15 mm 0 59 in 21 Connect the connector of magneto lead inside of the crankcase breather hose A KLX110 A3 Oc EENEG 1 20 GENERAL INFORMATION Cabl
12. 9 2 Specifications LR PM 9 4 rn EE 9 5 Front Wheel Removal mene mene mene nnne nnne nnnenrnnnnnnnrnn nnne 9 5 Front Wheel Installation arrei e ar a e e ea nnnm 9 5 Rear Wheel Rem OVa e a a E E ene nnn nn EAN Aa aA a aA e nnne nnns sensns 9 5 Rear Wheel Installation mtns i ia a a aea aienea ar ioed eendi esie 9 6 ER E ee EEN 9 7 RRC 9 8 Air Pressure Inspection Adjustment cccccceeeseeeeeeeeceeeeeeeeeeseeseeeeeeeeeeneeseeceeeeeeeeeens 9 8 Tires Inspection rico edi net re rer e e Pe LR PE REENEN EEN RR a EEN PERLE RD E SE ads 9 8 Tire Removal RR ei ee ser ER uds 9 9 Tire Installation ea t ee Drs hates HO RR E e Ie E RR Ee Rp he ENEE 9 10 PAD CANO et ccc E 9 11 Hub Bearing Removal EE 9 11 Hub Bearing INStallationisd EE 9 11 Bari INSP SCHON erre 9 11 Gill Ree EE 9 12 9 2 WHEELS TIRES Exploded View sg Cy x 6GJ020938W5 C WHEELS TIRES 9 3 Exploded View WL NOORWN Nipple Spoke Front Tire Rim Front Axle Rear Tire Rear Axle T1 T2 T3 T4 Apply high temperature grease Replacement Parts Apply soap and water solution or rubber lubricant 44 N m 4 5 kgf m 32 ft lb 64 N m 6 5 kgf m 47 ft lb 1 2 N m 0 12 kgf m 10 in Ib 25 N m 2 5 kgf m 18 ft lb 9 4 WHEELS TIRES Specifications Axle Runout 100 mm Rear 110 mm TIR 0 1 mm 0 004 in Item Standard Service Limit Wheels Rim Size Front 14 x 1 40 Rear 12
13. Magneto Cover Disassembly e Remove the magneto cover see Magneto Cover Re moval e Remove Screws A Clamps B Crankshaft Sensor Screws C Exciter Coil Screws D e Pull the wiring grommet e Remove the crankshaft sensor and stator as a set ELECTRICAL SYSTEM 14 9 Magneto Flywheel Magneto Cover Assembly e Run the magneto lead A as shown e Torque Plate Screws B 5 2 N m 0 53 kgf m 46 in Ib Exciter Coil Mounting Screws C 5 2 N m 0 53 kgf m 46 in Ib Crankshaft Sensor Mounting Screws D 2 9 N m 0 3 kgf m 26 in Ib Magneto Flywheel Removal e Remove the magneto cover see magneto Cover Re moval e Loosen the front footpeg assembly e Hold the flywheel steady with the flywheel holder A and remove the flywheel nut B Special Tool Flywheel Holder 57001 1313 e Thread the flywheel puller A and rotor puller B onto the flywheel C e Holding the flywheel puller turn the rotor puller until the flywheel is forced off the end of the crankshaft e Using the flywheel and rotor pullers remove the magneto flywheel Special Tools Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 Flywheel Puller M28 x 1 0 57001 1471 CAUTION If the rotor is difficult to remove turn the puller shaft using a wrench while tapping the head of the puller shaft with a hammer Do not attempt to strike the grab bar or the alternator rotor itself Striking the bar or the rotor can cause the bar to bend
14. Hub Bearing Removal e Remove the wheel see Front Rear Wheel Removal e To remove the grease seals pry out the grease seal using a screwdriver e Using the bearing remover shaft and bearing remover head remove the hub bearings A Special Tools Bearing Remover Shaft 9 57001 1265 B Bearing Remover Head 10 x12 57001 1266 C Hub Bearing Installation e Before installing the hub bearings blow any dirt or foreign particles out the hub with compressed air to prevent con tamination of the bearings e Replace the bearings with new ones e Install the bearings A using the bearing driver set B so that the marked or shield sides face out OPress in the bearings until they bottom out Special Tool Bearing Driver Set 57001 1129 NOTE OFor correct tire alignment the right bearing must be in stalled first rather than left bearing in both front and rear hubs e Replace the grease seal A with new ones e Apply high temperature grease to the grease seal lips e Press in the grease seal so that the seal surface is flush B with the end of the hole using the bearing driver set C Special Tool Bearing Driver Set 57001 1129 Bearing Inspection Since the hub bearings are made to extremely close tol erances the clearance cannot normally be measured CAUTION Do not remove any bearings for inspection If any bearings are removed they will need to be replaced with new ones e Turn each bearing in
15. JR Kawasaki KLX110 Motorcycle Service Manual Quick Reference Guide General Information Periodic Maintenance Fuel System Engine Top End Clutch Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Electrical System ech a 01 gt N OO OO Oo N IO Or B Oo No Troubleshooting This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Kawasaki KLX110 Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurrin
16. When inspecting the igniter observe the following to avoid damage to the igniter Do not disconnect the igniter while the engine is running This may damage the igniter Ignition Coil Primary Peak Voltage Check e Remove Radiator Shrouds Side Covers Seat e Disconnect the spark plug cap from mounting the spark plug A e Connect the new spark plug B to the spark plug cap then touch the engine with it NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug install to the cylinder head OThe correct value may not be obtained if disconnected 14 14 ELECTRICAL SYSTEM Ignition System e Connect the peak voltage adapter A between the termi nal of primary lead black and ground connection of the unit with the lead of the ignition coil B connected Special Tools Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Hand Tester 57001 1394 Connection Tester Positive Black Lead C Tester Negative Black Yellow Lead Ground D e Shift the gear to the neutral position then free the engine stop switch e Crank the engine by kicking the pedal several times to measure the peak voltage of the primary ignition coil Peak Voltage 100 V or above A WARNING Do not touch the metal portion of the probe in case of measu
17. 0 176 in Replace the valve if the stem is worn to less than the service limit Valve Guide Inside Diameter Inspection If a small bore gauge and micrometer are available mea sure the valve guide as follows e Measure the inside diameter A of the valve guide Since the guide wears unevenly measure the diameter at four place up and down the guide Valve Guide Inside Diameter Inlet and Exhaust Standard 4 500 4 512 mm 0 1772 0 1776 in Service Limit 4 55 mm 0 179 in lIf any measurement exceeds the service limit replace the valve guide GEi5011181 4 26 ENGINE TOP END Valve Valve Guide Valve to Guide Clearance Measurement If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the valve guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure valve valve guide clearance Valve Valve Guide Clearance Woble Method Standard Exhaust 0 06 0 11 mm 0 002 0 004 in Inlet 0 02 0 07 mm 0 0008 0 0028 in Service Limit Exhaust 0 19 mm 0 007 in Inlet 0 12 mm 0 0047 in e Repeat the measurement in a direction at a right angle to the first x If the reading exceeds the service limit replace the guide
18. 0 53 kgf m 46 in Ib e Insert the lower chain guide A securely as shown e Install the other removed parts Camshaft Chain Guide Wear e Visually inspect the rubber on the guides If the rubber is damaged or is missing places replace the guide 4 14 ENGINE TOP END Rocker Arm Rocker Arm Shaft Rocker Arm Removal e Remove Left Shroud Camshaft Sprocket Cover Camshaft Chain Tensioner Camshaft Sprocket Bolts A Camshaft Sprocket B Valve Adjusting Cover Bolts A Valve Adjusting Covers B Rocker Arm Shaft Stopper Screws C Rocker Arm Shaft Stopper D e While holding the rocker arm A with hand pull out the rocker arm shaft B and take off the rocker arms OMark and record the rocker arm locations so that the rocker arm can be reinstalled in their original positions Rocker Arm Installation e Clean the rocker arms and rocker arm shafts with a high flash point solvent e Apply a clean engine oil to the rocker arm shaft outside and rocker arm cam parts e Turn the camshaft so that the cam lobes point downward e Install the each rocker arm shaft running it through each rocker arm e Install the rocker arm shaft stopper A so that the each rocker arm shaft protrusion B face to face e Tighten the rocker arm shaft stopper screws Torque Rocker Arm Shaft Stopper Screws 5 2 N m 0 53 kgf m 46 in Ib e Install the camshaft sprocket OCheck and adjust the valve clearance CAUTION When ins
19. 1 2 US gt when engine is completely dry GENERAL INFORMATION 1 7 General Specifications Items KLX110 A1 Drive Train Primary Reduction System Type Gear centrifugal Reduction Ratio 3 048 64 21 KLX110 A1 3 409 75 22 KLX110 A2 Clutch Type Centrifugal amp wet multi disc Transmission Type 3 speed constant mesh return shift Gear Ratios 1st 3 273 36 11 KLX110 A1 3 000 36 12 KLX110 A2 2nd 1 938 31 16 3rd 1 350 27 20 Final Drive System Type Chain drive Reduction Ratio 2 642 37 14 KLX110 A1 2 357 33 14 KLX110 A2 Overall Drive Ratio 10 873 Q Top gear KLX110 A1 10 848 Top gear KLX110 A2 Frame Type Backbone Caster Rake Angle 25 5 Trail 54 mm 2 1 in Front Tire Type C803 Size 2 50 14 4PR 2 50 14 M C 4PR KLX110 A2 Rear Tire Type C803 Size 3 00 12 4PR 3 00 12 M C APR KLX110 A2 Rim Size Front 14 x 1 40 Rear 12 x 1 60 Front Suspension Type Telescopic fork Wheel Travel 110 mm 4 3 in Rear Suspension Type Swingarm Wheel Travel 107 mm 4 2 in Brake Type Front Drum Rear Drum Specifications are subject to change without notice and may not apply to every country 1 8 GENERAL INFORMATION Torque and Locking Agent The following tables lists the tightening torque for the major fasteners requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean
20. Front Fork Fork Oil Level Check Simplify e Refer to the Fork Oil Level Adjustment Simplify in the Periodic Maintenance chapter Oil Change Oil Level Adjustment each fork leg e Remove the front fork see this chapter e Remove the following Top Plug Fork Spring A WARNING The top plugs are under extreme spring force Use care when removing the top plugs Wear eye and face protection e Hold the fork tube upside down over a clean container and pump it to drain the oil e Fill the front fork to the top with specified oil Recommended Oil SHOWA SS 8 or equivalent Front Fork Oil Capacity completely dry 163 2 5 mL 5 51 0 08 US oz e Adjust the oil level OWith the fork fully compressed put the oil level gauge A and the stopper B and inspect the distance from the top A of the inner tube to the oil Special Tool Fork Oil Level Gauge 57001 1290 BY T n Lj I Y Oy Oil Level fully compressed without spring S Standard 89 2 mm 3 50 0 08 in NOS XIf no oil is drawn out there is insufficient oil in the fork tube Pour in enough oil then drawn out the excess oil e Install the parts removed see Front Fork Assembly 6M04011282 C 12 8 SUSPENSION Front Fork Front Fork Removal e Remove the front brake cable clamp A e Remove the front brake cable B e Remove the front wheel see Wheels Tires chapter e Remove the number plate e Loosen the upper and lower fork
21. L Apply a non permanent locking agent to the threads S Tighten the fasteners following the specified sequence Engine Top End Rocker Arm Shaft Stopper Screws Valve Adjusting Screw Locknuts Camshaft Sprocket Bolt Cylinder Head Nuts Cylinder Head Bolts Spark Plug Chain Tensioner Mounting Bolts Tensioner Cap Bolt Camshaft Sprocket Cover Bolts Camshaft Chain Guide Bolt Camshaft Chain Holder Screws Valve Adjusting Cap Bolts Spark Arrester Mounting Bolts Clutch Clutch Cover Screws KLX110 A1 A7F Clutch Cover Bolts KLX110A8F Clutch Cover Plate Screws Clutch Hub Nut Primary Clutch Hub Nut Secondary Clutch Spring Bolts KLX110 A1 A2 Clutch Spring Bolts KLX110 A3 Clutch Adjusting Screw Locknut Shift Drum Position Plate Screw Shift Drum Positioning Lever Pivot Bolt Kick Guide Screw Return Spring Pin Engine Lubrication System Oil Pipe Banjo Bolts Oil Pipe Clamp Screw Oil Pump Mounting Screw Oil Filter Cap Bolts Engine Oil Drain Plug Engine Removal Installation Engine Mounting Nuts Side Stand Mounting Nut 5 2 8 8 12 22 12 13 5 2 5 2 5 2 5 2 5 2 5 2 8 8 5 2 8 8 2 9 72 72 3 4 5 0 19 5 2 5 2 5 2 22 15 5 2 5 2 5 2 29 54 23 0 53 0 9 1 2 2 2 1 2 1 3 0 53 0 53 0 53 0 53 0 53 0 53 0 9 0 53 0 9 0 3 7 3 7 3 0 35 0 51 1 9 0 53 0 53 0 53 2 2 1 5 0 53 0 53 0 53 3 0 5 5 2 3 Torque Fast R k astener Nm kaim ftlb emarks Fuel Syste
22. NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide GE15011481 C ENGINE TOP END 4 27 Valve Valve Guide Valve Seat Repair Tool Purpose Tool Purpose Too small 45 Grind 45 Cutter increase O D of Seat area to spec Tool Purpose Tool Purpose Too narrow 45 Grind Tool Purpose 45 Cutter increase width of seat area beyond spec to increase O D Machinist s dye on seat 45 Grind Measure Seating Area O D Measure Seating Width 45 Cutter make seating area smooth and round Vernier Caliper check seat O D against spec Machinist s dye on seat 32 Grind 32 Cutter reduce O D of Seat area to spec Tool Purpose Vernier Caliper check seat width against spec Results Machinist s dye on seat 60 or 67 5 Grind Tool 60 or 67 5 Cutter reduce seat width to spec Purpose Lap Valve Tool Purpose valve lapper grinding compound perfectly match valve FINISHED and seat area check valve head for damage GEI5136B F 4 28 ENGINE TOP END Cylinder Piston Cylinder Removal e Remove the cylinder head e Take out the cylinder block with lower camshaft chain guide and remove the gasket There are knock pins on the cylinder base e Wrap a clean cloth A around the base of the piston so that no parts o
23. The surface of the valve must not be excessively worn x lf the throttle valve does not move smoothly or if it is very loose in carburetor body replace the carburetor If the spring tension is weak replace it e Turn the starter cable bracket to check that the starter butterfly valve A move smoothly and return with spring tension x lf the starter butterfly valve do not move smoothly replace the carburetor NOTE ODo not remove the air screw from the carburetor or change the air screw setting or you will lose the best setting e Disassemble the carburetor e Clean the carburetor e Check that the O rings on the float bowl drain plug and the intake pipe are in good condition xIf any of the O rings are not in good condition replace them e Remove the float valve needle e Check the float valve needle A If the needle is worn B as shown in the figure replace the valve needle e Push the rod C in the valve needle and then release it If the rod does not spring out replace the valve needle GCO6024BS1 C FUEL SYSTEM 3 15 Carburetor e Check the main jet A needle jet holder B and pilot jet C for any damage lf they are damaged replace them with new ones e Remove the throttle valve A and jet needle e Inspect the outside of the throttle valve for scratches and abnormal wear xIf the valve is badly scratched or worn replace it e Inspect the inside of the car
24. Throttle Cable Throttle Grip Carburetor Cap Spring Retainer Circlip Jet Needle Throttle Valve Choke Cable ldle Adjusting Screw Spring Air Screw Pilot Jet Float Valve Needle Main Jet Float Apply grease Apply oil 3 4 FUEL SYSTEM Exploded View FUEL SYSTEM 3 5 Exploded View Fuel Tank Cap Fuel Tank Fuel Tap Air Cleaner Housing Element Fuel Tank Cover KLX110A8F United States and Canada Models Apply adhesive Apply grease High quality foam air filter oil 4 9 N m 0 5 kgf m 43 in Ib KLX110 A3 KLX110A8F United States and Canada Models gt ODDAAARWNR gt a 3 6 FUEL SYSTEM Specifications Item Standard Service Limit Throttle Grip and Cable Throttle Grip Free Play Carburetor Make Type Main Jet Main Air Jet Jet Needle Throttle Valve Cutaway Pilot Jet Air Screw Idle Speed Service Fuel Level Float Height Air Cleaner Air Cleaner Element Oil 2 3 mm 0 08 0 12 in KEIHIN PB18 80 180 NCFA 3 0 38 38 1 1 4 turns out 1 250 1 350 r min rpm 3 0 1 mm 0 12 0 04 in below the bottom edge of carburetor body 10 7 2 mm 0 42 0 08 in High quality foam air filter oil Special Tool Fuel Level Gauge 57001 1017 FUEL SYSTEM 3 7 Throttle Grip and Cable Free Play Inspection e Refer to the Throttle Grip Free Play Inspe
25. mL x 0 02816 oz imp mL x 0 06102 cu in Units of Speed km h x 0 6214 mph Units of Force N x 0 1020 kg N 02248 Ib Units of Power a 9 807 N kW x 1 360 PS id SE S kW x 1 341 HP l PS x 0 7355 kW PS x 0 9863 HP Units of Temperature 9 C 40 5 F 40 5 PUPA NE mo dene 9 F F 4 32 68 104 176 212 248 284 40 20 0 20 i40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 40 207 o mi mi 6 a 40 dE 40 160 17 8 44 26 7 48 9 714 93 3 116 138 SC C PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart 2 2 Sprocket Wear Inspection 2 16 Specifications cccccceceeeeeeeeeeeeeeees 2 3 Chain Slipper Wear Inspection 2 17 Periodic Maintenance Procedures 2 5 Brakes sss 2 17 Fuel Gvsiem 2 5 Brake Lever Brake Pedal Free Fuel Hose and Connections Play Inspection 2 17 Inspechon ce eeeeeeeeeeeeeeeee 2 5 Front Brake Lever Free Play Fuel Tap Inspection 2 5 Adjustment uuuuuss 2 18 Fuel Tap Cleaning 2 5 Brake Pedal Free Play Throttle Grip Free Play Inspection 2 6 Adjustment uuuusse 2 18 Throttle Grip Free Play Brake Lining Wear Inspection 2 18 Adjustment 2 6 Cam Lever Angle Adjustment 2 20 Idle Speed Inspection
26. of the engine and air cleaner FUEL SYSTEM 3 11 Carburetor e Unscrew the cap A and pull out the throttle cable lower end with the throttle valve spring and jet needle as a set A WARNING If dirt or dust allowed to pass through into the car buretor the throttle may become stuck possibly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur If the throttle valve is not removed from the cable wrap clean cloths around the throttle valve to avoid damaging to it Carburetor Installation e Installation is the reverse of removal e After installing the carburetor perform the following OCheck fuel leakage from the carburetor A WARNING Fuel spilled from the carburetor is hazardous OAdjust the following Idle Speed Throttle Grip Free Play Carburetor Cleaning A WARNING Clean the carburetor in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of high flammable liquids do not use gasoline or low flash point solvents to clean the carburetor 3 12 FUEL SYSTEM Carburetor CAUTION Do not use compressed air on an assembled carbu retor or the float may be deformed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before c
27. B faces downward e Tighten the brake pedal mounting bolt Torque Brake Pedal Mounting Bolt 8 8 N m 0 9 kgf m 78 in Ib e Adjust the brake pedal free play GNI P GL12010BS1 C BRAKES 11 9 Brake Panel and Drum Brake Lining Wear Inspection e Refer to the Brake Lining Wear Inspection in the Periodic Maintenance chapter Cam Lever Angle Adjustment e Refer to the Cam Lever Angle Adjustment in the Periodic Maintenance chapter Brake Panel Removal e Remove the front or rear wheel see Wheels Tires chap ter e Separate the brake panel A from the wheel Brake Panel Installation e Installation is the reverse of removal e Adjust the brake lever and pedal free play Brake Panel Disassembly CAUTION Do not depress the brake pedal deeply in order to separate the brake rod from the brake cam lever joint this may extend the brake spring beyond its allowable spring extension Rotate the rear brake panel clockwise as far as it will go with the brake rod inserted into the brake cam lever joint then depress the brake pedal lightly the brake rod will be separated from the brake cam lever joint e Mark the position A of the cam lever before removal so that it can be installed later in the same position e Remove the brake cam lever 11 10 BRAKES Brake Panel and Drum e Remove the wheel and separate the brake panel from the wheel e Using a clean cloth around the linings to preve
28. E oed hada den ed ede 5 16 Kickstarter Assembly ctc pet eda xao reed pen Fem una E Me EROR LO RR DR RA En Pes REUS 5 16 Kickstarter Irispection ec cet Cete dte eret rete e pe ERR ee ETE d e DE e EET MR ERR EA RT RS 5 17 External Shift Mechanisme 5 18 External Shift Mechanism Hemoval emen een 5 18 External Shift Mechanism Installation eeeseeeen mmn 5 18 5 2 CLUTCH Exploded View KLX110 A1 GF021358W5 C CLUTCH 5 3 Exploded View KLX110 A1 OONOARWN A Clutch Cover Primary Clutch Shoe Linings Outer Race One way Clutch Primary Clutch Housing Clutch Spring Plate Clutch Spring Secondary Clutch Hub Friction Plate Steel Plate Clutch Wheel Clutch Housing Clutch Adjusting Screw Locknut Release Shaft Adjusting Screw Release Plate Release Ball Assembly Release Cam Gear Positioning Lever Gear Positioning Plate Shift Shaft Shift Pedal Shift Drum Cam Shift Drum Kick Pedal Return Spring Kick Shaft Rachet Ball Bearing Shift Pedal Bolt 2 9 N m 0 3 kgf m 26 in Ib 5 2 Nem 0 53 kgf m 46 in Ib 3 4 N m 0 35 kgf m 30 in lb 19 N m 1 9 kgf m 14 ft lb 72 N m 7 3 kgf m 53 ft lb 22 N m 2 2 kgf m 16 ft lb Apply engine oil Apply grease Apply a non permanent locking agent Apply molybdenum disulfide grease Follow the specific tightening sequence 5 4 CL
29. Float Removal e Remove the carburetor and disassembly the float bowl e Drive out the pivot pin A and remove the float B and float valve as a set Fuel System Cleanliness Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Make sure the engine is cold before working Wipe any fuel off the engine before starting it e Using a screwdriver turn out the drain plug A a few turns and drain the carburetor to a suitable container and check to see if water or dirt come out If any water or dirt appears during the above inspection clean the fuel system e Tighten the drain plug securely Carburetor Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position e Remove Right Shroud A Tubes carburetor side B Choke Cable Lower End C Intake Pipe Bolts D e Loosen the clamp screw E e Remove the carburetor e Stuff pieces of lint free clean cloths into the carburetor holder and the air cleaner intake duct to keep the dirt out
30. Ground Disconnect the ground wire from the battery before performing any disassembly operations on the motorcycle This prevents the engine from accidentally turning over while work is being carried out sparks from being generated while disconnecting the cables from electrical parts as well as damage to the electrical parts themselves For reinstallation first connect the positive cable to the positive terminal of the battery Installation Assembly Generally installation or assembly is the reverse of removal or disassembly However if instal lation or assembly sequence is given in this Service Manual follow it Note parts locations and cable wire and hose routing during removal or disassembly so they can be installed or assem bled in the same way It is preferable to mark and record the locations and routing whenever possible Tightening Sequence When installing bolts nuts or screws for which a tightening sequence is given in this Service Manual make sure to follow the sequence When installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit thus ensuring that the part has been installed in its proper location Then tighten them to the specified torque in the tightening sequence and method indicated If tightening sequence instructions are not given tighten them evenly in a cross pattern Conversely to remove a part first loosen all the bolts nuts or screws that are reta
31. Mainte nance chapter 10 6 FINAL DRIVE Sprockets Coupling Engine Sprocket Removal e Remove Bolts A Engine Sprocket Cover B e Remove the circlip A and take off the sprocket B with drive chain C e Pull the collar and O ring off the output shaft Special Tool Outside Circlip Pliers 57001 144 Engine Sprocket Installation e Apply high temperature grease to the O ring e Install the O ring A and collar B to the output shaft OThe chamfered side C of the collar must be faced in e Install the engine sprocket A and drive chain together e Fitthe circlip B with the round side facing C in as shown e Adjust the drive chain slack if necessary e Put the chain tension guide A on the engine sprocket cover B and install the sprocket cover GK05010BS1 C Q7 P FINAL DRIVE 10 7 Sprockets Coupling Rear Sprocket Removal e Remove the rear wheel see Wheels Tires chapter e Unscrew the rear sprocket bolts A and remove the rear sprocket B Rear Sprocket Installation e Install the rear sprocket facing the tooth number making A outward e Tighten the rear sprocket nuts Torque Rear Sprocket Nut 34 N m 3 5 kgf m 25 ft Ib e Install the rear wheel Sprocket Wear Inspection e Refer to the Sprocket Wear Inspection in the Periodic Maintenance chapter Rear Sprocket Warp Inspection e Raise the rear wheel so that it will turn freely and set a
32. Rear Shock Absorber Mounting Nut Upper 39 N m 4 0 kgf m 29 ft Ib Lower 39 N m 4 0 kgf m 29 ft lb Rear Shock Absorber Inspection e Refer to the Rear Shock Absorber Inspection in the Peri odic Maintenance chapter Rear Shock Absorber Scrapping A WARNING Since the rear shock absorber contains nitrogen gas do not incinerate the rear shock absorber with out first releasing the gas or it may explode Before a rear shock absorber is scrapped drill a hole at the point A shown to release the nitrogen gas completely Wear safety glasses when drilling the hole as the gas may blow out bits of drilled metal when the hole opens GM05040BS1 C GMO5098BS1 C SUSPENSION 12 13 Swingarm Swingarm Removal e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Remove Rear Wheel see Wheels Tires chapter Left Side Cover see Frame chapter Drive Chain Rear Shock Absorber Lower End e Remove the pivot shaft nut and pull out the pivot shaft A e Pull back the swingarm B and take off the swingarm e Remove Torque Link A Chain Guide B Chain Slipper C Chain Cover D e To remove the rubber bushing E at the pivot tap out the bushing with a suitable tool Swingarm Installation e Installation is the reverse of removal e Press in the rubber bushings A as shown e Tighten the pivot shaft nut after installed the rear
33. T I KURS SUSPENSION 12 3 Exploded View OONOARWN A Circlip Top Plug O ring Fork Spring Cylinder Unit Inner Tube Dust Seal Retaining Ring Oil Seal Outer Tube Gasket Allen Bolt Steering Stem Head Steering Stem 20 N m 2 0 kgfm 15 ft lb 29 N m 3 0 kgf m 22 ft lb Apply a non permanent looking agent to the threads Canada Model 12 4 SUSPENSION Exploded View GMO2177BW5 C SUSPENSION 12 5 Exploded View E EO A Pivot Shaft Swingarm Rear Shock Absober Rubber Bushing Flap Note the installing direction T1 T2 T3 Apply grease Replacement Parts CA 78 N m 8 0 kgf m 58 ft lb 25 N m 2 5 kgf m 18 ft lb 39 N m 4 0 kgf m 29 ft lb Canada Model 12 6 SUSPENSION Specifications Item Standard Service Limit Front Fork Oil Viscosity Oil Capacity Completely Dry Oil Level Fully Compressed Spring Removed Fork Spring Free Length SHOWA SS 8 or equivalent 163 2 5 mL 5 51 0 08 US oz 89 2 mm 3 50 0 08 in from top of inner tube 439 7 mm 17 31 in Special Tools Fork Cylinder Holder Handle 57001 183 Fork Cylinder Holder Adapter 57001 1011 Oil Seal amp Bearing Remover 57001 1058 Fork Oil Seal Driver 57001 1219 Jack 57001 1238 Fork Oil Level Gauge 57001 1290 430 9 mm 16 96 in SUSPENSION 12 7
34. and score the cylinder wall Cylinder Inside Diameter Measurement e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment at each of the 3 locations total of 6 measurements shown in the figure lf any of the cylinder inside diameter measurements ex ceeds the service limit the cylinder will have to bored to oversize and then honed Cylinder Inside Diameter Standard 52 997 53 009 mm 2 0865 2 087 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 53 10 mm 2 091 in or 0 05 mm 0 0020 in difference between any two measurements 10 mm 0 3937 in A 60 mm 2 3622 in B 20 mm 0 7874 in C Piston Outside Diameter Measurement e Measure the outside diameter A of the piston 7 8 mm B up from the bottom of the piston at a right angle to the direction of the piston pin Piston Outside Diameter Standard 52 981 52 993 mm 2 0859 2 0863 in Service Limit 52 83 mm 2 080 in NOTE OAbnormal wear such as a marked diagonal pattern across the piston skirt may mean a bent connecting rod or crankshaft GE16011581 C GE16010181 C ENGINE TOP END 4 31 Cylinder Piston Piston Cylinder Clearance Inspection The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measure ments and then computing
35. by measuring the diameter at the base of the cylinder 4 32 ENGINE TOP END Cylinder Piston Piston Ring End Gap Inspection e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Top 0 15 0 30 mm 0 0059 0 0118 in Second 0 30 0 45 mm 0 0118 0 0177 in Cil 0 10 0 60 mm 0 0039 0 0236 in Service Limit Top 0 6 mm 0 024 in Second 0 8 mm 0 032 in Oil 0 9 mm 0 035 in Piston Ring Piston Ring Groove Inspection e Visually inspects the piston rings and the piston ring grooves If the rings are worn unevenly or damaged they must be replaced x If the piston ring grooves are worn unevenly or damaged the piston must be replaced and fitted with new rings e Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to the groove sur faces If not the piston must be replaced e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Top 0 02 0 06 mm 0 0008 0 0024 in Second 0 01 0 05 mm 0 0004 0 0020 in Service Limit Top 0 16 mm 0 0063 in Second 0 15 mm 0 059 in Piston Ring Thickness
36. clamp bolts A e With a twisting motion work the fork leg down and out Front Fork Installation e f the fork leg was disassembled check the fork oil level e Install the fork aligning the top end A of the inner tube with the upper surface B of the steering stem head e Route the cables and hose according to the Cable Wire and Hose Routing section in the General Information chapter e Install the front wheel see Wheels Tires chapter e Tighten the following Torque Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft Ib Front Fork Clamp Bolts Lower 29 N m 3 0 kgf m 22 ft Ib e Check the front brake operation after installation Front Fork Disassembly each fork e Remove the front fork see Front Fork Removal e Remove the top plug and the fork spring e Remove the dust seal e Drain the fork oil with the fork upside down see Fork Oil Change e Hold the outer tube A in a vise e Stop the cylinder B from turning by using the front fork cylinder holder Special Tools Fork Cylinder Holder Handle 57001 183 C Fork Cylinder Holder Adapter 57001 1011 D Unscrew the Allen bolt E then take the bolt and gasket out of the bottom of the outer tube SUSPENSION 12 9 Front Fork e Remove the cylinder unit A and spring B from the fork e Separate the inner tube A from the outer tube B by pulling them out e Take the cylinder base A out of the outer tub
37. cover 1M07000BS1 HJ07002BSi C 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Stretch the chain taut by hanging a 98 N 10 kg 20 Ib weight A on the chain e Measure the length of 20 links B on the straight part C of the chain from pin center of the 1st pin to pin center of the 21st pin Since the chain may wear unevenly take measurements at several places lf any measurements exceeds the service limit replace the chain Also replace the engine and rear sprockets when the drive chain is replaced A WARNING If the drive chain wear exceeds the service limit re place the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control For safety use only the standard chain Drive Chain 20 Link Length Standard 254 0 254 6 mm 10 00 10 02 in Service Limit 259 mm 10 20 in Chain Lubrication The chain should be lubricated with a lubricant which will both prevent its exterior from rusting and also absorb shock and reduce friction in the interior of the chain An effective good quality lubricant specially formulated for chains is best for regular chain lubrication If a special lubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longe
38. dial gauge A against the rear sprocket B near the teeth as shown in the figure e Rotate C the rear wheel and read the dial gauge The difference between the highest and lowest dial gauge readings is the amount of runout warp If the runout exceeds the service limit replace the rear sprocket GK050111S1 Rear Sprocket Warp Standard Less than 0 4 mm 0 016 in Service Limit 0 5 mm 0 020 in Coupling Bearing Removal e Pull out the coupling collar from the left e Remove the oil seal e Using the bearing driver set A or some other suitable tool remove the bearing B by tapping from the drum side Special Tool Bearing Driver Set 57001 1129 GK05012BSi C 10 8 FINAL DRIVE Sprockets Coupling Coupling Bearing Installation e Inspect the bearing and replace it if necessary e Press in the bearing so that the marked side faces out until it is bottomed e Replace the oil seal with a new one e Press in the oil seal so that the seal surface is flush with the end of the hole OApply high temperature grease to the oil seal lips Special Tool Bearing Driver Set 57001 1129 Coupling Bearing Inspection and Lubrication Since the coupling bearing is made to extremely close tolerances the clearance cannot normally be measured e Wash the bearing with a high flash point solvent dry it do not spin it while it is dry and oil it Spin it by hand to check its condition lf it i
39. e Press the bearings until it bottoms out e Press the camshaft chain sprocket A oil pump gear B until it bottoms out on to the left and right flywheels as shown e Align bottom of sprocket tooth with opposit direction C of crank pin D G105011BS1 C G105063BS1 C CRANKSHAFT TRANSMISSION 8 9 Crankshaft Connecting Rod e Apply engine oil to the big end bearing e Press the crank halves onto the crankpin noting the crankpin direction until connecting rod side clearance is within specification as shown Side Clearance A 0 1 0 2 mm 0 004 0 008 in Crankpin Depth B 0 8 1 2 mm 0 032 0 047 in e Check the following items after the crankshaft assembly Connecting Rod Radial Clearance Connecting Rod Side Clearance Crankshaft Runout Connecting Rod Big End Seizure Inspection xin the case of serious seizure with damaged flywheels the crankshaft must be replaced xin the case of less serious damage disassemble the crankshaft and replace the crankpin needle bearing side washers and connecting rod Connecting Rod Big End Radial Clearance Inspection e Setthe crankshaft in flywheel alignment jig or on V blocks and place a dial gauge A against the big end of the con necting rod e Push B the connecting rod first towards the gauge and then in the opposite direction The difference between the two gauge readings is the radial clearance lf the radial clearance exceeds the service lim
40. iMOI P Piston Piston Pin Connecting Rod Inspection e Measure the inside diameter of both piston pin holes in the piston Piston Pin Hole Inside Diameter A Standard 13 001 13 007 mm 0 5119 0 5121 in Service Limit 13 07 mm 0 5146 in XIf either piston pin hole inside diameter exceeds the ser vice limit replace the piston e Measure the diameter of the piston pin Piston Pin Diameter B Standard 12 995 13 000 mm 0 5116 0 5118 in Service Limit 12 96 mm 0 5102 in xIf the piston pin diameter is less than the service limit at any point replace the piston pin 4 34 ENGINE TOP END Cylinder Piston Measure the inside diameter A of the connecting rod small end Connecting Rod Small End Inside Diameter Standard 13 003 13 014 mm 0 5119 0 5124 in Service limit 13 05 mm 0 5138 in If the inside diameter exceeds the service limit replace the connecting rod A GE16012781 ENGINE TOP END 4 35 Muffler Muffler Removal e Unscrew the muffler mounting bolt A e Remove the exhaust pipe holder nuts A e Pull out the muffler mounting bolt and remove the muffler assembly Muffler Installation e Check the gasket and replace it if damaged e After tightening the mounting bolt and nuts securely thor oughly warm up the engine wait until the engine cools down and tighten all mounting bolt and nuts Spark Arrester Cleaning e Refer to the Spark
41. inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Before ServIGIHg EE 1 2 Model Identtcatton eene nenne enn nen nenne nennen rennen nenne 1 5 General Specifications n enne nnn nnn nnne rsen nennen nnns sens 1 6 Torque ANG LOCKING AGEING ERES 1 8 Special Tools and Sealants ciii na a a a a E a a 1 11 Cable Wire and Hose Routing mener mener 1 17 Unit Conversion Table ern ete een et et ee eei a EE LITERE 1 22 1 2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle careful reading of the applicable section is recommended to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed descrip tions have been included wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is also required for successful work Especially note the following 1 Dirt Before removal and disassembly clean the motorcycle Any dirt entering the engine will shorten the life of the motorcycle For the same reason before installing a new part clean off any dust or metal filings 2 Battery
42. lightly by hand Brake Pedal Free Play Standard 20 30 mm 0 8 1 2 in If the pedal has improper play adjust it e Operate the pedal a few times to see that it returns to its rest position immediately upon release e Rotate the rear wheel to check for brake drag e Check braking effectiveness xIf there is any doubt as to the conditions of the brake check the brake parts for wear or damage 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Front Brake Lever Free Play Adjustment e Loosen the locknut at the front brake lever screw the ad juster fully in and tighten the locknut e Loose the nuts A at the lower end of the brake cable e Turn the nuts at the lower end of the front brake cable so that the brake lever has the correct amount of play and tighten the nuts e If sufficient adjustment can not be made with the adjuster B complate the adjustment with the adjuster at the brake lever and then tighten the locknut e Check for brake drag e Check braking effectiveness e Slide the dust cover back into place NOTE OFor minor corrections use the adjuster at the front brake lever Olf the brake lever adjustment cannot be made with the adjuster at the brake lever or the brake panel move the front brake cam lever to a new position on the brake camshaft Brake Pedal Free Play Adjustment e Turn the adjusting nut A at the brake cam lever so that the pedal has proper play Brake Lining W
43. linings are damaged or the surface cannot be re stored by sanding and cleaning replace the shoes as a set e Measure the thickness of the brake linings at a few point xIf the thickness A at any point is less than the service limit replace both shoes as a set 6Li12007BSi Brake Shoe Lining Thickness Standard Front 2 10 3 00 mm 0 08 0 12 in Rear 3 85 4 15 mm 0 152 0 163 in Service Limit Front 1 2 mm 0 05 in Rear 2 0 mm 0 08 in Camshaft Wear Inspection e Measure the shaft diameter A If itis worn down to less than the service limit replace the shaft e Measure the inside diameter B of the camshaft hole If itis worn past the service limit replace the brake panel Camshaft Diameter Standard Front 11 957 11 984 mm 0 471 0 472 in 129012 P Rear 14 957 14 984 mm 0 589 0 590 in Service Limit Front 11 88 mm 0 468 in Rear 14 88 mm 0 586 in Camshaft Hole Inside Diameter Standard Front 12 000 12 027 mm 0 472 0 474 in Rear 15 000 15 027 mm 0 591 0 592 in Service Limit Front 12 15 mm 0 478 in Rear 15 15 mm 0 596 in 11 12 BRAKES Brake Panel and Drum Brake Shoe Springs Inspection e Visually inspect the brake shoe springs for breaks or dis tortion If the springs are damaged in any way replace them e Measure A the free length of the brake shoe springs x If either is stretched beyond the service limit replace both s
44. m 46 in Ib 8 8 N m 0 9 kgf m 78 in Ib Apply engine oil 4 6 ENGINE TOP END Specifications Cylinder Head Cylinder Compression Cylinder Head Warp Usable range 865 1320 kPa 8 8 13 5 kgf cm 125 192 psi 5 kicks Item Standard Service Limit Camshaft Camshaft Cam height Exhaust 29 021 mm 29 201 mm 28 92 mm 1 1426 1 1496 in 1 139 in Inlet 28 984 mm 29 164 mm 28 88 mm 1 1411 1 1482 in 1 137 in Rocker Arms Shaft rocker Arm Inside Diameter 10 000 10 015 mm 10 05 mm 0 3937 0 3943 in 0 396 in Rocker Arm Shaft 9 980 9 995 mm 9 95 mm Diameter 0 3929 0 3935 in 0 392 in 0 05 mm 0 002 in Valve Valve Clearance Exhaust Inlet Valve Head Thickness Exhaust Inlet Valve Stem Bend Valve Stem Diameter Exhaust Inlet Valve Guide Inside Diameter Exhaust Inlet Valve valve Guide Clearance Wobble Method Exhaust Inlet Valve Seat Cutting Angle Valve Seat Surface Width Exhaust Inlet Outside Diameter Exhaust Inlet Valve Spring Free Length 0 04 0 08 mm 0 0016 0 00371 in 0 04 0 08 mm 0 0016 0 00371 in 1 15 1 45 mm 0 0453 0 0571 in 0 85 1 15 mm 0 0335 0 0453 in TIR 0 01 mm 0 0004 in or less 4 462 4 472 mm 0 1757 0 1761 in 4 475 4 490 mm 0 1762 0 1768 in 4 500 4 512 mm 0 1772 0 1776 in 4 500 4 512 mm 0 1772 0 1776 in 0 06 0 11 mm 0 002 0 004 in 0 02 0 07 mm 0
45. or the magnets to lose their magnetism Magneto Flywheel Installation e Using a high flash point solvent clean off the any oil or dirt that may be on the crankshaft tapered portion A and flywheel tapered portion B e Fit the woodruff key C securely in the slot of the crank shaft before installing the flywheel on the crankshaft e Tighten the flywheel nut while holding the flywheel steadily with the flywheel holder Torque Magneto Flywheel Nut 42 N m 4 3 kgf m 31 ft Ib KLX110 A1 M10 54 N m 5 5 kgf m 40 ft Ib KLX110 A2 M12 Special Tool Flywheel Holder 57001 1313 6P09072BSi C 14 10 ELECTRICAL SYSTEM Magneto Flywheel Magneto Flywheels Inspection e There are three types of magneto problems short open wire burned out or loss in flywheel magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in flywheel magnetism which may be caused by dropping or hitting the flywheel by leaving it near an electromagnetic field or just by ag ing will result in low output Inspect the coils and flywheel see Ignition System Regulator Rectifier Inspection e Remove Right Shroud Regulator Rectifier A e Disconnect the connector B from the regulator rectifier e Set the hand tester special tool to the x 1 kQ range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 If the rea
46. replaced as a set e Chip off the old gasket from the mating surfaces of the crankcase halves e Using compressed air blow out the oil passages A in the crankcase halves and the crankshaft e With a high flash point solvent clean off the mating sur faces of the crankcase halves and wipe dry 8 6 CRANKSHAFT TRANSMISSION Crankcase Splitting A WARNING Clean the engine parts in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or ex plosion could result e Using a press and the bearing driver set install new bear ings until they bottoms out OPress the output shaft bearing B in the left crankcase half A Special Tool Bearing Driver Set 57001 1129 e Apply high temperature grease to the lips of the oil seals e Press in the oil seals C of the left crankcase half so that the seal surface is flush with the end of the hole e Tighten the shift drum and drive shaft bearing retainer screws to the right crankcase Torque Shift Drum Bearing Retainer Screws B 2 9 N m 0 3 kgf m 26 in Ib Drive Shaft Bearing Retainer Screw A 5 2 Nem 0 53 kgf m 46 in Ib e Insert the crankshaft jig A between the crankshaft fly wheels opposite the connecting rod big end to protect fly wheel alignment This tool is easily adjust
47. seat area is incorrect place on the valve be sure to check the valve is the correct part If it is it may have been refaced too much replace the valve e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjustthe valve clearance see Valve Clearance Adjustment in the Peri odic Maintenance chapter GE15012381 GE15012081 ENGINE TOP END 4 25 Valve Valve Guide Valve Head Thickness Inspection e Measure the thickness of valve head Valve Head Thickness A Standard Exhaust valve 1 15 1 45 mm 0 0453 0 0571 in Inlet valve 0 85 1 15 mm 0 0335 0 0453 in Service Limit Exhaust valve 0 5 mm 0 02 in Inlet valve 0 5 mm 0 02 in If it is under the service limit replace the valve Valve Stem Bend Inspection e Support the valve at both ends of the straight stem por tion and set a dial gauge against the center of the stem e Turn the valve and read the variation in the dial gauge A Valve Stem Bend Standard TIR 0 01 0 0004 in mm or less Service Limit TIR 0 05 0 002 in mm If it is bent over the service limit replace the valve Valve Stem Diameter Inspection e Measure the diameter of the valve stem Valve Stem Diameter A Standard Exhaust valve 4 462 4 472 mm 0 1757 0 1761 in Inlet valve 4 475 4 490 mm 0 1762 0 1768 in Service Limit Exhaust valve 4 44 mm 0 175 in Inlet valve 4 46 mm
48. shock absorber Torque Swingarm Pivot Shaft Nut 78 N m 8 0 kgf m 58 ft Ib e Tighten the torque link nut Torque Torque Link Nut 25 N m 2 5 kgf m 18 ft Ib 8M060068 1 C Swingarm Rubber Bushing Inspection e Refer to the Swingarm Rubber Bushing Inspection in the Periodic Maintenance chapter STEERING 13 1 Steering Table of Contents Exploded View sai CRT 13 2 ene ue 13 4 singe c D EE 13 5 Steering IMS PSCUON ient ete ch Sedet bees te bate Mises va eos uentus Cie Ta n RON top dace sue sui iadaa 13 5 Steering ET d E EE 13 5 Steering Stem nn e E 13 5 Steering Stent InstallatiOn us iir ttt ep he ete ide oba el cea e EEGEN B aes ete de 13 5 Steering Stem enn EE 13 6 Steering Stem Race Installation Notes AAA 13 7 Steering Stem Bearing Lubrication eee eeeeeeee cece ee eeeeseeceee ener eeeeeeeeeeneceeeeeeeeeeneseeseeees 13 7 Steering Stem Bearing Inspection seeeeeeeeeeeeseeeseeseeeeen nennen nnne 13 7 Steering Stem Warp INSPECTION nnne nnne nnns 13 7 Handlebars or a crea es nts Ate che ah cela tial dee ee DM Sobel LE ME 13 8 Handlebar le RE 13 8 Handlebar Installation ici eiie ie ether SEENEN EES SEENEN AER e be nM rd 13 8 13 2 STEERING Exploded View STEERING 13 3 Exploded View OO Joo P Gobh A Handlebar Holder Handlebar Steering Stem Head Nut Steering Stem Head Stem Locknut Upper Steel Balls Head Pi
49. tester between the spark plug lead and the green terminal earth OSet the tester to the x 1 KQ range and read the meter If the meter does not read as specified replace the coil Measure primary winding resistance A Measure secondary winding resistance B Ignition Coil Winding Resistance Primary Windings 0 19 0 23 O Secondary Windings 2 5 3 7 KQ GP10015BS1 C ELECTRICAL SYSTEM 14 13 Ignition System x lf the hand tester reads as specified the ignition coil wind ings are probably good However if the ignition system still does not perform as it should after all other com ponents have been checked replace the coil with one known to be good e Check the spark plug lead for visible damage xIf the spark plug lead is damaged replace the coil Spark Plug Removal installation e Remove the plug cap e Remove or install the spark plug using the spark plug wrench A Special Tool Spark Plug Wrench Hex 16 57001 1262 Torque Spark Plug 13 N m 1 3 kgf m 113 in Ib e Installation is the reverse of removal Noting the following OFit the plug cap securely OPull up the spark plug cap lightly to make sure of the in stallation of the spark plug cap Spark Plug Gap e Refer to the Spark Plug Gap in the Periodic Maintenance chapter Spark Plug Cleaning and Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter Igniter Inspection CAUTION
50. that the snap ring was removed Use the piston pin puller assembly A if the pin is tight Special Tool Piston Pin Puller Assembly 57001 910 e Remove the piston rings A Carefully spread the ring opening with your thumbs and then push up on the op posite side of the ring to remove it GE16011381 Piston Installation NOTE OThe oil ring rails have no top or bottom e Install the oil ring expander A in the bottom piston ring groove so that the ends B but together never overlap e Install the oil ring steel rails one above the expander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston SS ORelease the rail into the bottom piston ring groove e With the marked side facing up install the second ring A and top ring B in that order LL RN GE16011481 C 4 30 ENGINE TOP END Cylinder Piston NOTE Olf a new piston is used check piston to cylinder clear ance see Piston Cylinder Clearance and use new pis ton rings e Install the piston so that the EX mark A on the piston faces to exhaust side e Fit a new piston snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OWhen installing a piston pin snap ring compress it only enough to install it no more CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out
51. the bearing must be faced to the clutch cover e Apply grease to the O ring and install it e Turn in the release plate A into the release shaft B fully but no tightly and then back it out the three turns and insert it into the hole C of clutch cover securely e Tighten the locknut into the release shaft from the oppo site side e Apply grease to the kick shaft oil seal lips e Check that the two dowel pins are in place on the crankcase e Install the clutch cover Be sure that the release cam A and release ball assembly B are not falling down KLX110 A1 A7F e Tighten the clutch cover screws following the tightening sequence Torque Clutch Cover Screws 5 2 N m 0 53 kgf m 46 in Ib KLX110A8F e Tighten the clutch cover bolts following the tightening se quence Torque Clutch Cover Bolts 8 8 N m 0 9 kgf m 78 in Ib e Adjust the clutch e Install the kick pedal A to the kick shaft B as shown GF05008BS1 C CLUTCH 5 9 Clutches Clutch Removal e Remove the clutch cover see this chapter e Remove Release Ball Assembly A Release Cam B Ball Bearing C Ball Bearing Holder D e Remove the primary clutch hub nut A while holding the primary clutch steady with the primary clutch holder B Special Tool Primary Clutch Holder 57001 1507 e Pull out the primary clutch hub C e Remove the secondary clutch hub nut A while holding the secondary clutch steady wit
52. the top plug and spring e Place a stand under the engine to raise the front wheel off the ground e Slowly compress the front fork fully by pushing up the outer tubes A using a jack or other suitable means under the front wheel e Place a stand or other suitable support B under the front wheel Use the oil level gauge to measure the fork oil level OWith the fork fully compressed put the oil level gauge A and the stopper B and adjust the distance from the top of the inner tube to oil Special Tool Fork Oil Level Gauge 57001 1290 Front Fork Oil Level fully compressed without spring Standard 89 2 mm 3 5 0 08 in lf no oil is drawn out there is insufficient oil in the fork tube Pour in enough oil then pump out the excess oil Recommended Fork Oil SHOWA SS 8 or equivalent e Measure the both diameters of the fork spring ends and insert the fork spring with the small diameter end A fac ing down 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Check both top plug O ring A for damage and replace them if necessary e Push down the top plug and install the circlip e Assemble the other fork tube in the same way as de scribed above e Install the parts removed Front Fork Inner Tube Inspection e Visually inspect the front fork for oil leakage damage on the outer surface of the inner tube A If necessary repair any damage e Nick or rust damage can sometimes be re
53. x 1 60 Rim Runout with tire installed Axial TIR 0 8 mm 0 03 in or less TIR 2 mm 0 08 in Radial TIR 1 0 mm 0 04 in or less TIR 2 mm 0 08 in TIR 2 mm 0 08 in Tires Standard Tire Front Size Make Type Rear Size Make Type Tire Air Pressure Front Rear 2 50 14 4PR 2 50 14 M C 4PR KLX110 A2 CHENG SHIN C803 3 00 12 4PR 3 00 12 4PR KLX110 A2 CHENG SHIN C803 100 kPa 1 0 kgf cm 14 psi 100 kPa 1 0 kgf cm 14 psi Special Tools Rim Protector 57001 1063 Bead Breaker Assembly 57001 1072 Tire Iron Protection of the Bead Bracker Assembly 57001 1072 Bearing Driver Set 57001 1129 Jack 57001 1238 Bearing Remover Shaft 9 57001 1265 Bearing Remover Head 10 x 12 57001 1266 WHEELS TIRES 9 5 Wheels Rims Front Wheel Removal e Remove Cotter Pin A Front Axle Nut B e Using a jack raise the front wheel off the ground e Remove Front Brake Cable End C Front Axle D Front Wheel Front Brake Panel Collar Front Wheel Installation e Apply high temperature grease to the grease seal e Install the collar A on the right side of the hub e Fit the tongue B on the fork leg into the groove A on the front brake panel e Tighten the front axle nut A Torque Front Axle Nut 44 N m 4 5 kgf m 32 ft lb e Install the cotter pin B through the front axle nut to front axle and spread its ends e Install the front brake cab
54. 0 08 in Radial TIR 2 mm 0 08 in 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Chain Slack Inspection e Support the mortorcycle perpendicular to the ground NOTE OClean the drive chain if it is dirty and lubricate it if it appears dry e Rotate the rear wheel to find the position where the chain is tightest e Push up A the chain midway between the engine sprocket and rear sprocket e The drive chain slack is that the drive chain B protrude within 0 5 mm 0 0 2 in C from the hollow D of the chain guard E x If the drive chain slack exceeds the standard adjust it Chain Slack Standard 0 5 mm 0 0 2 in Chain Slack Adjustment e Remove Cotter Pin A e Loosen Rear Torque Link Nut B Axle Nut C Brake Adjusting Nut D Right and Left Chain Adjuster Locknuts E CAUTION If you don t loosen the torque link nut it may lead to the brake parts damage when the adjusters are set e f the chain is too tight back out the left and right chain adjusting nuts A evenly and kick the wheel forward until the chain is too loose e Turn both chain adjusting nuts evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch B on the right chain adjuster C should align with the same swingarm mark D that the left chain adjuster notch aligns with e Tighten both chain adjuster locknuts e Tighten the a
55. 0008 0 0028 in 45 32 60 67 5 0 80 1 15 mm 0 0315 0 0453 in 0 80 1 15 mm 0 0315 0 0453 in 19 9 20 1 mm 0 784 0 791 in 22 9 23 1 mm 0 902 0 909 in 36 75 mm 1 447 in 0 5 mm 0 02 in 0 5 mm 0 02 in TIR 0 05 mm 0 002 in 4 44 mm 0 175 in 4 46 mm 0 176 in 4 55 mm 0 179 in 4 55 mm 0 179 in 0 19 mm 0 007 in 0 12 mm 0 0047 in 35 5 mm 1 40 in ENGINE TOP END 4 7 Specifications Item Standard Service Limit Cylinder Piston Cylinder Inside Diameter 52 997 53 009 mm 2 0865 2 0870 in 52 981 52 993 mm 2 0859 2 0863 in 0 010 0 022 mm 0 0004 0 0009 in 0 50 mm 0 0197 in 1 0 mm 0 0394 in Piston Outside Diameter Piston cylinder Clearance Oversize Piston and Rings Piston Ring groove Clearance Top 0 02 0 06 mm 0 0008 0 0024 in Second 0 01 0 05 mm 0 0004 0 0020 in Piston Ring Groove Width Top 0 81 0 83 mm 0 0319 0 0327 in Second 0 80 0 82 mm 0 0315 0 0323 in Piston Ring Thickness Top 0 77 0 79 mm 0 0303 0 0311 in Second 0 77 0 79 mm 0 0303 0 0311 in Piston Ring End Gap Top 0 15 0 30 mm 0 0059 0 0118 in Second 0 30 0 45 mm 0 0118 0 0177 in Oil 0 10 0 60 mm 0 0039 0 0236 in 12 995 13 000 mm 0 5116 0 5118 in 13 001 13 007 mm 0 5118 0 5121 in 13 003 13 014 mm 0 5119 0 5124 in Piston Pin Diameter Pist
56. 1 L 1 2 US qt 1 0 L 1 1 US qt 0 9 L 1 0 US qt Between upper and lower level lines Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Oil Pressure Gauge Adapter M10 x 1 25 57001 1182 Oil Pressure Cap 57001 1651 ENGINE LUBRICATION SYSTEM 6 5 Engine Oil Flow Chart GEN 1 69 16 m lt gt OD E Kee Ed ROK NY 7i N SSIS SY La SS M Y LLLZLZLL ILL 77 CR AAS aa E y ei ke aad cy E Lu 6604006BN4 C 1 Camshaft 11 Oil Passage Cylinder Head 2 Oil Pipe 12 Oil Passage Camshaft 3 Cylinder Head 13 Oil Passage Right Engine Cover 4 Primary Clutch Housing 14 Oil Passage Crankshaft 5 Clutch Cover 15 Oil Passage to Cylinder Head 6 Crankshaft 16 Oil Passage to Crankshaft 7 Oil Filter 17 Oil Passage from Oil Filter 8 Bypass Valve 18 Oil Passage to Oil Filter 9 Oil Pump 19 Oil Passage to Cil Pump 10 Oil Screen 6 6 ENGINE LUBRICATION SYSTEM Engine Oil Oil Level Inspection e Refer to the Oil Level Inspection in the Periodic Mainte nance chapter Oil Changing e Refer to the Oil Changing in the Periodic Maintenance chapter ENGINE LUBRICATION SYSTEM 6 7 Oil Filter Element Oil Screen Oil Filter Element Replacement e Refer to the Oil Filter Element Replacement in the Peri odic Maintenance chapter Oil Screen Cleaning e Drain the engine oil e Remove the clutch cover see Cl
57. 2 N m 2 2 kgf m 16 ft lb 29 N m 3 0 kgf m 22 ft lb 42 N m 4 3 kgf m 31 ft lb KLX110 A1 54 N m 5 5 kgf m 40 ft lb KLX110 A2 72 N m 7 3 kgf m 53 ft lb Apply engine oil Apply high temperature grease Apply a non permanent locking agent Apply liquid gasket Replacement Parts Follow the specific tightening sequence KLX110 A1 KLX110 A2 8 4 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting Rod Big End Radial Clearance KLX110 A1 Big End Radial Clearance KLX110 A2 Big End Side Clearance Crankshaft Runout 0 009 0 023 mm 0 0004 0 0009 in 0 006 0 020 mm 0 0002 0 0008 in 0 1 0 2 mm 0 004 0 008 in Less than 0 03 mm 0 001 in TIR 0 07 mm 0 0028 in 0 07 mm 0 0028 in 0 4 mm 0 016 in TIR 0 08 mm 0 003 in Transmission Shift Fork Ear Thickness 3 9 4 0 mm 0 154 0 157 in 3 8 mm 0 15 in Gear Shift Fork Groove Width 4 05 4 15 mm 0 159 0 163 in 4 3 mm 0 17 in Shift Fork Guide Pin Diameter 4 9 5 0 mm 0 193 0 197 in 4 8 mm 0 19 in Shift Drum Groove Width 5 05 5 20 mm 0 199 0 205 in 5 3 mm 0 21 in Special Tools Outside Circlip Pliers 57001 144 Bearing Puller 57001 158 Crankcase Splitting Tool Assembly 57001 1098 Bearing Driver Set 57001 1129 Crankshaft Jig 57001 1174 Sealant Kawasaki Bond Liqu
58. 20 Link Length 254 0 254 6 mm 10 00 10 02 in 259 mm 10 20 in Sprocket Rear Sprocket Warp Less than 0 4 mm 0 016 in 0 5 mm 0 020 in Special Tools Outside Circlip Pliers 57001 144 Bearing Driver Set 57001 1129 FINAL DRIVE 10 5 Drive Chain Chain Slack Inspection e Refer to the Chain Slack Inspection in the Periodic Main tenance chapter Chain Slack Adjustment e Refer to the Chain Slack Adjustment in the Periodic Main tenance chapter Drive Chain Removal e Remove Drive Chain Cover Engine Sprocket Cover e Remove the clip from the drive chain master link using pliers and remove the master link e Free the drive chain from the sprockets being careful that the chain does not get dirty from contact with the ground Drive Chain Installation e The direction of the master link clip A must be as shown B Direction of Drive Chain Rotation A WARNING Incorrect installation of the master link clip can al low it to catch on an adjacent part If the clip dis lodges the chain could come a part and this could result in rear wheel lockup and loss of control GKO4077BSi C e Adjust the chain slack e Put the chain tension guide A on the engine sprocket cover B and install the sprocket cover B Qo P Chain Wear Inspection e Refer to the Chain Wear Inspection in the Periodic Main tenance chapter Chain Lubrication e Refer to the Chain Lubrication in the Periodic
59. 4 102 in 0 5 mm 0 02 in 0 6299 0 6306 in Special Tools Primary Clutch Holder 57001 1507 Clutch Holder 57001 1508 Friction Plate Thickness 3 1 3 3 mm 0 12 0 13 in 2 9 mm 0 11 in Friction Plate Warp 0 2 mm 0 008 in or less 0 3 mm 0 01 in Steel Plate Warp 0 15 mm 0 006 in or less 0 3 mm 0 01 in Clutch Spring Free Length 24 00 mm 0 94 in 23 00 mm 0 91 in KLX110 A1 Clutch Spring Free Length 22 04 mm 0 87 in 20 35 mm 0 80 in KLX110 A2 Kick Shaft Kick Shaft Diameter SC SEN 15 92 mm 0 6268 in Kick Gear Inside Diameter 16 000 16 018 mm 16 04 mm 0 6315 in CLUTCH 5 7 Clutch Cover Clutch Cover and Oil Screen Removal e Drain the engine oil see Engine Lubrication System e Remove Kick Pedal A Footpeg B Engine Guard C Brake Pedal hanging D e Remove Clutch Cover Screws A KLX110 A1 A7F Clutch Cover Bolts A KLX110A8F Clutch Cover B e Unscrew the clutch adjusting screw locknut A e The release plate B and the release shaft adjusting screw C come out with the cover e Pull out the oil screen A 5 8 CLUTCH Clutch Cover Clutch Cover and Oil Screen Installation e Clean any metal particles and other dirt out of the oil Screen e Using compressed air blow out any particles which may obstruct the oil passage A in the clutch cover e Check that the ball bearing is in place The shield side of
60. 80103S1 14 18 ELECTRICAL SYSTEM Switches Gear Position Switch Inspection e Remove the gear position switch head and examine the contact points for presence of oxidation oil or dirt etc Clean the contact points and ensure that the switch finger is working correctly e Establish that the switch finger A is grounded properly by connecting the hand tester B across the engine or frame ground C and the switch finger contact points Check to see that the connection has continuity abot zero ohms x If the reading is the switch finger earth is faulty or poor Special Tool Hand Tester 57001 1394 e Establish that the switch head contact point LG Lead A is grounded properly by connecting the hand tester B across the engine or frame ground C and the switch head contact point Check to see that connection has continuity about 200 ohms If not check the ground terminal and the igniter ground e Establish that the switch head contact point G R Lead A is open by connecting the hand tester B across the engine or frame ground C and the switch head contact point Check to see that connection has discontinuity ec x lf the reading is about zero ohms the circuit is short TROUBLESHOOTING 15 1 Troubleshooting Table of Contents Troubleshooting Guida RT CNAE KSENA AEA 15 2 15 2 TROUBLESHOOTING Troubleshooting Guide NOTE Cylinder head not sufficiently tightened OThi
61. Arrester Cleaning in the Periodic Main tenance chapter CLUTCH 5 1 Clutch Table of Contents Exploded View ha NS 5 2 Exploded View KEX110 A2 uisu dirette tnter td ape canes RE HEX Rambla sp det px ud de 5 4 SPOCCIICATONS T 5 6 GIULCM COVE En 5 7 Clutch Cover and Oil Screen Removal eeeeeees eese 5 7 Clutch Cover and Oil Screen Installation eee eeececeeeeeeeeeeeeeaeeeeeeeeeeeeeeneeeeeeeeeeeeeeeeaaeees 5 8 El 5 9 Clutch RemoVal EE 5 9 Cl tchiInstallatio TE 5 9 Secondary Clutch Disasserribly z uidet nat ioa enr a e o or tat et addo rt 5 11 Secondary Clutch Assembly reris ren kr tpe ER CER RON RN RAM TR HR SER ed 5 12 Primary Clutch Housing Wear Inspection cccceceeeeeeeeeneneeeeeeeeeeeeeeeeeeeeeeeeeeeeeneenaaeees 5 12 Primary Clutch Shoe Lining Wear Inspection cece eeeeeeeenene eter eee eeeenaeeeeeeeeeeeeneeneeeeeeees 5 13 One Way Clutch Inspection EE 5 13 Clutch Plate Wear and Damage Inspection sseeeeee 5 14 Clutch Plate Warp Inspechon mnm 5 14 Secondary Clutch Housing Finger Damage Inspection eesseeeeeeee 5 14 Secondary Clutch Hub Spline Damage Inspection 5 15 Secondary Clutch Spring Free Length Measurement 5 15 Glutchi Adjustment o ee ree eot aid EES 5 15 lee lt 5 16 Kickstarter HRemoval ene nne emere nennt nnne ennt enses nnns nnne nnns nensis 5 16 Kickstarter InstallatiOn 22 recette rte Rete ER a aa EE
62. GROS018BSi C 5 14 CLUTCH Clutches OCheck that the rollers A in the one way clutch is installed as shown when viewed from the right side of the engine Clutch Plate Wear and Damage Inspection e Visually inspect the friction and steel plates for uneven wear discoloration missing friction material cracks or other damage If any plates show signs of damaged replace the friction and steel plates as a set e Measure the thickness of the friction plates A at several points Friction Plate Thickness Standard 3 1 3 3 mm 0 12 0 13 in Service Limit 2 9 mm 0 11 in If any of the measurement is less than the service limit replace the plates as a set Clutch Plate Warp Inspection e Place each friction plate or steel plate B on a surface plate A and measure the gap between the surface plate and each plate with a thickness gauge C The gap is the amount of friction and steel plate warp If any of the clutch plate is warped beyond the service limit replace the plate with a new one Friction Plate and steel Plate Warp Standard 0 15 mm 0 006 in or less Steel Plate 0 2 mm 0 008 in or less Friction Plate Service Limit 0 3 mm 0 01 in Secondary Clutch Housing Finger Damage Inspection e Visually inspect the clutch housing finger A where the friction plate tangs B hit them x If they are badly worn or if there are groove cuts where the tangs hit replace the housing Also replace the f
63. Idle adjusting screw maladjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Compression Low Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring land clearance excessive Cylinder head gasket damaged Spark plug dirty damaged or maladjusted Spark plug cap or high tension wiring dam aged Spark plug cap shorted or not in good con tact Spark plug incorrect Crankshaft sensor trouble Ignition coil damaged Igniter broken Flywheel magneto damaged Fuel air mixture incorrect Idle adjusting screw maladjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Choke valve closed Float level too high or too low Fuel tank air vent obstructed Carburetor holder loose Compression low Cylinder piston worn Piston rings bad worn weak broken or sticking Piston ring land clearance excessive Cylinder head gasket damaged Cylinder head not sufficiently tightened down Cylinder head warped No valve clearance Spark plug loose Valve spring broken or weak Valve not seating properly Valve bent worn or carbon accumulation on the seating surface Crankshaft oil seal deteriorated or dam aged Other Throttle valve doesn t slide smoothly Engine oil viscosity too high Brake dragging Poor Running or No Power at High Speed Firing incorrect Spark plug
64. If runout exceeds the service limit replace the axle Axle Runout 100 mm 4 0 in Rear Axle 110 mm 4 3 in Standard 0 1 mm 0 004 in Service Limit 0 2 mm 0 008 in 6J04030581 9 8 WHEELS TIRES Tires Air Pressure Inspection Adjustment e Remove the valve cap e Using tire air pressure gauge A measure the tire pres sure when the tires are cold Adjust the tire air pressure to suit track conditions and rider preference but do not stray too far from the recom mended pressure Track Condition Tire Pressure When the track is wet muddy sandy 80 kPa 0 8 kgf cm EE or slippery reduce the tire pressure 11 psi to increase the tire tread surface on the ground l When the track is pebbly or hard increase the tire pressure to prevent damage or punctures through the tires will skid more easily l 100 kPa 1 0 kgf cm 14 psi e Tighten the valve cap securely Tires Inspection As the tire tread wears down the tire becomes more sus ceptible the puncture and failure e Remove any imbedded stones or other foreign particles from the tread e Visually inspect the tire for cracks and cuts replacing the tire in case of bad damage Swelling or high spots indi cate internal damage requiring tire replacement A WARNING To ensure safe handling and stability use only the recommended standard tires for replacement in flated to the standard pressur
65. P Gite Che E Oil Level INSPECTION vs ecce rt tet A deiert Rete ce set decet E eT ee lee EPOR NC HH P T eer ee eee Oil Filter Element Oil Screen nennen emere mener enne Oil Filter Element Replacement eee 6 7 Oil Screen Cleaning EE 6 7 Engine Oil PUMP idarato atit nba suben anger C ea A oa ETAN RE 6 8 Engine Oil Pump une EE 6 8 Engine Oi Pump Installalloni 5er lela adhe E eaa 6 8 Engine Oil Pump Inspection 6 8 QI Elle 6 9 Oil Pipe REMOVAL EE 6 9 Oil Pipe Installatign e iere a re eerte re Rue ager ir trc er ce de 6 9 Oil Pressure Measurement nemen enne nnne nen eren nnne eren 6 10 Oil Pressure Measurement mem em emere en a a a ree ree rene rne rne ener 6 10 6 2 ENGINE LUBRICATION SYSTEM Exploded View 6802020BN5 C ENGINE LUBRICATION SYSTEM 6 3 Exploded View NOORWN Oil Pump Oil Screen Oil Pipe Copper Washer Crankcase Breather Tube OU Filter Drain Plug T1 T2 T3 Apply grease Replacement Parts 5 2 N m 0 53 kgf m 46 in Ib 15 N m 1 5 kgfm 11 ftlb 29 N m 3 0 kgf m 21 ft lb 6 4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Service Limit Engine Oil Grade Viscosity Capacity When Engine is Completely Dry When Filter is Removed When Filter is Not Removed Level API SE SF or SG API SH or SJ with JASO MA MA1 or MA2 KLX110 A1 A6F API SH SJ or SL with JASO MA MAT or MA2 KLX110A7F SAE 10W 40 1
66. Standard Top 0 77 0 79 mm 0 0303 0 0311 in Second 0 77 0 79 mm 0 0303 0 0311 in Service Limit Top 0 7 mm 0 028 in Second 0 7 mm 0 028 in GE16124BS1 C ENGINE TOP END 4 33 Cylinder Piston Piston Ring Groove Width Standard Top 0 81 0 83 mm 0 0319 0 0327 in Second 0 80 0 82 mm 0 0315 0 0323 in Service Limit Top 0 90 mm 0 035 in Second 0 90 mm 0 035 in xIf the clearance exceeds the service limit remove the pis ton rings and measure the thickness of the piston rings and the width of the ring grooves If the ring has worn down to less than the service limit replace the ring if the groove width exceeds the service limit replace the piston NOTE OThese tables apply to oversize pistons and rings as well as standard and pistons and rings Piston Piston Pin Connecting Rod Wear Inspection e Visually inspect the snap rings A are fitted in place xIf the ring shows weakness or deformation replace the ring Also if the pin hole groove shows excessive wear replace the piston e Visually inspect the piston pin hole and connecting rod small end hole xIf the piston pin hole shows uneven wear replace the pis ton If the rod small end hole shows uneven wear replace the rod or crankshaft assembly e Visually inspect the outer surface of the piston pin B xIf the pin shows color change or stepped wear replace the pin and needle bearing amp
67. Standard 5 05 5 20 mm 0 199 0 205 in Service Limit 5 3 mm 0 21 in CRANKSHAFT TRANSMISSION 8 15 Transmission Gear Dog Gear Dog Hole Damage Inspection e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes Ball and Needle Bearing Wear Inspection CAUTION Do not remove the bearings for inspection Remove may damage them e Check the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol 0113014981 vent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin A a bearings by hand to check its condition xIf the bearings are noisy do not spin smoothly or have any rough spots replace them e Check the needle bearing OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage xIf it is any doubt as to the condition of a needle bearing replace it Oil Seal Inspection e Inspect the oil seals Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged WHEELS TIRES 9 1 Wheels Tires Table of Contents etes E
68. UTCH Exploded View KLX110 A2 S A T e e e S GF021368W5 C CLUTCH 5 5 Exploded View KLX110 A2 OONOARWN A Clutch Cover Primary Clutch Shoe Linings Race One way Clutch Primary Clutch Housing Clutch Spring Plate Clutch Spring Secondary Clutch Hub Friction Plate Steel Plate Clutch Wheel Clutch Housing Clutch Adjusting Screw Locknut Release Shaft Adjusting Screw Release Plate Release Ball Assembly Release Cam Gear Positioning Lever Gear Positioning Plate Shift Shaft Shift Pedal Shift Drum Cam Shift Drum Kick Pedal Return Spring Kick Shaft Ratchet Oil Seal Shift Pedal Bolt Apply engine oil Apply grease Apply a non permanent locking agent Apply molybdenum disulfide grease Follow the specific tightening sequence 2 9 N m 0 3 kgf m 26 in Ib 5 2 N m 0 53 kgf m 46 in Ib 3 4 N m 0 35 kgf m 30 in Ib 5 0 N m 0 51 kgf m 44 in Ib KLX110 A3 19 N m 1 9 kgf m 14 ftlb 72 N m 7 3 kgf m 53 ft lb 22 N m 2 2 kgf m 16 ft lb 5 2 N m 0 53 kgf m 46 in Ib KLX110 A2 A7F 8 8 N m 0 9 kgf m 78 in Ib KLX110A8F 5 6 CLUTCH Specifications Primary Clutch Shoe Groove Depth 1 0 mm 0 04 in Secondary Clutch Item Standard Service Limit Primary Clutch Primary Clutch Housing Inside 104 0 104 2 mm 104 5 mm 4 114 in Diameter 4 094
69. Visually inspect the oil pump body A outer rotor B in ner rotor C and cover D x If there is any damage or uneven wear replace the rotors or oil pump assembly ENGINE LUBRICATION SYSTEM 6 9 Oil Pipe Oil Pipe Removal e Remove the banjo bolts A and oil pipe clamp screw B Oil Pipe Installation e Before installation flush out the pipe with a high flash point solvent e Discard the used copper washers and install new washers on each side of the pipe fittings e Lightly tighten the banjo bolts and oil pipe clamp screw to a snug fit and tighten them to the specified torque Torque Oil Pipe Banjo Bolts 15 N m 1 5 kgf m 11 ft Ib Oil Pipe Clamp Screw 5 2 N m 0 53 kgf m 46 in Ib 6 10 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement e Remove the oil filter cap see Oil Filter Element Replace ment in the Periodic Maintenance chapter and attach the oil pressure cap A adapter B and gauge C Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Oil Pressure Gauge Adapter M10 x 1 25 57001 1182 Oil Pressure Cap 57001 1651 e Start the engine and warm up the engine e Run the engine at the specified speed and read the oil pressure gauge If the oil pressure is much lower than the standard check the oil pump and crankshaft bearing insert wear xIf the reading is much higher than the standard check the oil pump screen and oil filter first oil passages f
70. able to fit in any gap between the flywheel Special Tool Crankshaft Jig 57001 1174 e Fit the crankshaft into the right crankcase half using a press A G104001BS1 C CRANKSHAFT TRANSMISSION 8 7 Crankcase Splitting e Install Shift Drum A Transmission Shaft Assemblies B Shift Forks C e Check that the shift drum is in neutral position e Make sure that the mating surfaces of the crankcase halves are completely free of oil or contamination e Apply liquid gasket to the mating surface of the left crankcase half as shown Sealant Kawasaki Bond Liquid Gasket Black 92104 1003 e Check that two dowel pins A O rings B and drive shaft spacer C in place e Fit the crankcase halves together hitting with a plastic hammer on the left crankcase side e Tighten the crankcase screws in that order shown NOTE OApply a non permanent locking agent to the No 10 tightening order screw Tightening Torque Crankcase Screws 5 2 N m 0 53 kgf m 46 in Ib e Remove the crankshaft jig OCheck to see that the crankshaft and output shaft all turn freely If the crankshaft will not turn it is probably not centered Tap the mount portion of the crankcase with a plastic ham mer A to reposition it If it does not free up split the crankcase again and find the cause Spinning the output shaft shift the transmission through all the gears to make certain there is not bi
71. ace e Remove the remaining ball bearings from the lower bear ing outer race There are 23 steel balls installed in the lower outer race e Remove Steering Stem Cap A Upper Inner Race B Upper Steel Balls C OThere are 23 steel balls installed in the upper outer race Steering Stem Installation e Apply grease liberally to the upper and lower outer races in the head pipe so that the steel balls will stick in place during stem insertion and install upper and lower steel balls e Using the stem nut wrench temporarilly tighten hand tighten the stem locknut to press the steel balls against the outer race 13 6 STEERING Steering e Install the stem head and washer and tighten the stem head nut lightly e Settle the bearing in place as follows OTighten the stem locknut to 39 N m 4 0 kgf m 29 ft lb of torque To tighten the steering stem locknut to the specified torque hook the wrench A on the stem locknut and pull the wrench at the hole by 22 2 kg force B in the direction shown Special Tool Steering Stem Nut Wrench 57001 1100 OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged OAgain back out the stem locknut a fraction of a turn until it turns lightly OTurn the stem locknut lightly clockwise until it just be comes hard to turn Do not overtighten or the steering will be too tight Torque Steering Stem Lock
72. aft bearing worn or damaged Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Igniter trouble Fuel air mixture incorrect Main jet clogged or wrong size Fuel level too low Carburetor holder loose Air cleaner clogged Air cleaner poorly sealed or missing Air cleaner duct loose Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Brakes dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Clutch Operation Faulty Clutch slipping No clutch release play Friction plate worn or warped Steel plate worn or warped Clutch spring or weak Clutch release maladjusted Clutch release mechanism trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Clutch release play excessive Clutch plate warped or too rough Clutch spring tension uneven Engine oil deteriorated Engine oil level too high Engine oil viscosity too high Clutch housing frozen on drive shaft Clutch release mechanism trouble Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Shift return spring weak or broken Shift pawl spring broken Shift return spring pin loose Gear set level binding on pivot bolt External shift mechanical arm worn Shift drum damaged Jumps out of g
73. aged parts GENERAL INFORMATION 1 5 Model Identification KLX110 A1 Left Side View KLX110 A1 Right Side View 1 6 GENERAL INFORMATION General Specifications Items KLX110 A1 Dimensions Overall Length 1 555 mm 61 2 in Overall Width 660 mm 26 0 in Overall Height 955 mm 37 6 in Wheelbase 1 065 mm 41 9 in Road Clearance 190 mm 7 5 in Seat Height 650 mm 25 6 in Dry Mass KLX110 A1 A8F 64 kg 628 N 141 Ib Curb Mass KLX110A9F 64 kg 628 N 141 Ib Front 31 kg 304 N 68 Ib Rear 37 kg 363 N 82 Ib Fuel Tank Capacity 3 8 L 1 0 US gal Performance Minimum Turning Radius 1 6 m 5 2 ft Engine Type 4 stroke SOHC single cylinder Cooling System Bore and Stroke Displacement Compression Ratio Carburetion System Starting System Ignition System Ignition Timing Spark Plug Valve Timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication System Engine Oil Grade Viscosity Capacity Air cooled 53 0 x 50 6 mm 2 09 x 1 99 in 111 cm 6 77 cu in 9 5 1 Carburetor KEIHIN PB18 Kick Magneto CDI From 10 BTDC 91 300 r min rpm to 31 BTDC 24 000 r min rpm NGK CR6HSA 0 BTDC 80 ABDC 260 35 BBDC 45 ATDC 260 Forced lubrication wet sump API SE SF or SG API SH or SJ with JASO MA MAT or MA2 KLX110 A1 A6F API SH SJ or SL with JASO MA MAT or MA2 KLX110A7F SAE 10W 40 1 1 L
74. ain Plug 29 N m 3 0 kgf m 21 ft Ib e Pour in the specified type and amount of oil Recommended Engine Oil Type API SE SF or SG API SH or SJ with JASO MA MA1 or MA2 KLX110 A1 A6F API SH SJ or SL with JASO MA MA1 or MA2 KLX110A7F Viscosity SAE 10 W 40 Capacity 1 1 L 1 2 us qt When engine is completely dry 1 0 L 1 1 us qt When filter is removed 0 9 L 1 0 us qt When filter is not removed 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ODo not add any chemical additive to the oil Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospher ic conditions in your riding area Oil Filter Element Replacement e Drain the engine oil e Remove the engine guard see Engine Removal section in the Engine Removal Installation chapter e Remove the oil filter cap bolts A and oil filter cap B e Replace the filter element with a new one e Set the spring into the oil filter cap NOTE Olnstall the filter element so that the bypass valve A side outward e Fit a new O ring onto the oil filter cap e Apply grease to the O ring e Install the oil filter cap Torque Oil Filter Cap Bolts 5 2 N m 0 53 kgf m 46 in Ib Wheels Tires Wheels Inspection e Place the jack under the
75. al Free Play Brake Drum Brake Shoes Shoe Lining Thickness Front Rear Shoe Spring Free Length Front Rear Drum Inside Diameter Front Rear Camshaft Diameter Front Rear Camshaft Hole Inside Diameter Front Rear Cam Lever Angle 4 5 mm 0 16 0 20 in 20 30 mm 0 79 1 18 in 2 10 3 00 mm 0 08 0 12 in 3 85 4 15 mm 0 152 0 163 in 30 8 31 2 mm 1 213 1 228 in 32 5 mm 1 280 in 90 000 90 087 mm 3 543 3 547 in 110 000 110 087 mm 4 331 4 334 in 11 957 11 984 mm 0 471 0 472 in 14 957 14 984 mm 0 589 0 590 in 12 000 12 027 mm 0 472 0 474 in 15 000 15 027 mm 0 591 0 592 in 80 90 Special Tool Inside Circlip Pliers 57001 143 1 2 mm 0 05 in 2 0 mm 0 08 in 32 6 mm 1 28 in 34 1 mm 1 34 in 90 75 mm 3 57 in 110 75 mm 4 36 in 11 88 mm 0 468 in 14 88 mm 0 586 in 12 15 mm 0 478 in 15 15 mm 0 596 in BRAKES 11 7 Brake Lever Brake Pedal Brake Lever Brake Pedal Free Play Inspection e Refer to the Brake Lever Brake Pedal Free Play Inspec tion in the Periodic Maintenance chapter Front Brake Free Play Adjustment e Refer to the Front Brake Lever Free Play Adjustment in the Periodic Maintenance chapter Brake Pedal Free Play Adjustment e Refer to the Brake Pedal Free Play Adjustment in the Pe riodic Maintenance chapter Brake Cable Removal e Free the brake cable from the brake
76. and Locking Agent Fastener Electrical System Gear Position Switch Screw Spark Plug Magneto Flywheel Nut 10 mm KLX110 A1 Exciter Coil Mounting Screws Crankshaft Sensor Mounting Screw Magneto Cover Screws KLX110 A1 A7F Magneto Cover Bolts KLX110A8F Exciter Coil Plate Screw Crankshaft Sensor Plate Screw Magneto Cover Damper Magneto Flywheel Nut 12 mm KLX110 A2 E Remarks N m kgf m ft Ib 2 9 0 3 26 in lb 13 1 3 113 in lb 42 4 3 31 54 5 5 40 5 2 0 53 46 in lb 2 9 0 3 26 in lb 5 2 0 53 46 in lb S 8 8 0 9 78 mb S 5 2 0 53 46 in lb 5 2 0 53 46 in lb 2 9 0 3 26 in lb The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads dia mm N m 5 3 4 4 9 6 5 9 7 8 8 14 19 10 25 34 12 44 61 14 73 98 16 115 155 18 165 225 20 225 325 Torque kgf m 0 35 0 50 0 60 0 80 1 4 1 9 2 6 3 5 4 5 6 2 7 4 10 0 11 5 16 0 17 0 23 0 23 33 ft lb 30 43 in lb 52 69 in lb 10 0 13 5 19 0 25 33 45 54 72 83 115 125 165 165 240 Special Tools and Sealants GENERAL INFORMATION 1 11 Oil Pressure Gauge 5 kgf cm 57001 125 7570125ST C Fork Cylinder Hold
77. and press the holder to the clutch housing OBefore installing the clutch housing mark E on the tip of optional tooth 1 place OThe gear shall be rotated clockwise F more than 1 tooth and less than 2 teeth Confirm that making is rotated e Install the clutch housing If the one way clutch and race dropped from the primary clutch housing install it as follows OPut the one way clutch A in the clutch housing halfway with the rotation mark B facing out OFit the race C into the one way clutch and push them together in the clutch housing KLX110 A2 ii CLUTCH 5 11 Clutches e Install the plate with the line mark A facing out noting the proper position e Install the primary clutch shoe linings e Tighten the primary clutch nut while holding the primary clutch steady with the primary clutch holder Special Tool Primary Clutch Holder 57001 1507 Torque Primary Clutch Hub Nut 72 N m 7 3 kgf m 53 ft Ib e Install the ball bearing holder A and ball bearing B e Apply grease to the release cam and release ball assem bly e Install the release cam A and release ball assembly B e Install the release lever C to the shift shaft with shift shaft line D aligning to release lever line E e Install the clutch cover e Adjust the clutch Secondary Clutch Disassembly e Remove the secondary clutch see Clutch Removal e Unscrew the clutch spring bo
78. and these systems make up the manual s chapters The Quick Reference Guide shows you all of the products system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE x Indicates a conditional step or what action to take based on the results of the test or
79. ange Tester Lead Another Lead g mum White Lead 0 2 1 0 Yellow Lead 0 1 0 8 Crankshaft Sensor Resistance Measurement e Remove the left side cover e Disconnect the magneto lead connector A e Set the hand tester to the x 100 O range and connect it to the lead from the crankshaft sensor to check the resis tance Special Tool Hand Tester 57001 1394 x If the reading is not the specified value replace the stator Crankshaft Sensor Resistance Unit Q Reading Range Tester Lead Another Lead x 100 Q Blue Yellow Lead 50 200 14 12 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal e Remove Left Side Cover Spark Plug Cap e Disconnect the ignition coil leads A e Unscrew the bolt B and remove the ignition coil C Ignition Coil Installation e Installation is the reverse of removal e Apply silicone grease to the spark plug lead end A e Turn in the spark plug cap B securely e Install the ignition coil mounting bolt A with the ground terminal B as shown see Cable Wire and Hose Routing section in the General Information chapter Ignition Coil Inspection e Remove the ignition coil e Measure the primary winding resistance OConnect the hand tester between the coil terminals Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read the meter e Measure the secondary winding resistance OPull the spark plug cap off the lead OConnect the hand
80. buretor body for these same faults x lf it is badly scratched or worn replace the entire carbu retor B Sliding Surface e Check the jet needle A and needle jet holder B for wear xA worn needle jet holder or jet needle should be replaced e Check the tapered portion A of the pilot screw B for wear or damage If the pilot screw is worn or damaged on the tapered por tion it will prevent the engine from idling smoothly Re place it e Disassemble the carburetor and clean the fuel air pas sages with a high flash point solvent and compressed air e Stuff the lint free clean cloths into the air cleaner housing to keep dirt or other foreign material from entering A WARNING If dirt or dust is allowed to pass through into the car buretor the throttle valve may become stuck pos sibly causing an accident 6606010281 3 16 FUEL SYSTEM Air Cleaner Air Cleaner Housing Removal e Remove the left shroud e Loosen the air cleaner duct clamp A e Unscrew the air cleaner mounting bolts A and remove the air cleaner housing B Air Cleaner Housing Installation e Installation is the reverse of the removal e Install the intake portion A of air cleaner housing into the frame hole B Element Removal e Remove the left shroud e Unscrew the mounting screws A and remove the air cleaner housing cover B e Pull out the element A FUEL SYSTEM 3 17
81. ction in the Pe riodic Maintenance chapter Free Play Adjustment e Refer to the Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter Throttle Cable and Choke Cable Installation e Install the throttle cable and choke cable in accordance with the Cable Wire and Hose Routing section in the Gen eral Information chapter e After the installation adjust each cable properly A WARNING Operation with an incorrectly routed or improperly adjusted cable result in an unsafe riding condition Cable Lubrication and Inspection e Whenever the choke cable or the throttle cable are re moved or in accordance with the Periodic Maintenance Chart lubricate these cables Refer to the General Lubri cation in the Periodic Maintenance chapter OApply a thin coating of grease to the cable upper or lower ends OUse a commercially available pressure cable lubricator to lubricate these cables OWith the cable disconnected at both ends the cable should move freely in the cable housing 3 8 FUEL SYSTEM Carburetor Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Idle Speed Adjustment e Refer to the Idle Speed Adjustment in the Periodic Main tenance chapter Fuel Level Inspection A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Always stop the en gine and do not smoke Make sure the area is well ventilated and from an
82. damaged replace them with new ones Nut Bolt and Fastener to be checked Wheels Spoke Nipples Front Axle Nut Cotter Pin Front Axle Nut Rear Axle Nut Cotter Pin Rear Axle Nut Final Drive Chain Adjuster Locknuts Rear Sprocket Nuts Torque Link Nut Torque Link Nut Cotter Pin Brakes Front Brake Adjuster Rear Brake Adjusting Nut Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin Suspension Front Fork Clamp Bolts Swingarm Pivot Shaft Nut Rear Shock Absorber Mounting Bolts and Nuts Steering Steering Stem Head Nut Handlebar Holder Bolts Engine Engine Mounting Bolts Nuts Shift Pedal Bolt Exhaust Pipe Holder Nuts Muffler Mounting Bolt and Nut Others Side Stand Bolt Footpeg Mounting Bolts Front Fender Mounting Bolts FUEL SYSTEM 3 1 Fuel System Table of Contents Exploded WAT et ue 3 6 Throttle Grip and Cable eerte eet te trece hee ee Ra gear dcr re de 3 7 Free Play IMS POCHOM deeg rx 3 7 Free Play Agjustme nt coiere erede e tel bre Eeer 3 7 Throttle Cable and Choke Cable Installation ccccccccccccccceccceeeeeeceeeeeeeeeeeeeeseeeeeeeeeees 3 7 Cable Lubrication and Inspechon emnes 3 7 ie Tieni Pn 3 8 Idle Speed Inspection sssssssssssssssssseeeneneeme nemen enne 3 8 TER EE 3 8 Fuel Level Inspection 3 8 Fuel Level Adjustment m x E 3 9 Float ne UE 3 10 Fuel System Cleanliness Inspection eseseeeeeseeseee
83. de Stand Side Stand Inspection e See ifthe side stand A moves smoothly and retracts fully B If not clean and grease the pivot C e Check the side stand spring D for damage If necessary replace the spring Electrical System Spark Plug Gap e Remove the spark plug see Electrical System chapter e Measure the gap with a wire type thickness gauge xIf the gap is incorrect carefully bend the side electrode with a suitable tool to obtain the correct gap Insulator A Center Electrode B Plug Gap C Side Electrode D Spark Plug Gap 0 6 0 7 mm 0 024 0 028 in Spark Plug Cleaning and Inspection e Clean the spark plug preferably in a sandblasting device 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 corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug B men 6S15002BS1 C SEIN SSDS EC ER ee Lanan Riess K w A GP100123S1 C 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy condi
84. ding is not the specified value replace the reg ulator rectifier Regulator Rectifier Internal Resistance Unit kQ Tester Lead Connection Terminal L E L 10 100 E 10 100 AT s e Tester Lead Connection CAUTION Use only Hand Tester 57001 1394 for this test An ohmmeter other than the Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the regulator will be damaged E A B GPO9010281 ELECTRICAL SYSTEM 14 11 Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or spark plug lead while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the electrical connections while the engine is running This is to prevent igniter damage The negative side is grounded This is to prevent damage to the diodes and Igniter Igniter Removal e Remove Seat Connector A Igniter B Exciter Coil Resistance Measurement e Remove the left side cover e Disconnect the magneto lead connector A e Set the hand tester to the x 10 O range and connect it to the leads from the exciter coil to check the resistance Special Tool Hand Tester 57001 1394 lf the reading is not the specified value replace the stator Exciter Coil Resistance Unit Q R
85. dirty damaged or maladjusted Spark plug cap or high tension lead dam aged TROUBLESHOOTING 15 3 Troubleshooting Guide Spark plug cap shorted or not in good con tact Spark plug incorrect Ignition coil trouble Crankshaft sensorl trouble Stator coil shorted or open Igniter trouble Fuel air mixture incorrect Main jet clogged or wrong size Jet needle or needle jet worn Jet needle clip in wrong position Fuel level too high or too low Air jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Air cleaner duct poorly sealed Carburetor holder loose Fuel to carburetor insufficient Water or foreign matter in fuel Fuel tank air vent obstructed Fuel line clogged Fuel tap clogged Air cleaner duct loose Compression low Cylinder piston worn Piston rings bad worn weak broken or sticking Piston ring land clearance excessive Cylinder head gasket damaged Cylinder head not sufficiently tightened down Cylinder head warped No Valve clearance Spark plug loose Valve not seating properly Valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Miscellaneous Float level too high too or too low Main jet clogged Throttle valve does not fully open Air cleaner clogged Water or foreign matter in fuel Brake dragging Clutch slipping Overheating Engine oil level too high Engine oil viscosity too high Cranksh
86. e NOTE OCheck and balance the wheel when a tire is replaced with a new one Standard Tire Front Size 2 50 14 4PR 2 50 14 M C 4PR KLX110 A2 Make CHENG SHIN Type C803 Rear Size 3 00 12 4PR 3 00 12 M C 4PR KLX110 A2 Make CHENG SHIN Type C803 WHEELS TIRES 9 9 Tires Tire Removal e Remove the wheel from the motorcycle see Wheels Re moval e To maintain wheel balance mark A the valve stem posi tion on the tire with chalk so thatthe tire can be reinstalled in the same position e Take out the valve core B to let out the air e Remove the valve stem nut C OWhen handling the rim be careful not to damage the rim flanges e Remove the bead protector nut e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with mineral oil engine oil or gaso line because they will cause deterioration of the tire e Break the beads away from both sides of the rim with the bead breaker A Special Tool Bead Breaker Assembly 57001 1072 e Step on the side of the tire opposite valve stem pry the tire off the rim with the tire iron A of the bead breaker protecting the rim with rim protectors B Special Tools Rim Protector 57001 1063 Tire Iron Protection of the Bead Breaker As sembly 57001 1072 CAUTION Take care not to insert the tire
87. e B e Remove the retaining ring A from the outer tube e Remove the oil seal B Special Tool Oil Seal amp Bearing Remover 57001 1058 12 10 SUSPENSION Front Fork Front Fork Assembly each fork e Assembly is the reverse of disassembly e Replace the following parts removed with a new one Retaining Ring Oil Seal Bottom Allen Bolt Washer e Inspect the following and replace them with new ones if damaged Inner Tube see Inner Tube Insspection Top Plug O ring e Insert the cylinder unit and spring in the inner tube e Insert the cylinder base A in the cylinder unit B OThe cylinder base must be installed with the tapered side facing upward e Insert the inner tube and cylinder unit as a set into the outer tube e Apply a non permanent locking agent to the bottom Allen bolt and tighten it to the specified torque using the front fork cylinder holder Torque Bottom Allen Bolts 20 N m 2 0 kgf m 15 ft Ib Special Tools Fork Cylinder Holder Handle 57001 183 Fork Cylinder Holder Adapter 57001 1011 e Install the oil seal A by tapping with the fork oil seal driver B until it stops Special Tool Fork Oil Seal Driver 57001 1219 e Install the following Retainer Dust Seal e Measure the both diameters of the fork spring ends and insert the fork spring with the small diameter end A fac ing down e Pour the fork oil see Fork Oil change e Install the front fork see this chapter Front Fo
88. e Wire and Hose Routing MAIN HARNESS HOSE AND CABLE ROUTING Viewed From Rear H 1 0 GI Ex ES CG Viewed From Viewed From Front 6B09054BN5 C GENERAL INFORMATION 1 21 Cable Wire and Hose Routing Frame Align the damper center with the frame hole Apply adhesive to diagonal line portion Clamp Run the carburetor drain hose into a hole of the engine guard Ignition Coil Lead Inlet Fuel Hose Crankcase Breather Hose Engine Guard 10 Carburetor Drain Hose 11 Clamp 12 Clutch Cover 13 Cylinder Head 14 Carburetor 15 Choke Cable 16 Throttle Cable 17 Regulator Rectifier 18 Inlet Fitting Oc EENEG 1 22 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length km x 0 6214 mile Prefix Symbol Power m x 3 281 ft mega M x 1000 000 mm x 0 03937 in kilo k x 1000 centi C x 0 01 milli m x 0 001 Units of Torque micro u x 0 000001 N m x 0 1020 kgf m N m x 0 7376 ft lb N m x 8 851 in Ib Units of Mass kgf m x 9807 Mm ko x 2 205 Ib kgf m x 7 233 ft Ib g x 0 03527 oz kgf m x 86 80 in Ib Units of Volume Units of P L 02642 gal US nits of Pressure L x 0 2200 B gal imp kPa x 0 01020 kgf cm L x 105 qt US kPa x 0 1450 psi L 0 8799 qt imp kPa x 0 7501 cmHg L T 2413 pint US kgf cm x 98 07 kPa L x 1816 pint imp E e rx iP mL x 003381 oz US ong E ee Es
89. ear Shift fork worn Gear groove worn Gear dogs holes and or recesses worn Shift drum groove worn Shift drum set lever spring weak or broken Shift fork guide pin worn Shift pawl spring weak or broken 15 4 TROUBLESHOOTING Troubleshooting Guide Drive shaft output shaft and or gear splines worn Overshifts Shift drum set lever spring weak or broken Shift pawl spring weak or broken Abnormal Engine Noise Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Overheating Spark plug incorrect Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston holes worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft journals worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure or damaged Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Loose magneto flywheel Abnormal Drive Train Noise Clutch noise Clutch housing or hub damaged Clutch housing friction plate clearance ex cessive Clutch housing gear primary gear backlash excessive Transmission noise Crankcase bearing worn Metal chip jammed in gear teeth Transmission gears worn or chipped Engine o
90. ear Inspection e Check the brake lining wear indicator A only rear brake points within the USABLE RANGE B when the brake is fully applied If does not the brake shoes must be immediately re placed and the other brake parts examined PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures e Check that the brake cam lever A comes to an 80 90 angle B with the brake rod or cable C when the brake is fully applied xIf it does not adjust the brake cam lever angle Cam Lever Angle Standard 80 90 A WARNING Since a cam lever angle greater than 90 reduces braking effectiveness cam lever angle adjustment should not be neglected 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cam Lever Angle Adjustment CAUTION Do not depress the brake pedal deeply in order to separate the brake rod from the brake cam lever joint this may extend the brake spring beyond its allowable spring extension Rotate the rear brake panel clockwise as far as it will go with the brake rod inserted into the brake cam lever joint then depress the brake pedal lightly SIS P the brake rod will be separated from the brake cam lever joint e Remove the wheel see Wheels Tires chapter e Remove the bolt A and take off the cam lever B OBefore removing the brake cam lever mark C on the cam lever and camshaft at the same position e Mount the cam lever at a new position so that
91. ease of cranckcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the inlet side of the engine While the engine is operating the vapors are drawn into combustion chamber where they are burned along with the fuel and air supplied by the carburetor 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED California State 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 replace ment of any device or element of design incorporated into any new motorcycle for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the motorcycle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related parts e Carburetor and internal pars e Spark plug e Magneto ignition system e Air cleaner element TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the fo
92. eats and may cause serious engine damage NOTE OValve clearance must be checked when the engine is cold at room temperature Valve Clearance when engine cold Inlet and Exhaust 0 04 0 08 mm 0 0016 0 0031 in e Remove Left Shroud Spark Plug see Electrical System chapter Camshaft Sprocket Cover A see Camshaft Sprocket Removal in the Engine Top End chapter Valve Adjusting Covers B see Rocker Arm Removal in the Engine Top End chapter PERIODIC MAINTENANCE 2 9 Periodic Maintenance Procedures e Turn the camshaft sprocket plate A counterclockwise and align the line B on the camshaft sprocket with the projection C on the mating surface of the cylinder head e Measure the clearance of each valve by inserting a thick ness gauge A between the adjusting screw and the valve stem lf a valve clearance is incorrect adjust it e Install the other removed parts Valve Clearance Adjustment e Use a valve adjusting screw holder A to holding the valve adjusting screw B loosen the adjusting screw locknut C and insert the 0 05 mm thickness gauge between valve and adjusting screw and turn the adjusting screw until the adjusting screw stops Special Tool Valve Adjusting Screw Holder 57001 1217 e Tighten the locknut Torque Adjusting Screw Locknut 8 8 N m 0 9 kgf m 78 in Ib e Remove the thickness gauge Spark Arrester Cleaning A WARNING To avoid burns be sure the e
93. echon ee eeeeeeeeeteeeeeeeee 2 25 Chain Slack Inspection 2 14 General Lubrication 2 26 Chain Slack Adjustment 2 14 Lubrication Aerer 2 26 Chain Wear Inspection 2 15 Nut Bolt and Fastener Tightness 2 27 Chain Lubrication 2 16 Tightness Inspection 2 27 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition FREQUENCY Initial Every 100 hours See OPERATION 12 Page months e 2 11 e Spark plug clean gap t e 2 25 Engine oil change Clutch inspection T o e 2 10 e Valve clearance inspection T e 2 8 OU filter element replace e 2 12 E e Air cleaner element clean t e D e 2 7 e ldle speed inspection T Every ride 2 7 e Throttle grip play inspection T e 2 6 e Brake lever pedal play inspection t Every ride 2 17 Every ride 218 Every year 2 26 Every ride Sp Every ride 216 Every year 22 Steering play inspection T e 2 24 C CHASSIS E ENGINE e Emission Related T Replace add adjust or torque if necessary PERIODIC MAINTENANCE 2 3 Specifications Item Standard Service Limit Fuel System Throttle Grip Free Play Idle Speed Air Cleaner Element Oil Engine Top End Valve Clearance Exhaust Inlet Clutch Clutch Adjusting Screw E
94. eeeee eee 3 10 Carburetor Removal nene nnn nent nnn nn nnne nnns nnns nnns nnns senis 3 10 Carburetor Installaton rnmrenenn nennen nnn f 3 11 Garburetor ln e E 3 11 Carburetor Disassembly eer eret trc ten Epub He ua ENERSER RARE TERRE RAD RR EE open ea REPRE 3 12 Carburetor EE 3 13 Carburetor Inspection cccccceccceccceceeeaeecaeeeecenecneeceeeceeecaeecsaecececseseeeeeaaaecaaeneaeeaaesaaenaas 3 14 Alt CICA TT 3 16 Air Cleaner Housing Removal EE 3 16 Air Cleaner Housing INStAMlAN E 3 16 Element ETALON EE E E E A en eeee nene nennen ren rennen rennen nnns 3 16 Element Installation 3 2 eter re re mee Saya bw er deg a rec cu 3 17 Element Cleaning and Inspection eeeeeeeesssessseeeeeeeeee enne nter nnns 3 17 Oil Draining P 3 17 gib Ae Hr 3 18 Fuel Tank Removal retener ee a e dua Pr i P fh RC n 3 18 Fuel Tank Installation 2 rri ee E e te ete e FU td RE e ro a Pe n 3 18 Fuel Tap Remowval sss sae cae enne enne nnne nennen nennen rennen rennen 3 18 Fuel Tap Installations sided ies ee tne dat Ee o ERE ENTRE E MER RARE RR 3 18 Fuel Tap Inspectlon iii e e de Havanese C DRE E E RR ORE ERES Ee UP DR e 3 19 Fuel Tank and Tap leaning sot ce bare tee bond best on diti a M i Rd e apr od bo c PH RU Dog uad 3 19 3 2 FUEL SYSTEM Exploded View FUEL SYSTEM 3 3 Exploded View Oc EENEG
95. eft Side Cover Muffler A Intake Pipe Bolts A Spark Plug Cap B ENGINE REMOVAL INSTALLATION 7 5 Engine Removal Installation e Remove the bolts A and the engine guard B e Remove the brake pedal return spring A e Support the rear part of the frame on the jack A e Support the engine with a suitable stand A e Remove the bolts A and take offthe front footpeg bracket B with side stand 7 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove the three engine mounting bolts A and dis mount the engine Engine Installation e Support the engine with a suitable stand and set it at the correct position e Install the lower A middle B and upper C engine mounting bolts from left side of the engine e Tighten the engine mounting nuts Torque Engine Mounting Nuts 54 N m 5 5 kgf m 40 ft Ib e Install the removed parts e Adjust the drive chain see Final Drive chapter CRANKSHAFT TRANSMISSION 8 1 Crankshaft Transmission Exploded View Specifications Crankcase Splitting Table of Contents GCrANKEASS SS DIMM G MEA Grankcase ASSembly mnri secet Sails Bian ed Rares Eden Dee geb edu Crankshaft Connecting ROG usi e e ah edente qt pipes exerc pO NR Av thie ei isa ue ds Crankshaft Disassembly and Assembhy nene Disassembly Assembly Connecting Rod Big End Seizure Inspection
96. entical e Lightly oil the valve guide outer surface e Heat the cylinder head around the valve guide hole to about 120 150 C 250 302 F e Drive the valve guide in from the top of the cylinder head until the circlip stops the guide from going in too far e Allow the cylinder head to cool e Ream the valve guide with the valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 4 5 57001 1333 Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Seat Inspection e Remove the valve e Check the valve seat surface A between the valve B and valve seat C OCoat valve seat with machinists dye OPush the valve into the guide ORotate the valve against the seat with a lapping tool OPull the valve out and check the seating pattern on the valve head It must be the correct width and even all the way around e Measure the outside diameter D of the seating pattern on the valve seat lf the outside diameter is too large or too small repair the seat see Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 19 9 20 1 mm 0 784 0 791 in Inlet 22 9 23 1 mm 0 902 0 909 in GE15011782 C NOTE OThe valve stem and guide must be in good condition or this check will
97. er Handle 57001 183 7570183ST C Steering Stem Bearing Driver 57001 137 Compression Gauge 20 kgf cm 57001 221 7570137ST C Inside Circlip Pliers 57001 143 7570143ST C Outside Circlip Pliers 57001 144 7570144ST C 7570221ST C Valve Spring Compressor Assembly 57001 241 7570241ST C Bearing Puller Adapter 57001 317 7570317ST C Bearing Puller 57001 158 Piston Pin Puller Assembly 57001 910 7570158ST C 7570910ST C 1 12 GENERAL INFORMATION Special Tools and Sealants Fork Cylinder Holder Adapter 57001 1011 i S T571011ST C Fuel Level Gauge 57001 1017 7571017ST C Oil Seal amp Bearing Remover 57001 1058 7571058ST C Rim Protector 57001 1063 7571063ST C Bead Breaker Assembly 57001 1072 75710728T C Crankcase Splitting Tool Assembly 57001 1098 ST571098ST Steering Stem Nut Wrench 57001 1100 Valve Seat Cutter 45 627 5 57001 1114 Valve Seat Cutter 32 625 57001 1118 D T571100ST C ST571114ST C T571118ST C Valve Seat Cutter 60 530 57001 1123 Q 7T571123ST C Special Tools and Sealants GENERAL INFORMATION 1 13 Valve Seat Cutter Holder Bar 57001 1128 7571128ST C Bearing Driver Set 57001 1129
98. er adjustment xIf the steering is too tight loosen the stem locknut a frac tion of a turn if the steering is too loose tighten the lock nut a fraction of a turn Special Tool Steering Stem Nut Wrench 57001 1100 NOTE OTurn the locknut 1 8 turn at a time maximum e Tighten the following Torque Steering Stem Head Nut 44 N m 4 5 kgf m 32 ft Ib Front Fork Lower Clamp Bolts 29 N m 3 0 kgf m 22 ft lb PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures e Mount the handlebar holders B so that the arrows C on the holder point at the front A OAlign the punch mark D on the handlebar to the mating surface of each clamps of the handlebar e Tighten the clamp bolts front first and then the rear If the handlebar clamp is correctly installed there will be no gap at the front and a gap E at the rear after tightening e Torque the handlebar holder bolts Torque Handlebar Holder Bolts 25 N m 2 5 kgf m 18 ft Ib Steering Stem Bearing Lubrication e Remove the steering stem see Steering chapter e Wipe the old grease off the races and balls washing them in a high flash point solvent if necessary Replace the bearing part if they show wear or damage Apply grease liberally to the upper and lower races and stick the bearing balls in place with grease There are 23 steel balls A installed in the upper or lower outer races xInstall the steering stem Adjust the steering Si
99. es 14 11 Crankshaft Sensor Resistance Measurement eeeeneneeeeeeeeeeeeeeeeeeeeeeeeeeeeeneenaaes 14 11 ignition Coil REMOVAl EE 14 12 Ignition Col dmstallatigfr uie ce s roi rm eret e teta oe Roten te tre i eaaet kde bod Depp 14 12 ignition Coil NSpectiON Oc 14 12 Spark Plug Removal lnstallation EE 14 13 Sparc E OO Ga O EE EE E EA AA A 14 13 14 Spark Plug Cleaning and Inspection dE Geen 14 13 Igniter leeden E 14 13 c elfe D m 14 17 Switch InSpectiOI 2 anui ti diiit tr etie M esed seek saad paced calaneteesincgon sd toads ound gerd Apre at sudo u ds 14 17 Gear Position Switch Removal ote reete oerte due e a gota turpes ir iu des 14 17 Gear Position SwitelilnstallallOFr ss uou dett rot ufu er cest coquat Ducha id poeta Fo gei rand 14 17 Gear Position Switch Inspection sssesssssssssse renes 14 18 14 2 ELECTRICAL SYSTEM Exploded View GP023828W5 C ELECTRICAL SYSTEM 14 3 Exploded View OO Joo P Gobh A Engine Stop Switch Main Harness Regulator Rectifier lgniter Exciter Coil Crankshaft Sensor Flywheel Magneto Cover Spark Plug Gear Position Switch Ignition Coil Frame Damper KLX110 A1 42 N m 4 3 kgf m 31 ft lb KLX110 A1 M10 54 N m 5 5 kgf m 40 ft lb KLX110 A2 M12 5 2 N m 0 53 kgf m 46 in Ib 18 Nem 1 3 kgfm 113 in Ib 2 9 N m 0 3 kgf m 26 in Ib 5 2 N m 0 53 kgfm 46 in Ib KLX110 A1 A7F 8 8 N m 0 9 k
100. ew Holder 57001 1217 Jack 57001 1238 Fork Oil Level Gauge 57001 1290 Steering Stem Nut Wrench 57001 1100 PERIODIC MAINTENANCE 2 5 Periodic Maintenance Procedures Fuel System Fuel Hose and Connections Inspection e Check the fuel hose A for the following Fuel leakage Loose or improperly positioned line clamp B Deteriorated or damaged line Replace the fuel hose if any fraying cracks or bulges are noticed e When installing route the hoses according to Cable Wire and Hose Routing section in the General Informa tion chapter e When installing the fuel hoses avoid sharp bending kink ing flattening or twisting and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed Replace the hose if it has been sharply bent or kinked Fuel Tap Inspection e Remove the fuel tap see Fuel System chapter e Check the fuel tap filter screen A for any breaks or dete rioration If the fuel tap screen have any breaks or is deteriorated it may allow dirt to reach the carburetor causing poor run ning Replace the fuel tap x If the fuel tap leaks or allows fuel to flow when it is at OFF position replace the damaged O ring B 6609016BSi C Fuel Tap Cleaning A WARNING Clean the tap in a well ventilated area and take care that there is no sparks or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasol
101. frame so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 e Spin the wheel lightly and check for roughness or binding e If roughness or binding is found replace the hub bearings e Visually inspect the front and rear axles for damage e If axle damaged or bent replace it Spoke Tightness Inspection e Check that all the spokes A are tightened evenly x Standard spoke tightening torque is shown below Over or under tightening may cause breakage Torque Spokes nipples 1 2 N m 0 12 kgf m 10 in Ib e Check the rim runout A WARNING If any spoke breaks it should be replaced immedi ately A missing spoke places an additional load on the other spokes which will eventually cause other spokes to break l l SAE 20W 50 SAE 20W 40 SAE 10W 50 20 10 40 C 4 L 14 SAE 10W 4 SAE 10W 30 E V H 20 32 50 0 30 L 68 86 J 104 F GSO9010BS1 C PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures Wheel Bearing Inspection e Raise the front wheel off the ground e Turn the end of handlebar to left or right fully feel the excessive play for front wheel bearing by pushing and pulling A the tire e Spin the wheel lightly and check for roughness or binding If roughness or biding is found check the front wheel bearing e Raise the rear wheel off the ground e Feel the excessive
102. g an obligation to make such changes to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2001 Kawasaki Heavy Industries Ltd 8th Edition 1 May 16 2008 K LIST OF ABBREVIATIONS A ampere s Ib pound s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celsius r revolution DC direct current rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s Q ohm s L liter s Read OWNER S MANUAL before operating EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in compliance with applicable regulations of the California Air Resources Board 1 Crankcase Emission Control System This system eliminates the rel
103. gf m 78 in Ib KLX110A8F Apply grease Apply silicone sealant 14 4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Magneto Regulator rectifier Resistance Ignition System Crankshaft Sensor Resistance Air Gap Ignition Coil Primary Winding Resistance Secondary Winding Resistance Exciter Coil Resistance Spark Plug Standard Plug Gap Peak Voltage Ignition Coil Primary Crankshaft Sensor Exciter Coil Special Tools Spark Plug Wrench in the text 50 200 Q Blue Yellow Ground 0 7 mm 0 028 in 0 19 0 23 Q 2 5 3 7 KQ 0 2 1 0 Q White Ground 0 1 0 8 Q Yellow Ground NGK CR6HSA 0 6 0 7 mm 0 024 0 028 in 100 V or above 4 6 V or above 15 V or above Hex 16 57001 1262 Hand Tester 57001 1394 Flywheel Puller M28 x 1 0 57001 1471 Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 Flywheel Holder 57001 1313 Peak Voltage Adapter 57001 1415 Kawasaki Bond Silicone Sealant 56019 120 ELECTRICAL SYSTEM 14 5 iagram D iring W 00011 25086 MOJON Z Z 40sueg 3n g y4eds 149Uusxue 42 n P 93ut10 uo13103 uoo49 1031 oop o en g 1431 ASSI useip yseg 91 09000u T A 38 ya ya A 38 A 18 n a 9po 10 09 141399 403 e n30y A 18 Z oijeuS3ey U34e3 eue e S 5 e YOR ME Uo 1 SOd 48 9 A X8 youlmg doig ouiSug 38 HM 4 38
104. h the clutch holder B OSearch the positions of three notches on the clutch hub where the clutch holder is fixed ORemove two clutch spring bolts C which hinder the set ting the clutch holder and enter into two holes of the clutch holder before setting it OSet the clutch holder Special Tool Clutch Holder 57001 1508 e Remove the primary clutch A and secondary clutch B together ODo not remove the one way clutch from the primary clutch e Remove the spacer from the drive shaft Clutch Installation e Apply engine oil to the clutch sleeves drive shaft and crankshaft e Install the spacer A to the drive shaft e Insert the secondary clutch OBe sure to install the spacer B between secondary clutch housing and clutch wheel KLX110 A1 OHard to install the secondary clutch turn the drive shaft while pushing the clutch e Tighten the secondary clutch nut while holding the sec ondary clutch holder Torque Secondary Clutch Hub Nut 72 N m 7 3 kgf m 53 ft Ib Special Tool Clutch Holder 57001 1508 GFO05005BSi C GF050086BSi C 5 10 CLUTCH Clutches e Install Needle Bearing A Primary Clutch Housing B Needle Bearing C Primary Clutch Sleeve D KLX110 A2 If the primary clutch housing disassembled assemble it as follows Olnstall the gear B to the primary clutch housing A Olnstall the spring C to the holder D OFit the tooth form of the gears
105. he OFF position e Pull the fuel hose off the fuel tap e Remove the fuel tank mounting bolt A and band B e Remove the fuel tank C e Drain the fuel tank Fuel Tank Installation e Check the rubber damper A on the frame xlf the damper is damaged or deteriorated replace it e Install the rubber damper A noting its installing direction as shown OAlign the damper center with the frame hole B OApply adhesive to diagonal line portion C e Be sure the fuel hose is clamped to the fuel tap to prevent leaks e Insert the fuel tank breather hose outlet end into the num ber plate hole Fuel Tap Removal e Remove the fuel tank and drain it e Remove the mounting bolts A and take out the fuel tap B Fuel Tap Installation e Be sure the O ring is in good condition to prevent leaks e Be sure to clamp the fuel hose to the tap to prevent leaks FUEL SYSTEM 3 19 Fuel Tank Fuel Tap Inspection e Refer to the Fuel Tap Inspection in the Periodic Mainte nance chapter Fuel Tank and Tap Cleaning A WARNING Clean the tank in a well ventilated area and take care that there is no sparks or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent to clean the tank e Remove the fuel tank and drain it e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Po
106. he following procedures NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head OThe correct value may not be obtained if disconnected OConnect the peak voltage adapter A of the tester to the terminals of the magneto lead connector B Special Tools Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Hand Tester 57001 1394 Connection Adapter Positive White Lead C Adapter Negative Engine Ground D OCrank the engine by kicking the pedal several times to measure the peak voltage of the exciter coil Peak Voltage DC 15 V or Above xIf the voltage is less than the specified check the exciter coil 14 16 ELECTRICAL SYSTEM Ignition System Troubleshooting Faulty ignition Malfunctioned engine Wiring and connect portion of the ignition system inspection Good Faulty ignition Malfunctioned engine No good Voltage is less than the Good specified value Voltage is specified but faulty ignition No good Voltage is none or almost none Defective ignition coil Replace the malfunctioned Repair Inspect Speed of cranking engine is slow Kicking power too weak Tester resistance too low Use Inspect 1 Peak voltage adapter and connection 2 Engi
107. id Gasket Black 92104 1003 CRANKSHAFT TRANSMISSION 8 5 Crankcase Splitting Crankcase Splitting e Remove the engine see Engine Removal Installation chapter e Set the engine on a clean surface and hold the engine steady while parts are being removed e Remove Cylinder Head see Engine Top End chapter Cylinder see Engine Top End chapter Piston see Engine Top End chapter Clutch Cover see Clutch chapter Primary Clutch Secondary Clutch see Clutch chapter Kick Shaft see Clutch chapter Oil Filter amp Oil Pump see Engine Lubrication System chapter External Shift Mechanism see Clutch chapter Magneto Cover see Electrical System chapter Magneto Flywheel see Electrical System chapter Gear Position Switch Crankcase Screws A e Using the crankcase splitting tool assembly A split the crankcase Special Tool Crankcase Splitting Tool Assembly 57001 1098 e Once the crankcase is split remove the crankcase split ting tool and separate the crankcase halves e Remove the crankshaft from the crankcase half using a press CAUTION Do not remove the ball needle bearings and the oil seals unless it is necessary Removal may damage them e Press the remaining bearing out of the crankcase half if the bearing remains on the crankcase half Crankcase Assembly CAUTION Right and left crankcase halves are machined at the factory in the assembled state so the crankcase halves must be
108. il insufficient or too thin Kick ratchet gear not properly disengaging from kick gear Kick idle gear worn or chipped Drive chain noise Drive chain adjusted improperly Chain worn Rear and or engine sprocket s worn Chain lubrication insufficient Rear Wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock absorber damaged Brake noise Brake linings over worn or worn unevenly Drum worn unevenly or scored Brake spring s weak or broken Foreign matter in hub Brake not properly adjusted Other noise Bracket nut bolt etc mounted or tightened Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve stem oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Main jet too large or fallen off Choke valve closed Float level too high Brown smoke Main jet too small Fuel level too low Air cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Steering stem locknut too tight Steering stem bearing damaged Steering stem bearing race s dented or worn Steering stem lubrication inadequate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm bushing damaged Rim warped Spokes loose Front rear axle runout excessive Wheel bearing worn Handlebar holder bolt loose Steeri
109. in the carburetor drain plug e Turn the fuel tap to the OFF position and remove the fuel level gauge lf the fuel level is incorrect the float level can not be ad justed on this model Inspect the float float valve needle and the contacting surface between the carburetor body and its float valve needle If they are damaged replace them e Install the carburetor Fuel Level Adjustment A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Always stop the en gine and do not smoke Make sure the area is well ventilated and from any source of flame or sparks this includes any appliance with a pilot light e Remove the carburetor drain the fuel into a suitable con tainer e Remove the float bowl A taking out the screws B with lockwashers e Check the float level A Float B Float Valve Needle Rod contacted but unloaded C Float bowl mating surface D Float height Float Height 10 7 2 mm 0 42 0 08 in xIf the float height is incorrect the float height can not be adjusted on this model Inspect the float float valve nee dle NOTE OFloat height is the distance from the float bowl mat ing surface of the carburetor body with the gasket re moved to the top of the float ODo not push the needle rod in during the float height measurement Measure the height with the carburetor upside down GI 9 6606012981 C 3 10 FUEL SYSTEM Carburetor
110. ine or low flash point solvent to clean the tap e Clean the fuel tap filter screen in a high flash point sol vent e Pour high flash point solvent through the tap in all lever positions e Dry the tank and tap with compressed air e Install the tap in the tank Torque Fuel Tap Bolts 4 9 N m 0 5 kgf m 43 in lb KLX110 A3 e Install the fuel tank 2 6 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Grip Free Play Inspection If the throttle grip has excessive free play due to cable stretch or misadjustment there will be a delay in throttle re sponse Also the throttle valve may not open fully at full throttle On the other hand if the throttle grip has no play the throttle will be hard to control and the idle speed will be erratic Check the throttle grip play periodically in accor dance with the Periodic Maintenance Chart and adjust the play if necessary The throttle cable routing is shown in Cable Harness Hose Routing section in the General Information chapter e Check throttle grip free play B by lightly turning the throt tle grip A back and forth If the free play is improper adjust the throttle cable Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in Throttle Grip Free Play Adjustment e Loosen the locknut A at the upper end of the throttle cable e Turn the adjuster B until the proper amount of throttle grip free play is obtained e Tighten the locknut
111. ing e Clean the fuel and air passages with a high flash point A solvent and compressed air e Install the needle jet A into the carburetor so that the a smaller diameter end B of the jet goes in first 6606013381 C e Carefully screw in the needle jet holder It will seat against the needle jet pushing the end of the jet into the carbu retor bore CAUTION Do not force the needle jet holder A and main jet B or overtighten them The needle jet or the car buretor body could be damaged requiring replace ment 6606013481 C e Turn in the air screw A fully but not tightly and then back it out 1 1 4 turns e After installing the carburetor do the following OCheck the fuel leakage OAdjust the following items if necessary Throttle grip free play Idle speed 3 14 FUEL SYSTEM Carburetor Carburetor Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the carburetor see Carburetor Removal e Before disassembling the carburetor check the fuel level If the fuel level is incorrect inspect the rest of the carbu retor before correcting it e Check that the throttle valve A moves smoothly and re turn back with the spring tension
112. ining the part a 1 4 turn before removing them 5 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 6 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removing screws held by non permanent locking agent in order to avoid damaging the screw heads 7 Edges Watch for sharp edges as they could cause injury through careless handling especially during major engine disassembly and assembly Use a clean piece of thick cloth when lifting the engine or turning it over High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com monly available in North America is standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 9 Gasket O ring Replace a gasket or an O ring with a new part when disassembling Remove any foreign matter from the mating surface of the gasket or O ring to ensure a perfectly smooth surface to prevent oil or compression leaks 10 Liquid Gasket Locking Agent Clean and prepare surfaces where liquid gasket or
113. ir should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems
114. irons so deeply that the tube gets damaged e Remove the tube when one side of the tire is pried off e Pry the tire off the rim 6J05040181 6J05060381 6J05010481 9 10 WHEELS TIRES Tires Tire Installation e Inspect the rim and tire and replace them if necessary e Install the tube e Apply a soap and water solution or rubber lubricant to the rim flange and tire beads e Position the tire on the rim so that the valve A is at the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire see Tire Removal e Insert the valve stem into the rim and screw the nut on loosely e Fit the rim protectors and use tire irons to install the tire bead NOTE OTo prevent rim damage be sure to place the rim protec tors at any place the tire irons are applied Pry one side of the tire back onto the rim Fit the bead protector into the tire e Pry the other side of the tire onto the rim starting at the side opposite the valve OTake care not to insert the tire irons so deeply that the tube is damaged e Install the other side of the tire bead onto the rim in the same manner e Check that the tube is not pinched between the tire and rim e Tighten the bead protector nut and valve stem nut e Check and adjust the air pressure after installing e Install the air valve cap 6J05080481 WHEELS TIRES 9 11 Hub Bearing
115. it the crank shaft should be either replaced or disassembled and the crankpin needle bearing and connecting rod big end ex amined for wear Connecting Rod Big End Radial Clearance Standard KLX110 A1 0 009 0 023 mm 0 0004 0 0009 in KLX110 A2 0 006 0 020 mm 0 002 0 0008 in Service Limit 0 07 mm 0 0028 in Connecting Rod Big End Side Clearance Inspection e Measure the side clearance A of the connecting rod with a thickness gauge If the clearance exceeds the service limit replace the crankshaft Connecting Rod Big End Side Clearance Standard 0 1 0 2 mm 0 004 0 008 in Service Limit 0 4 mm 0 016 in 8105020BSi C 6105018BSi C GIO5006BS1 C 8 10 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rod Crankshaft Runout Inspection e Set the crankshaft in a flywheel alignment jig or on V blocks and place a dial gauge A against the points indi cated e Turn the crankshaft slowly The maximum difference in gauge readings is the crankshaft runout Measurement Point B 7 mm 0 28 in Crankshaft Runout Standard Less than 0 03 mm 0 001 in TIR Service Limit 0 08 mm 0 003 in TIR KLX110 A2 Crankshaft Alignment Inspection x If the runout at either point exceeds the service limit align the flywheels so that the runout falls within the service limit e In the case of horizontal misalignment which is the most common strike the projecting
116. lace the camshaft e Measure the height A of each cam Cam Height o Standard Exhaust 29 021 29 201 mm 1 1426 1 1496 in Inlet 28 984 29 164 mm 1 1411 1 1482 in GE11012281 Service Limit Exhaust 28 92 mm 1 139 in Inlet 28 88 mm 1 137 in lf any cam is worn down past service limit replace the camshaft Camshaft Bearing Inspection e Visually inspect each camshaft bearing A If there is any damage replace the camshaft e Turn the bearing back and forth while checking for rough ness or binding If roughness or binding is found replace the camshaft xIf it is noisy does not spin smoothly or has any rough spots replace the camshaft ENGINE TOP END 4 17 Cylinder Head Compression Measurement e Warm up the engine thoroughly e Stop the engine e Remove the spark plug and attach compression gauge and adapter firmly into the spark plug hole Special Tools Compression Gauge 57001 221 A Compression Gauge Adapter M10 x 1 0 57001 1317 B e With the throttle fully open turn the engine over sharply with the kick starter several times until the compression gauge stops rising the compression is the highest read ing obtainable Cylinder Compression Usable Range 865 1320 kPa 8 8 13 5 kgf cm 125 192 psi 5 kicks The following table should be consulted if the obtainable compression reading is not within the us able range Problem C
117. le and adjust it Rear Wheel Removal e Using the jack under the frame so that the rear wheel is raised off the ground Special Tool Jack 57001 1238 e Remove the clip A from the master link using pliers and free the drive chain B from the rear sprocket 9 6 WHEELS TIRES Wheels Rims e Remove Adjusting Nut A Cotter Pin B Rear Torque Link Nut C Rear Torque Link Bolt D Cotter Pin E Rear Axle Nut F CAUTION Do not depress the brake pedal deeply with the brake rod inserted into the brake cam lever joint this may elongate the spring beyond its allowable spring extension e To remove the brake rod end from the brake cam lever first turn the brake panel clockwise A as far as it will go then depress the brake pedal lightly the brake rod B will be separated from the brake cam lever joint C e Pull out the rear axle and remove the rear wheel from the rear wheel coupling and from the motorcycle Rear Wheel Installation e Apply high temperature grease to the grease seal e Install the collar A on the left and right of the rear hub e Install the rear wheel e Install the drive chain e Adjust the drive chain slack see Final Drive chapter e Turn the brake panel clockwise until the brake cam lever joint goes beyond the brake rod end then insert the brake rod end into the joint hole CAUTION Do not insert the brake rod into the cam lever joint by depressing the brake pedal deeply
118. leaning the carbu retor with a cleaning solution This will prevent damage to or deterioration of the parts Do not use a strong carburetor cleaning solution which could attack the plastic parts instead use a mild high flash point cleaning solution safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged e Disassemble the carburetor e Immerse all the metal parts in a carburetor cleaning solu tion e Rinse the parts in water e When the parts are clean dry them with compressed air e Blow through the air and fuel passages with compressed air e Assemble the carburetor Carburetor Disassembly e Remove the carburetor see Carburetor Removal e Pull the whole of spring A to the cap B side and hold it e Take out the cable lower end C from the throttle valve assembly D e Pull out the retainer A and jet needle with circlip B FUEL SYSTEM 3 13 Carburetor e Remove the following parts from the carburetor body Idle Adjusting Screw A O ring B Re T Spring C T Air Screw D M d P Washer E B Gs Spring F 30057 O ring G s O ring H S Pilot Jet A Needle Jet B Needle Jet Holder C Main Jet D Float Valve Needle E Float F Pin G O ring H Float Bowl I 6606013281 C Carburetor Assembly e Clean the disassembly parts before assembl
119. lever e Remove Front Brake Adjusting Nuts A Brake Cable Lower End B Front Brake Cable Guide Clamp C e Pull the brake cable out of the frame Brake Cable Installation e Run the brake cable according to the Cable Wire and Hose Routing Section of the General Information chapter e Adjust the brake lever free play Brake Cable Lubrication e Whenever the cable is removed or in accordance with the Periodic Maintenance Chart lubricate the brake ca ble Refer to the General Lubrication in the Periodic Main tenance chapter OApply a thin coating of grease to the cable upper end OUse a commercially available pressure cable lubricator to lubricate the cable OWith the cable disconnected at both ends the cable should move freely in the cable housing Brake Pedal and Rod Removal e Remove Rear Brake Adjusting Nut A Brake Rod B Brake Cam Lever Joint C Spring D 11 8 BRAKES Brake Lever Brake Pedal Brake Pedal Return Spring A Brake Pedal Mounting Bolt B Brake Pedal C with Rod D Cotter Pin and Washer A Rod B O rings C Brake Pedal and Rod Installation e Brake pedal and rod installation is the reverse of removal e Bend the cotter pin A securely on both sides as shown e Apply a multi purpose grease to the pedal pivot and O rings e Before installing the brake pedal set in the return spring each end to the brake pedal Olnstall the return spring A so that its long hook portion
120. llation Hmmm nenennnis 10 5 Chain Wear nspechon nennen nnn ener nenne nnns n enses 10 5 Chain Bee ET 10 5 Sprockets COUplING EE 10 6 Engine Sprocket ne EE 10 6 Engine Sprocket Installation WEE 10 6 Rear Sprocket Removal eden pe eroe ee eee re e eere SE vr gc cu ds 10 7 Rear Sprocket Installation mnes 10 7 Sprocket Wear Inspechon nenne enn rnnt nnne nnns nennen 10 7 Rear Sprocket Warp Inspection 10 7 Coupling Bearing Removal teet ede eto o re ces Den ree EEN 10 7 Coupling Bearing Installation METTEG 10 8 Coupling Bearing Inspection and Lubrication sseee 10 8 Coupling Damper Inspechon nnne nnne 10 8 10 2 FINAL DRIVE Exploded View FINAL DRIVE 10 3 Exploded View OO Joo P Gobh A Engine Sprocket Cover Engine Sprocket Swingarm Chain Slipper Chain Guide Locknut Adjusting Nut Chain Adjuster Drive Chain Coupling Damper Rear Axle Chain Tension Guide Torque Link Chain Cover 25 N m 2 5 kgf m 18 ft lb 78 N m 8 0 kgf m 58 ft lb 34 N m 3 5 kgf m 25 ft lb 64 N m 6 5 kgf m 47 ft lb Apply high temperature grease Apply heavy oil Replacement parts 10 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Make Type KLX110 A1 DID 420MBK1 KLX110 A2 A4 A6F DID 420DX Link KLX110 A1 88 links Link KLX110 A2 86 links Drive Chain Slack 0 5 mm 0 0 2 in
121. llowing 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 incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below e Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations e Removal of the muffler s or any internal portion of the muffler s e Removal of the air box or air box cover e Modifications to the muffler s or air inlet system by cutting drilling or other means if such modifications result in increased noise levels Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repa
122. lts A and take off the spring plate B and springs C e Remove the clutch hub A and clutch wheel B e Remove the secondary clutch plate C 5 12 CLUTCH Clutches Secondary Clutch Assembly e Install the friction plates A and steel plates B on the secondary clutch hub C starting with a friction plate and alternating them OThe grooves D on the friction plate surfaces are cut tan gentially and radially Install the friction plates so that the grooves run toward the direction of the clutch housing rotation counterclockwise viewed from the engine right side CAUTION If new dry steel plates and friction plates are in stalled apply engine oil to the surfaces of each plate to avoid clutch plate seizure e Install the clutch wheel on the clutch hub e Install the clutch spring plate A with the springs and spring bolts temporarily and fit the clutch hub and plate assembly into the clutch housing B e Install the last friction plate A fitting the tangs in the grooves on the housing as shown e Tighten the clutch spring bolts Torque Secondary Clutch Spring Bolts 3 4 N m 0 35 kgf m 30 in Ib 5 0 N m 0 51 kgf m 44 in Ib KLX110 A3 Primary Clutch Housing Wear Inspection e Measure the inside diameter A of the clutch housing slid ing surface OUse a vernier calipers and measure at several points as shown lf any measurement is greater than the service limit re place the primar
123. ly e Assemble the crankcase 8 14 CRANKSHAFT TRANSMISSION Transmission Shift Fork Bending Inspection e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power A 90 Shift Fork Ear Gear Shift Fork Groove Wear Inspection e Measure the thickness A of the shift fork ears x lf the thickness of a shift fork ear is less than the service limit the shift fork must be replaced Shift Fork Ear Thickness Standard 3 9 4 0 mm 0 154 0 157 in Service Limit 3 8 mm 0 15 in Gl13012181 C e Measure the width A of the gear shift fork grooves in the transmission gears If a gear shift fork groove is worn over the service limit the gear must be replaced Gear Shift Fork Groove Width Standard 4 05 4 15 mm 0 159 0 163 in Service Limit 4 3 mm 0 17 in Hr 7 Ju Shift Fork Guide Pin Shift Drum Groove Wear Inspection e Measure the diameter A of each shift fork guide pin and measure the width B of each shift drum groove lf the guide pin on any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 4 9 5 0 mm 0 193 0 197 in Service Limit 4 8 mm 0 19 in 8113012251 6 If any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width
124. m Fuel Tap Bolts KLX110 A3 4 9 0 5 43 in Ib 46 in lb 78 mb 104 in Ib 16 104 in Ib 113 in lb 46 in lb 46 in lb 46 in lb 46 in lb 46 in lb 46 in lb 78 mb 46 in lb 78 mb 26 in lb 53 53 30 mb 44 in lb 14 46 in lb 46 in lb 46 in lb 16 11 46 in lb 46 in lb 46 in lb 21 40 17 L S Wo GENERAL INFORMATION 1 9 Torque and Locking Agent Fastener Remarks Crankshaft Transmission Crankcase Screws 46 in lb L 1 S Bearing Retainer Screw 5 mm 26 in Ib Bearing Retainer Screw 6 mm 46 in Ib Shift Return Spring Pin 16 L Shift Drum Allen Bolt 46 in lb L Magneto Flywheel Nut 10 mm KLX110 A1 31 Magneto Flywheel Nut 12 mm KLX110 A2 40 Clutch Hub Nut 53 Wheels Tires Spoke Nipples 1 2 0 12 10 in Ib Front Axle Nut 44 4 5 32 Rear Axle Nut 64 6 5 47 Torque Link Nut 25 2 5 18 Final Drive Swingarm Pivot Shaft Nut 58 Rear Sprocket Nuts 25 Rear Axle Nut 47 Torque Link Nut 18 Brakes Front Axle Nut 32 Rear Axle Nut 47 Brake Pedal Bolt 78 in Ib Rear Cam Lever Mounting Bolt 60 in Ib Suspension Front Fork Clamp Bolts Upper 15 Lower 22 Front Fork Bottom Allen Bolts 15 Torque Link Nuts Front 18 Rear 18 Swingarm Pivot Shaft Nut 58 Rear Shock Absorber Mounting Nuts Upper 29 Lower 29 Steering Front Fork Clamp Bolts Upper 15 Lower 22 Steering Stem Head Nut 32 Handlebar Holder Bolts 18 Steering Stem Locknut 43 in Ib 1 10 GENERAL INFORMATION Torque
125. nce repeated cleaning opens the pores of the ele ment replace it with a new one Also if there is a break in the element material or any other damage to the ele ment replace the element with a new one 2 8 PERIODIC MAINTENANCE Periodic Maintenance Procedures A WARNING Clean the element in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element e Remove the air cleaner element A see Fuel System chapter e Clean the element in a bath of a high flash point solvent using a soft bristle brush Squeeze it dry in a clean towel Do not wring the element or blow it dry the element can be damaged e Check all the parts of the element for visible damage If any of the parts of the element are damaged replace them e After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess then wrap it in a clean rag and squeeze it as dry as possible Be careful not to tear the sponge filter e Remove the towel from the carburetor e Install the element Engine Top End Valve Clearance Inspection CAUTION If valve clearance is left unadjusted wear will even tually cause the valves to remain partly open which lowers performance burns the valves and the valve s
126. nding OAfter making the 32 grind return to the seat O D mea surement step above e To measure the seat width use a vernier calipers to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat If the seat width is too narrow repeat the 45 grind until the seat is slightly too width and then return to the seat O D measurement step above If the seat width is too wide make the 60 or 67 5 A grind described below x If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 or 67 5 angle until the seat width is within the specified range OTo make the 60 or 67 5 grind fit 60 or 67 5 cutter to the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 or 67 5 grind return to the seat width measurement step above Correct Width B e Lap the valve to the seat using a lapper once the seat width and O D are within the ranges specified above OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with fine grinding compound Lapper A Valve Seat B Valve C e The seating area should be marked about in the middle of the valve face If the
127. nding and that all the gears shift properly e Clean the cylinder and oil filter cap of the mating surface and wipe off the liquid gasket forced out e Install the removed parts 6104028BSi C 8 8 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rod Crankshaft Disassembly and Assembly CAUTION Since assembly of the crankshaft demands exact ing tolerance the disassembly and reassembly of the crankshaft should only be performed by experienced mechanics with the necessary tools and equipment The crankpin connecting rod and light crankshaft are available separately as spare parts however it is recommended that the crank shaft assembly be replaced rather than attempting to replace the components Disassembly e f it should be necessary to disassemble the crankshaft e Remove the camshaft chain drive sprocket and bearing using the bearing puller if the drive sprocket and bearing remains on the crankshaft e Remove the camshaft chain drive sprocket oil pump gear and bearings using the bearing puller KLX110 A2 e Use a press to remove the crankpin e Removal of the crankpin separates the flywheels con necting rod big end needle bearing and crankpin Special Tool Bearing Puller 57001 158 Assembly e Press the bearing until it bottoms out e Press the camshaft chain drive sprocket on to the left fly wheel as shown Sprocket A Crank Pin B 28 4 0 3 mm 1 12 0 01 in C KLX110 A2
128. ne stop switch 3 Exciter stator coil peak voltage no good part KAWASAKI Hand Tester Lacking of sampling Sampling few times Exciter stator coil peak voltage All good All good C D I Unit is defective No good Replace the malfunctioned part or inspect in proper way GP10187B F ELECTRICAL SYSTEM 14 17 Switches Switch Inspection e Using the hand tester check to see that only the con nections shown in the table have continuity about zero ohms Special Tool Hand Tester 57001 1394 If the switch has an open or short repair it or replace it with a new one Engine Stop Switch Connection Y R Stop Run Gear Position Switch Connection Ground i5 OR Ne O Lr o Gear Position Switch Removal e Remove Engine Sprocket Cover see Final Drive chapter Screws A Gear Position Switch B e Disconnect the gear position switch lead connector C e Remove O ring A Gear Position Switch Finger B Spring C GPi8010281 Gear Position Switch Installation e Insert the spring into the hole in the shift drum e Insert the switch finger A so that the small diameter B is toward hole side e Apply grease to the O ring A sS e Clean the contact points on the position switch R e Tighten the gear position switch screw S Torque Gear Position Switch Screw 2 9 N m 0 3 kgf m 26 in lb e Install the other removed parts GPi
129. ner on the cylinder block e Apply a non permanent locking agent to the threads of mounting bolts A and tighten it the specified torque Torque Chain Tensioner Mounting Bolts 5 2 N m 0 53 kgf m 46 in Ib e Take out the holder plate e Install the O ring and tighten the cap bolt Torque Tensioner Cap Bolt 5 2 N m 0 53 kgf m 46 in Ib e Install the left side cover 4 10 ENGINE TOP END Camshaft Chain Tensioner Replacement Chain Tensioner Installation OA replacement chain tensioner spare parts has a push rod holder plate e Apply a non permanent locking agent to the threads of the tensioner mounting bolts e Install the tensioner on the cylinder block and tighten the mounting bolts Torque Chain Tensioner Mounting Bolts 5 2 N m 0 53 kgf m 46 in Ib e Remove the plate to release the push rod e Install the O ring and tighten the cap bolt Torque Tensioner Cap Bolt 5 2 N m 0 53 kgf m 46 in Ib CAUTION Do not pull the rod holder plate while the tensioner is removed This could detach the rod and the ten sioner cannot be installed easily ENGINE TOP END 4 11 Camshaft Sprocket Camshaft Sprocket Removal e Remove Left Shroud Engine Sprocket Cover see Final Drive chapter Magneto Cover see Electrical System chapter e Remove the camshaft sprocket cover bolts A and take off the cover B e Turn the crankshaft counterclockwise until the line adjoin ing the line ma
130. ng clockwise and insert the other end of the spring into the crankcase e Install the plastic spring guide e Install the clutch cover Kickstarter Assembly e Apply a thin coat of molybdenum disulfide grease A to the ratchet teeth and the kick gear inside Ratchet B Kick Gear C Kick Shaft D Spring Guide E Return Spring F e Replace the circlips that were removed with new ones e Align the ratchet punch mark A with the punch mark B on the kick shaft CAUTION Misalignment of the ratchet changes the kick spring preload Light preload could cause mech anism noise and heavy preload could weaken or break the spring G119002BS2 C CLUTCH 5 17 Kickstarter Kickstarter Inspection e Visually inspect the parts and portion listed below Kick shaft return spring A Ratchet gear spring B Ratchet portion C of the kick gear D and ratchet gear E lf there is any kind of damage replace the damaged part e Measure the kick shaft diameter A where the kick gear fits If it is under the service limit replace the shaft e Measure the inside diameter B of the kick gear If it exceeds the service limit replace the gear Kick Shaft Kick Gear Diameter Standard B i zi 2 z ll Kick Shaft 15 941 15 968 mm 0 6276 0 6287 m in coe f Kick Gear Leg 16 018 mm 0 6299 0 6306 Service Limit Kick Shaft 15 92 mm 0 62668 in Kick Gear 16 04 mm 0 6315 in
131. ng stem head nut Handlebar pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering stem bent Front fork leg bent not properly TROUBLESHOOTING 15 5 Troubleshooting Guide Right left front fork oil level uneven Rear shock absorber oil leaking Rear shock absorber and or swingarm bent Tire air pressure too low Shock absorption unsatisfactory Brake Doesn t Hold Too hard Drum Brake Front fork oil excessive Front fork oil viscosity too high Brake not properly adjusted Front fork bent Linings overworn or worn unevenly Tire air pressure too high Drum worn unevenly or scored Too soft Cam camshaft shaft hole worn Front fork oil viscosity too low Oil grease on lining and drum Front fork rear shock absorber spring weak Dirt water between lining and drum Front fork oil leaking Overheated MODEL APPLICATION Year Model Beginning Frame No ama onon AA amo mone EE 2004 KLX110 A3 JKALXSA104DA14318 ms anons US 7 mn mmm C UN 2007 _KLXTIOATF JKALXI10AADA49621 2008 KLXTIOABF JKALXTIOAADAS6151 mo ammor EE L1 This digit in the frame number changes from one machine to another WE Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1283 08 Printed in Japan
132. ngine Lubrication System Engine Oil Type Viscosity Capacity Level Tires Rim Runout with tire installed Axial Radial Final Drive Drive Chain Slack Drive Chain 20 link Length Brakes Brake Lever Free Play Brake Pedal Free Play Brake Cam Lever Angle Front Rear Suspension Fork Oil Viscosity Fork Oil Level Fully Compressed Without Spring Electrical System Standard Plug Spark Plug Gap 2 3 mm 0 08 0 12 in ates 1 250 1 350 r min rpm Basse High quality foam air filter oil EE 0 04 0 08 mm 0 0016 0 0031 in 0 04 0 08 mm 0 0016 0 0031 in 1 4 turn out API SE SF or SG API SH or SJ with JASO MA MA1 or MA2 KLX110 A1 A6F API SH SJ or SL with JASO MA MA1 or MA2 KLX110A7F SAE 10W 40 1 1 L 1 2 us qt when engine is completely dry 1 0 L 1 1 us qt when filter is removed 0 9 L 1 0 us qt when filter is not removed Between upper and lower level lines TIR 0 8 mm 0 03 in or less TIR 1 0 mm 0 04 in or less TIR 2 mm 0 08 in TIR 2 mm 0 08 in 0 5 mm 0 0 2 in oe 254 0 254 6 mm 10 00 10 02 in 259 mm 10 20 in 4 5 mm 0 16 0 20 in ae 20 30 mm 0 79 1 18 in 80 90 ses 80 90 SEN SHOWA SS 8 or equivalent mee 89 2 mm 3 5 0 08 in Ee NGK CR6HSA S 0 6 0 7 mm 0 024 0 028 in Ger 2 4 PERIODIC MAINTENANCE Specifications Special Tools Valve Adjusting Scr
133. ngine and run it for sev eral minutes at idle speed This fills the oil filter with oil Then stop the engine and wait several minutes until the oil settles e If the motorcycle has just been used wait several minutes for all the oil to drain down e Situate the motorcycle so that it is perpendicular to the ground e Check that the engine oil level is between the upper A didi La and lower B levels in the gauge The oil level should be between the lines next to the gauge xIf the oil level is too high remove the excess oil using a syringe or some other suitable device xIf the oil level is too low add oil through the oil filler open ing Use the same type and make of oil that is already in the engine NOTE Olf the oil must be refilled but the type and brand of the oil already in the engine are unidentified change the oil in the engine completely Oil Change e Support the motorcycle perpendicular to the ground e Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily Then stop the engine e Place an oil pan beneath the engine e Remove the engine oil drain plug A and the oil filler open ing to drain the oil OThe oil in the oil filter can be drained by removing the filter e After the oil has completely drained install the drain plug with its gasket Replace the drain plug gasket with a new one if it is dam aged e Tighten the drain plug Torque Engine Oil Dr
134. non permanent locking agent will be used Apply them sparingly Excessive amount may block engine oil passages and cause serious dam age 3 x CO x GENERAL INFORMATION 1 3 Before Servicing 11 Press When using a press or driver to install a part such as a wheel bearing apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit 12 Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary Replace any ball or needle bearings that were removed with new ones Install bearings with the manufacturer and size marks facing out applying pressure evenly with a suitable driver Apply force only to the end of the race that contacts the press fit portion and press it evenly over the base component 13 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals Oil or grease seals should be pressed into place using a suitable driver applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole unless instructed otherwise When pressing in an oil or grease seal which has manufacturer s marks press it in with the marks facing out 14 Circlip Retaining Ring and Cotter Pin When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more Install the circli
135. not be valid xIf the valve seating pattern is not correct repair the seat e Measure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F xIf the width is too wide G too narrow H or uneven J repair the seat see Seat Repair Valve Seat Width Standard Exhaust 0 80 1 15 mm 0 0315 0 0453 in Inlet 0 80 1 15 mm 0 0315 0 0453 in 4 22 ENGINE TOP END Valve Valve Guide Valve Seat Repair e Repair the valve seat with the valve seat cutters Special Tools Valve Seat Cutter Holder 4 5 57001 1330 Valve Seat Cutter Holder Bar 57001 1128 Inlet Special Tools Valve Seat Cutter 45 627 5 57001 1114 Valve Seat Cutter 32 025 57001 1118 Valve Seat Cutter 60 630 57001 1123 Exhaust Special Tools Valve Seat Cutter 32 622 57001 1206 Valve Seat Cutter 45 622 57001 1205 Valve Seat Cutter 67 5 522 57001 1207 lf the manufacturer s instructions are not available use the following procedure Seat Cutter Operating Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purpose than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with
136. nt grease or oil from getting on them remove and install the brake shoes A by pulling up on the center of the linings e Pull the brake camshaft out from the brake panel inside Brake Panel Assembly e Lubricate the brake camshaft e Fit the indicator A on the serration so that it points to the extreme right of the USABLE RANGE B Rear panel only Brake Drum Wear Inspection xlIf the drum is worn unevenly or if it is scored turn the drum down on a brake drum lathe or replace the hub with a new one Do not turn it down to the service limit and do not turn it down if any diameter measurement exceeds the service limit e Measure the inside diameter A of the brake drum Since uneven drum wear will decrease braking effectiveness take measurement at a minimum of two places If any diameter measurement exceeds the service limit replace the hub with a new one Brake Drum Inside Diameter Standard Front 90 000 90 087 mm 3 543 3 547 in Rear 110 000 110 087 mm 4 331 4 334 in Service Limit Front 90 75 mm 3 57 in Rear 110 75 mm 4 36 in BRAKES 11 11 Brake Panel and Drum Brake Shoe Lining Wear Inspection e Visually inspect the linings for uneven wear and file or sand down any high spots With a wire brush remove any foreign particles imbedded in the lining surface Wash off any oil or grease with a high flash point solvent Do not use one which will leave an oily residue xIf the
137. nut 4 9 N m 0 5 kgf m 43 in Ib e Install the front fork see the Suspension chapter NOTE OTighten the fork upper clamp bolts first next the stem head nut last the fork lower clamp bolt Torque Steering Stem Head Nut 44 N m 4 5 kgf m 32 ft Ib Front Fork Clamp Bolt Upper 20 N m 2 0 kgf m 15 ft lb Lower 29 N m 3 0 kgf m 22 ft lb e Install the parts removed see the appropriate chapter A WARNING Do not impede the handlebar turning by routing the cables wires and hoses improperly see the Gen eral Information chapter e Check and Adjust Steering Front Brake Throttle Cable Steering Stem Race Removal e To remove the outer races A pressed into the head pipe insert a bar C into the head pipe B and hammer evenly around the circumference of the opposite race to drive it out GNO7030181 STEERING 13 7 Steering e Remove the lower inner race on the steering stem with a bearing puller A Special Tools Bearing Puller 57001 158 Bearing Puller Stud 57001 1190 B Bearing Puller Adapter 57001 317 C Steering Stem Race Installation Notes e Apply engine oil to the outer races and then drive them into the head pipe using the bearing driver set A Special Tool Bearing Driver Set 57001 1129 e Drive the lower inner race A onto the steering stem using the stem bearing driver B Special Tool Steering Stem Bearing Driver 57001 137
138. o the throttle cable upper end e Install the brake lever holder as shown OPosition the brake lever holder so that its vertical parting line A is aligned with punch mark B on the handlebar e Install the throttle grip assembly OPosition the throttle housing so that its vertical parting line A is aligned with punch mark B on the handlebar STEERING 13 9 Handlebar e Install the engine stop switch OPosition the engine stop switch so that its edge A is aligned with the punch mark B on the handlebar ELECTRICAL SYSTEM 14 1 Electrical System Table of Contents Exploded VieW CP 14 2 eene le 14 4 WV LAGE AIM eR m 14 5 Le 14 6 Electrical WING Rm 14 7 MTEC Pe HE 14 7 Magneto Flywheel EE 14 8 Magneto Cover Removal EE 14 8 Magneto Gover Installation rette ren tree Puce E Eden opere For ap er epe aun ads 14 8 Magneto Cover Disasseimblys semota bre e ta cac Lo ptem duds 14 8 Magneto Cover Assembly teo et I P E ates See de 14 9 Magneto Flywheel Removal EE 14 9 Magneto Flywheel Installation eeeseeeeeeeeeeeeeeeseee eene nennen nnne 14 9 Magneto Flywheels Inspection rescindere A tee een 14 10 Regulator Rectifier INSPeCtion cccccesseeenccceeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeenseecenseeensees 14 10 Ignition SyStE c mm 14 11 el ROMO E 14 11 Exciter Coil Resistance Measurement ccccceceseeeenceeeeseeeeeseeeceeeeeeeeesseeeaneeeeeeeeeees
139. on Pin Hole Inside Diameter Connecting Rod Small End Inside Diameter 53 10 mm 2 091 in 52 83 mm 2 080 in 0 16 mm 0 0063 in 0 15 mm 0 0059 in 0 90 mm 0 035 in 0 90 mm 0 035 in 0 7 mm 0 028 in 0 7 mm 0 028 in 0 6 mm 0 024 in 0 8 mm 0 032 in 0 9 mm 0 035 in 12 96 mm 0 5102 in 13 07 mm 0 5146 in 13 05 mm 0 5138 in Special Tools Compression Gauge 57001 221 Valve Spring Compressor Assembly 57001 241 Piston Pin Puller Assembly 57001 910 Valve Seat Cutter 45 627 5 57001 1114 Valve Seat Cutter 32 625 57001 1118 Valve Seat Cutter 60 630 57001 1123 Valve Seat Cutter Holder Bar 57001 1128 Valve Spring Compressor Adapter 020 57001 1154 Valve Seat Cutter 32 622 57001 1206 Valve Seat Cutter 45 622 57001 1205 Valve Seat Cutter 67 5 622 57001 1207 Valve Adjusting Screw Holder 57001 1217 Compression Gauge Adapter M10 x 1 0 57001 1317 Valve Seat Cutter Holder 4 5 57001 1330 Valve Guide Arbor 4 5 57001 1331 Valve Guide Reamer 4 5 57001 1333 4 8 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type cam chain tensioner The push rod does not return to its original position once it moves out to take up cam chain slack Ob serve all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolt
140. or clogging Oil Pressure Standard 88 147 kPa 0 9 1 5 kgf cm 13 21 psi 24 000 r min rpm oil temperature 50 C 122 F e Stop the engine e Remove the oil pressure gauge adapter and oil pressure cap A WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed e Install the oil filter cap see Oil Filter Element Replace ment in the Periodic Maintenance chapter ENGINE REMOVAL INSTALLATION 7 1 Engine Removal Installation Table of Contents Exploded A iT 7 2 Engine Removal lnstallation EE 7 4 Ge Dale EE 7 4 Erigiri amp TEE 7 6 7 2 ENGINE REMOVAL INSTALLATION Exploded View 6H02092885 C ENGINE REMOVAL INSTALLATION 7 3 Exploded View 1 Footpeg Mounting Bolts G Apply grease T1 54 N m 5 5 kgf m 40 ft Ib T2 23 N m 2 3 kgf m 17 ft lb 7 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal e Drain the engine oil see Engine Lubrication chapter e Squeeze the brake lever slowly and hold it with a band A A WARNING Be sure to hold the front brake when removing the engine or the motorcycle may fall over It could cause an accident and injury e Remove Shift Pedal A Engine Sprocket Cover B Engine Sprocket A Drive Chain B Breather Tube Lower End C Magneto Lead Connectors D Gear Position Switch Lead Connector E Right and L
141. p with its chamfered side facing load side as well Replace any circlips retaining rings and cotter pins that were removed with new ones as re moval weakens and deforms them If old ones are reused they could become detached while the motorcycle is driven leading to a major problem 15 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film During assembly make sure to apply oil to any sliding surface or bearing that has been cleaned Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives therefore make sure to wipe it off and apply fresh grease or oil Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended 16 Direction of Engine Rotation To rotate the crankshaft manually make sure to do so in the direction of positive rotation Pos itive rotation is counterclockwise as viewed from the left side of the engine To carry out proper adjustment it is furthermore necessary to rotate the engine in the direction of positive rotation as well 17 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed Replacement parts will be damaged or lose their original function once they are removed There fore always replace
142. paired by using a wet stone to remove sharp edges or raised areas which cause seal damage lf the damage is not repairable replace the inner tube Since the damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced e Temporarily assemble the inner and outer tubes and pump them back and forth manually to check for smooth operation CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Rear Shock Absorber Inspection Since the rear shock absorber is sealed units which can not be disassembled only external checks of operation are necessary e With the shock absorber removed compress it and see that the compression stroke is smooth and that there is damping in addition to spring resistance to compression When the unit is released the spring should not suddenly snap it to full length It should extend smoothly with no table damping When the shock absorber is operated there should be no oil leakage PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures e Check the rubber bushings A xIf they are worn cracked hardened or otherwise dam aged replace them Swingarm Pivot Inspection e Check for wear or damage to the shock absorber and the swing arm mount pivot point while compressing A the rear suspension a few times e Use the jack under the f
143. pe Lower Steel Balls Steering Stem Lower Inner Race Lower Outer Race Upper Outer Race Upper Inner Race Stem Cap Front Fender Mounting Bolts Apply adhesive cement Apply 2 stroke oil Apply grease 44 N m 4 5 kgf m 32 ft lb 20 N m 2 0 kgf m 15 ft lb 4 9 N m 0 5 kgf m 43 in Ib 25 N m 2 5 kgf m 18 ft lb 29 N m 3 0 kgf m 22 ft lb 13 4 STEERING Specifications Special Tools Steering Stem Bearing Driver 57001 137 Steering Stem Nut Wrench 57001 1100 Jack 57001 1238 Bearing Driver Set 57001 1129 Bearing Puller 57001 158 Bearing Puller Stud 57001 1190 Bearing Puller Adapter 57001 317 STEERING 13 5 Steering Steering Inspection e Refer to the Steering Inspection in the Periodic Mainte nance chapter Steering Adjustment e Refer to the Steering Adjustment in the Periodic Mainte nance chapter Steering Stem Removal e Remove Front Wheel see Wheels Tires chapter Front Brake Cable Clamp Front Fender Handlebar see Handlebar Removal Front Fork see Suspension chapter e Remove the steering stem head nut and washer e Remove the steering stem head e Pushing up on the stem base A and remove the steering stem locknut B with the steering stem nut wrench C then remove the steering stem D and stem base Special Tool Steering Stem Nut Wrench 57001 1100 e As the stem is removed some of the steel balls will drop out of the lower outer r
144. play for rear wheel bearing by pushing and pulling the tire e Spin A the wheel lightly and check for roughness or bind ing x If roughness or binding is found check the rear wheel and coupling of bearings Rim Runout Inspection e Place the jack under the frame so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 e Inspect the rim for small cracks dents bending or warp ing xIf there is any damage to the rim it must be replaced e Set a dial gauge against the side of the rim and rotate the rim to measure axial runout A The difference be 3810810 1 c tween the highest and lowest dial readings is the amount of runout e Set a dial gauge to the outer circumference of the rim and rotate the rim to measure radial runout B The dif ference between the highest and lowest dial readings is the amount of runout e If rim runout exceeds the service limit check the hub bear ing first Replace them if they are damaged If the prob lem is not to the bearings correct the rim warp runout A certain amount of rim warp can be corrected by recen tering the rim Loosen some spokes and tighten others within the standard torque to change the position of dif ferent parts of the rim If the rim is badly bent however it should be replaced Rim Runout with tire installed Standard Axial TIR 0 8 mm 0 03 in or less Radial TIR 1 0 mm 0 04 in or less Service Limit Axial TIR 2 mm
145. prings Brake Shoe Springs Inspection Standard Front 30 8 31 2 mm 1 213 1 228 in Rear 32 5 mm 1 28 in Service Limit Front 32 6 mm 1 28 in Rear 34 1 mm 1 34 in Brake Panel Lubrication e Refer to the Brake Panel Lubrication in the Periodic Main tenance chapter SUSPENSION 12 1 Suspension Table of Contents Exploded VieW EE 12 2 eene e TEE 12 6 mitos gon ET 12 7 Fork Oil Level Check Simplify iui rater tetti oat dei alas dee perpe 12 7 Oil Change Oil Level Adjustment each fork leg cece eee eeneeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeenaaes 12 7 Front Wel de CU 12 8 Front Eork Installation ideo re Wie Al ere t pe ere eege ga da ag der pa Cu 12 8 Front Fork Disassembly each fork 1 12 8 Front Fork Assembly each fork Edel eue ended ipae ebd e dAn 12 10 Front Fork Inner Tube Inspection eene mener 12 10 Dust Seal Oil Seal Inspection sssssssssssssse eene 12 11 Spring Tension Inspection emere ener nennen nennen 12 11 Rear Shock Abeorber A 12 12 iur anes earlier ie in ear ee ees 12 12 lef e EEN 12 12 Rear Shock Absorber Inspection memes 12 12 Rear Shock Absorber Scrapping cee eeeee cece eeee eee eeee eee see eeeeseeeseeeeeeeeeeeeeeeeeeees 12 12 ee EE 12 13 Swingarm e EEN 12 13 le a D E 12 13 Swingarm Rubber Bushing Inspection eee ceceeeeeeee eee ee eeeeeeeeee etree eeeeneaeaeeeeeeeeeenenenaaeees 12 13 12 2 SUSPENSION Exploded View T
146. r and provide better lubrication e If the chain appears especially dirty it should be cleaned before lubrication e Apply oil to the sides of the rollers and between the side plates of the links so that oil will penetrate to the bushings and pins where most wear takes place e Wipe off any excess oil Oil applied area A Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage lf they are worn as illustrated or damaged replace the sprocket with new ones and inspect the drive chain wear Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocket B Direction of Rotation C NOTE Olf a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket inspect the chain GK04080851 C EZ A GK04030381 GKO5017BS1 C PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Chain Slipper Wear Inspection e Visually inspect the chain slipper A on the swingarm and replace it if worn or damaged Brakes Brake Lever Brake Pedal Free Play Inspection e Check the front brake lever free play A when the brake is lightly applied Lever Free Play Standard 4 5 mm 0 16 0 20 in If the lever has improper play adjust it e Operate the lever a few times to see that it returns to its rest position immediately upon release e Check the brake pedal free play A when the pedal is pushed down
147. r dirt will fall into the crankcase Cylinder Installation NOTE Olf the cylinder block is replaced with a new one piston to cylinder clearance must be checked against the speci fied value e Install a new cylinder base gasket A and be sure that two knock pins B are properly fitted in the crankcase e Pull the camshaft chain taut top avoid kicking it and use a wrench on the crankshaft to set the piston at BTDC e Position the piston ring opening as follows Top Ring Front A Second Ring Rear B Upper Steel Rail About 30 90 of angle to the right C Expander Rear D Lower Steel Rail About 30 90 of angle to the left C Piston E e Apply engine oil to the piston rings and the cylinder inside surface e Pull the camshaft chain up through the cylinder and insert a screwdriver to keep the chain from falling back into the engine e Place the upper camshaft chain guide inside the cylinder blocks e Fit the bottom of the cylinder over the piston rings press ing in on opposite sides of the rings as necessary Take care that the rings do not slip out of their proper positions e Insert the lower camshaft chain guide A all the way down e Install the cylinder head Opening Position 30 90 4530 90 ENGINE TOP END 4 29 Cylinder Piston Piston Removal e Remove the cylinder e Remove Pliers A Snap Ring B e Remove the piston by pushing its pin pull out the side
148. rame so that the rear wheel is raised off the ground Special Tool Jack 57001 1238 e Move the swingarm A side to side to check for worn damaged or loose suspension pivot components lf any play is detected check for looseness of swingarm pivot bolt or for damage to the swingarm rubber bushings Swingarm Rubber Bushing Inspection e Visually inspect the rubber bushings A lf they are deteriorated or damaged replace them 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection e Using the jack raise the front wheel off the ground Special Tool Jack 57001 1238 e With the front wheel pointing straight ahead alternately nudge each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop x If the steering binds or catches before the stop check the routing of the cables hoses and harnesses x If the steering feels tight adjust or lubricate the steering e Feel for steering looseness by pushing and pulling A the forks If you feel looseness adjust the steering Steering Adjustment e Remove the number plate e Using the jack raise the front wheel off the ground Special Tool jack 57001 1238 e Remove the handlebar e Loosen the front fork lower clamp bolts A and steering stem head nut B e Turn the steering stem locknut A with the steering stem nut wrench B to obtain the prop
149. rankcase see Crankcase Splitting e Pull out the shift rods and take out the shift forks e Remove the drive and output shaft assemblies as a set e Holding the shift drum with suitable bar unscrew the shift drum Allen bolt A e Remove the cam holder B shift drum cam C and dowel pin D e Remove the shift drum E Transmission Disassembly e Remove the transmission shafts e Using the circlip pliers to remove the circlip disassemble the transmission shaft Special Tool Outside Circlip Pliers 57001 144 Transmission Assembly e Assemble the transmission gears as shown OReplace the old circlip with a new one if it is removed OThe drive shaft gears can be identified by size the small est diameter gear is 1st gear and the largest is 4th not working Be sure that all parts are put back in the correct sequence facing the proper direction and that the circlip and the washer are properly in place 2nd Gear A 3rd Gear B 4th Gear not working C 1st Gear D Circlip E Shim F Apply Engine Oil G Bushing H KLX110 A2 OThe output shaft gears can be identified by size the largest diameter gear is 1st gear and the smallest is 4th not working Be sure that all parts are put back in the correct sequence and facing the proper direction and that the circlip is properly in place 2nd Gear A 3rd Gear B 4th Gear not working C 1st Gear D Circlip E Spacer F 6113011951
150. refully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read the tester If the tester does not read 0 Q the lead is defective Re place the lead or the wiring harness B if necessary 6GPO07001BSi C 14 8 ELECTRICAL SYSTEM Magneto Flywheel Magneto Cover Removal e Drain the engine oil e Remove Shift Pedal Engine Sprocket Cover see Final Drive chapter e Pull off the magneto connector A e Remove Magneto Cover Screws A KLX110 A1 A7F Magneto Cover Bolts A KLX110A8F Magneto Cover B Magneto Cover Installation e Check that two dowel pins are in place in the left crankcase half e Replace the gasket e Apply silicone sealant A around the circumference of the wiring grommet e Install the magneto cover Sealant Kawasaki Bond Silicone Sealant 56019 120 KLX110 A1 A7F e Tighten the magneto cover screws following the tighten ing sequence as shown Torque Magneto Cover Screws 5 2 N m 0 53 kgf m 46 in Ib KLX110A8F e Tighten the magneto cover bolts following the tightening sequence as shown Torque Magneto Cover Bolts 8 8 N m 0 9 kgf m 78 in Ib e Fill the engine with engine oil see Engine Lubrication System chapter
151. ressor Adapter 420 57001 1154 B e Remove the tool and then remove the spring retainer spring and spring seat e Push out the valve e Pull off the valve stem oil seal Valve Installation e Replace the valve stem oil seal A e Push a new valve stem oil seal into place If a new valve is to be used check the valve to guide clearance If there is too much clearance install a new valve guide e Apply a thin coat of molybdenum disulfide grease to the valve stem C e Check to make sure that the valve and the valve seat are making proper contact e Install spring D so that the closed coil end E faces the spring seat B painted side faced the spring retainer e Install the spring retainer F press it down with the valve spring compressor assembly and put on the split keepers G e After making sure that the split keepers and valve stem are all properly fitted remove the tool e Install Camshaft Rocker Arm amp Arm Shaft Cylinder Head OCheck the valve clearance and adjust if necessary Valve Guide Removal e Remove Cylinder Head Valve Valve Stem Oil Seal e Heat the area around the guide to about 120 150 C 250 302 F and hammer lightly on the valve guide arbor A to remove the guide from the top of the head Special Tool Valve Guide Arbor 4 5 57001 1331 ENGINE TOP END 4 21 Valve Valve Guide Valve Guide Installation OValve guides are id
152. riction plates if their tangs are damaged GF08007BS1 C GFO6040281 GF08040481 C GFOGO008BS1 C CLUTCH 5 15 Clutches Secondary Clutch Hub Spline Damage Inspection e Visually inspect where the teeth on the steel plates wear against the clutch hub splines xIf there are notches worn into the clutch hub splines A replace the clutch hub Also replace the steel plates if their teeth are damaged Secondary Clutch Spring Free Length Measurement e Measure the spring free length A If measurement is less than the service limit replace it Clutch Spring Free Length Standard KLX110 A1 24 00 mm 0 94 in KLX110 A2 22 04 mm 0 87 in Service Limit KLX110 A1 23 00 mm 0 91 in KLX110 A2 20 35 mm 0 80 in 6GF06030381 Clutch Adjustment e Refer to the Clutch Adjustment in the Periodic Mainte nance chapter 5 16 CLUTCH Kickstarter Kickstarter Removal e Remove the clutch cover e Remove the return spring A with pliers e Remove Spring Guide B e Remove the kick shaft assembly C twisting it counter clockwise e There is a thrust washer between the kick shaft end and the crankcase Kickstarter Installation e Apply molybdenum disulfide grease to the thrust washer e Put the thrust washer A on the kick shaft end and fit the kick shaft assembly in the crankcase e Fitthe return spring end into the kick shaft turn the spri
153. rim of the flywheel with a plastic soft lead or brass hammer as indicated in the figure e Recheck the runout with a dial gauge repeating the process until the runout falls within the service limit OVertical misalignment is corrected either by driving a wedge in between the flywheels or by squeezing the flywheel rims in a vise depending on the nature of the misalignment G105062BS1 C 6105015B51 C CRANKSHAFT TRANSMISSION 8 11 Crankshaft Connecting Rod e n the case of both horizontal and vertical misalignment correct the horizontal misalignment first e Recheck big end side clearance after aligning crankshaft see Connecting Rod Big End Side Clearance NOTE 5 Olf crankshaft alignment cannot be corrected by the above method replace the crankpin or crank halves as required Recheck the runout and repeat the process ES a until the runout is within service limit CAUTION d Don t hammer the flywheel at the point A GIO05008BS2 C Crankshaft Main Bearing Wear Inspection e Wash the bearings in high flash point solvent blow them dry DO NOT SPIN THEM and lubricate them with en gine oil e Turn A each bearing over by hand and see that it makes no noise turns smoothly and has no rough spots xIf any of the bearings are defective replace them 6113014981 8 12 CRANKSHAFT TRANSMISSION Transmission Transmission and Shift Mechanism Removal e Split the c
154. ring the voltage or you may receive a se rious electric shock lf the voltage is less than the specified value see the troubleshooting Crankshaft Sensor Peak Voltage Check e To check the peak voltage do the following procedures ODisconnect the magneto lead connector NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head OThe correct value may not be obtained if disconnected OConnect the peak voltage adapter A of the tester to the terminals of the magneto lead connector B Special Tools Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Hand Tester 57001 1394 Connection Adapter Positive Blue Yellow Lead C Adapter Negative Engine Ground D OCrank the engine by kicking the pedal several times to measure the peak voltage of the crankshaft sensor Peak Voltage 4 6 V or above A WARNING Do not touch the metal portion of the probe in case of measuring the voltage or you may receive a se rious electric shock If the voltage is less than the specified check the crank shaft sensor ELECTRICAL SYSTEM 14 15 Ignition System Exciter Coil Peak Voltage Check e Disconnect the connector of the main harness from the igniter e To check the peak voltage do t
155. rk Inner Tube Inspection e Refer to the Inner Tube Inspection in the Periodic Main tenance chapter Ee Ge SISCH DEZ d GM04014581 C SUSPENSION 12 11 Front Fork Dust Seal Oil Seal Inspection e Inspect the dust seal B for any signs of deterioration or damage Replace it if necessary e Replace the oil seal A with a new one whenever it has been removed Spring Tension Inspection e Since a spring becomes shorter as it weakens check its free length A to determine it condition xIf the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced fro motorcycle stability Fork Spring Free Length Standard 439 7 mm 17 31 in Service Limit 430 9 mm 16 96 in 6M04042BSi C 6M04011681 12 12 SUSPENSION Rear Shock Absorber Removal e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Remove the shock absorber mounting bolt A nut and pull off the shock absorber B e To remove the rubber bushings A tap out the bushing with a suitable tool Installation e Press in the rubber bushings A as shown e Install the shock absorber e Tighten the shock absorber mounting bolt and nut Torque
156. rk on the camshaft sprocket A aligns of the sprocket cover mating surface projection B e Remove the camshaft chain tensioner e With a wrench on the magneto flywheel bolt to keep the crankshaft from turning remove the camshaft sprocket bolts A e Remove camshaft sprocket B e Use a screwdriver A or wire to keep the chain B from falling down into the cylinder clock CAUTION Always pull the camshaft chain taut while turning the crankshaft when the camshaft chain is loose This avoids kinking the chain on the lower crank shaft sprocket A kicked chain could damage both the chain and the sprocket 4 12 ENGINE TOP END Camshaft Sprocket Camshaft Sprocket Installation e Check crankshaft position to see that the T mark A on the magneto flywheel aligns with the index mark B on the crankcase e Remember to pull the camshaft chain taut before rotating the crankshaft e Pull the lower side of the chain taut and fit it onto the sprocket so that the line A on the sprocket aligns with the mark on the sprocket cover mating surface projection B e Fit the sprocket up into place OTurn the camshaft so that the cam lobes point downward while holding the sprocket steady to align the bolt holes A e Install the sprocket B e Apply a non permanent locking agent to the camshaft sprocket bolts e Keep the crankshaft from turning by holding a wrench on the magneto flywheel bolt e Tighten the sprocke
157. rk plug cap D e Unscrew the intake pipe bolts A e Remove Camshaft Sprocket Cover Camshaft Chain Tensioner Camshaft Sprocket e Remove the cylinder head bolts A nuts B and take off the cylinder head ENGINE TOP END 4 19 Cylinder Head Cylinder Head Installation e Check to see that the two dowel pins A are in place on the cylinder e Install a new cylinder head gasket B e Fit the cylinder head onto the cylinder block using a screwdriver or wire to keep the chain from falling down into the cylinder block e Apply a non permanent locking agent to the cylinder head bolts e Tighten the cylinder head nuts and bolts following the tightening sequence as shown First Cylinder Head Bolts 5 9 N m 0 6 kgf m 52 in Ib Torque Cylinder Head Nuts 13 N m 1 3 kgf m 113 in Ib Final Cylinder Head Bolts 12 N m 1 2 kgf m 104 in Ib Torque Cylinder Head Nuts 22 N m 2 2 kgf m 16 ft Ib e Install the camshaft sprocket e Install the other removed parts GE140108S1 Cylinder Head Cleaning e Scrape out any carbon and wash the head with a high flash point solvent 4 20 ENGINE TOP END Valve Valve Guide Valve Removal e Remove Cylinder Head Rocker Arm amp Rocker Arm Shaft Camshaft e Using the valve spring compressor assembly to press down the valve spring retainer remove the split keeper Special Tools Valve Spring Compressor Assembly 57001 241 A Valve Spring Comp
158. rrectly routed or damaged cable could result in an unsafe riding condition e Check idle speed using a tachometer xIf the idle speed is out of the specified range adjust it Idle Speed Standard 1 250 1 350 r min rpm Idle Speed Adjustment CAUTION The pilot screw A is set at the factory and should not be adjusted But if necessary set the pilot screw as follows e Turn in the air screw and count the number of turns until it seats fully but not tightly OFor United States model The air screw adjuster special tool may be used Special Tool Pilot Screw Adjuster 57001 1665 e Back out the same number of turns counted when turned in This is to set the screw to its original position NOTE OA carburetor has different turns out of the pilot screw for each individual unit When setting the pilot screw use the turns out determined during disassembly Use the specifications in this manual only if the original num ber is unknown e Start the engine and warm it up thoroughly e Turn the idle adjusting screw B until idle speed is correct OOpen and close the throttle a few times to make sure that the idle speed is within the specified range Readjust if necessary Air Cleaner Element Cleaning and Inspection NOTE Oln dusty areas the element should be cleaned more frequently than recommended interval OAfter riding through rain or on muddy roads the element should be cleaned immediately OSi
159. s from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Chain Tensioner Instal lation Do not turn over the crankshaft while the tensioner is removed This could upset the cam chain timing and damage the valves e Remove the left side cover e Loosen the cap bolt A before tensioner removal for later disassembly convenience e Unscrew the mounting bolts B and remove the camshaft chain tensioner C CAUTION Do not turn over the crankshaft while the tensioner is removed This could upset the cam chain timing and damaging the valves e Remove the fuel tank mounting bolt and band and move the fuel tank A backward e Remove the camshaft chain tensioner B while the push rod E clockwise D and compressing F it with a suitable screwdriver C GE10002BS1 C ENGINE TOP END 4 9 Camshaft Chain Tensioner Camshaft Chain Tensioner Installation e Remove the tensioner cap bolt and O ring e While compressing the push rod A turn it clockwise B with a suitable screwdriver until the rod protrusion comes to about 10 mm from the tensioner body CAUTION Do notturn the rod counterclockwise at installation This could detach the rod and the tensioner cannot be reinstalled e While holding the rod in position with a suitable push rod holder plate A install the tensio
160. s is not an exhaustive list giving every down possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Cylinder head warped Spark plug loose No valve clearance Valve spring broken or weak Valve not seating properly valve bent worn Engine Doesn t Start Starting Difficulty Sr carbon aecarmulation on 1e Seating Engine won t turn over rface Valve seizure Su Cylinder piston seizure Poor Running at Low Speed Spark weak Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Camshaft seizure Transmission gear or crankcase bearing seizure Kickstarter return spring broken Kick ratchet gear not engaging No fuel flow No fuel in tank Fuel tap turned off Tank cap air vent obstructed Tank cap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level too high Float valve worn or stuck open Starting technique faulty When flooded kick with the throttle fully opened to allow more air to reach the engine No spark spark weak Engine stop switch turned off Spark plug dirty damaged or maladjusted Spark plug cap or high tension lead dam aged Spark plug cap shorted or not in good con tact Ignition coil damaged Stator coil damaged Igniter broken Flywheel magneto damaged Engine stop switch shorted Wiring shorted or open Fuel air mixture incorrect
161. s noisy doesn t spin smoothly or has any rough sports it must be replaced e f the bearing is to be used again rewash it with a high flash point solvent dry it and pack it with good quality bearing grease Turn the bearing around by hand a few times to make sure the grease A is distributed uniformly inside the bearing and wipe the old grease out of the coupling before bearing installation Coupling Damper Inspection e Remove the rear wheel coupling and inspect the rubber dampers A x Replace the dampers if they appear damaged or deterio rated BRAKES 11 1 Brakes Table of Contents Exploded TEE 11 2 el lee le TEE 11 6 Brake Lever Brake Pedal Reiten eie eiut EE See 11 7 Brake Lever Brake Pedal Free Play Inspection cccccccececcceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeneess 11 7 Front Brake Free Play Adjustment ccceeeeeeeeeeseeeeeeeeeeeeseneneeeeeeeeeeseesseneenenseeeeneees 11 7 Brake Pedal Free Play Adjustment 2 ccccceeeeeeeeeeseeeneeceeeeeeneeeeeeeeneeeeeesenseneeeeasenee 11 7 Brake Cable Hemoval emen ener nnn nnn n nnns nnn nnns nnns nnns s nnnis 11 7 Brake Cable Installation emere 11 7 Brake Cable Lubricatton mnn nnn rennen nennen 11 7 Brake Pedal and Rod Removal nennen nnne nnns 11 7 Brake Pedal and Rod Installaton e 11 8 Brake Panel and Drum 11 9 Brake Lining Wear Inspectiori orto ueste o eta tt eege Geier 11 9 Cam Lever Angle Adjustment
162. shaft Chain Installation 4 13 Cylinder Installation 4 28 Camshaft Chain Guide Wear 4 13 Piston Hemoval 4 29 Rocker Arm Rocker Arm Shaft 4 14 Piston Installation 4 29 Rocker Arm Remowval 4 14 Cylinder Inside Diameter Rocker Arm Installation 4 14 Measurement ssseseeeeer enerne 4 30 Rocker Arm amp Arm Shaft Wear 4 15 Piston Outside Diameter Camtshaft escas etes 4 16 Measurement ssseseeeeer rennen 4 30 Camshaft Removal 4 16 Piston Cylinder Clearance Camshaft Installation 4 16 Inspechon eneee 4 31 Camshaft Inspection 4 16 Boring Honing 4 31 Camshaft Bearing Inspection 4 16 Piston Ring End Gap Inspection 4 32 Cylinder Head 4 17 Piston Ring Piston Ring Groove Compression Measurement 4 17 Inspechon cece eenen 4 32 Cylinder Head Removal 4 18 Piston Piston Pin Connecting Cylinder Head Installation 4 19 Rod Wear Inspection 4 33 Cylinder Head Cleaning 4 19 Piston Piston Pin Connecting Valve Valve Guide 4 20 Rod Inspection 4 33 Valve Removal 4 20 MUG rss scies tette ies 4 35 Valve Installation 4 20 Muffler Remowval 4 35 Valve Guide Removal
163. t C 32 D Speeified Seating Surface width E 60 or 67 5 Cut F 60 or 67 5 e Measure the outside diameter O D of the seating sur face with a vernier calipers xIf the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range If the outside diameter of the seating surface is too large make the 32 grind described below Original Seating Surface B NOTE ORemove all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 or 67 5 grinding operation eas ier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact If the outside diameter A of the seating surface is within the specified range measure the seat width as described below e Grind the seat at a 32 angle B until the seat O D is within the specified range GEi5011981 GEi5012181 GE15012281 4 24 ENGINE TOP END Valve Valve Guide OTo make the 32 grind fit a 32 cutter to the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgri
164. t bolts Torque Camshaft Sprocket Bolts 12 N m 1 2 kgf m 104 in Ib e Install the camshaft chain tensioner e Check the camshaft chain timing OTurn the crankshaft two turns in the counterclockwise the crankshaft is at TDC and re check the camshaft chain timing x lf the timing mark is aligned the camshaft chain timing is correct CAUTION Rotation of the crankshaft with improper camshaft timing could cause the valve to contact each other or the piston and bend If any resistance is felt when turning the crankshaft stop immediately and check the camshaft chain timing ENGINE TOP END 4 13 Camshaft Sprocket Camshaft Chain Removal e Drain the engine oil e Remove Left Shroud Camshaft Chain Tensioner Camshaft Sprocket Cylinder Head Magneto Cover see Electrical System chapter Magneto Flywheel see Electrical System chapter Woodruff Key see Electrical System chapter e Remove the camshaft chain holder A and chain guides B e Take off the camshaft chain Camshaft Chain Installation e Check to see that the crankshaft position is in TDC and re adjust if necessary e Install the camshaft chain to the crankshaft and it is pulled up to the camshaft sprocket pass through camshaft chain hole in the cylinder e Keep the chain e Install the upper chain guide and camshaft chain holder Torque Camshaft Chain Guide Bolt 5 2 N m 0 53 kgf m 46 in Ib Camshaft Chain Holder Screws 5 2 N m
165. tall the valve adjusting covers be careful not to drop of protrude the O rings from the cover grooves If the O ring is installed improperly oil will leak ENGINE TOP END 4 15 Rocker Arm Rocker Arm Shaft Rocker Arm amp Arm Shaft Wear e Visually inspect where the cam and valve stem wear on each arm xIf there is any damage or uneven wear replace the arm OMeasure the inside diameter A of each rocker arm with a cylinder gauge Rocker Arm Inside Diameter Standard 10 000 10 015 mm 0 3937 0 3943 in Service Limit 10 05 mm 0 3957 in If it exceeds the service limit replace the rocker arm OMeasure the diameter B of each rocker arm shaft where the rocker arm fits Rocker Arm Shaft Diameter Standard 9 980 9 995 mm 0 3929 0 3935 in Service Limit 9 95 mm 0 3917 in If the diameter is less than the service limit replace the rocker arm shaft 4 16 ENGINE TOP END Camshaft Camshaft Removal e Remove Left Shroud Camshaft Chain Tensioner Camshaft Sprocket Rocker Arms e Pull out the camshaft A Camshaft Installation e Clean the camshaft with a high flash point solvent e Apply clean engine oil to all cam parts e Install the camshaft in the cylinder head e Install the rocker arm e Install the other removed parts OCheck and adjust the valve clearance Camshaft Inspection e Visually inspect the cam for wear or damage xIf there is any damage or wear rep
166. the cam lever has a proper angle when the brake is fully applied Cam Lever Angle Standard 80 90 Torque Rear Cam Lever Mounting Bolt 7 N m 0 7 kgf m 60 in Ib A WARNING When remounting the cam lever be sure that the position of the wear indicator on the serrated shaft is not altered A change in cam lever angle is caused by wear of internal brake parts Whenever the cam lever angle is adjusted also check for drag and proper opera tion taking particular note of the brake lining wear indicator position In case of doubt as to braking effectiveness disas semble and inspect all internal brake parts Worn parts shall result in the brake to lock or fail e Install the wheel see Wheels Tires chapter e Adjust the brake free play Brake Panel Lubrication e Disassemble the rear brake panel see Brakes chapter e Clean all old grease out of the brake parts with a cloth e Apply high temperature grease to the following Brake Shoe Anchor Pin A Spring Ends B Cam Surfaces C Cam Shaft Groove D GL12006BS1 C PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Suspension Fork Oil Level Adjustment Simplify e Using the jack under the frame and stabilize the motor cycle Special Tool Jack 57001 1238 e Remove the number plate e Remove the cap from the top of the fork tubes and push down the top plug A and remove the circlip B from each fork tube e Pull out
167. the difference between the two values Measure the piston diameter as just described and measure the cylinder diameter at the very bottom of the cylinder Piston Cylinder Clearance Standard 0 010 0 022 mm 0 0004 0 0009 in NOTE OWhenever the piston or cylinder has been replaced with a new one the motorcycle must be broken in the same as with a new machine Boring Honing When boring and honing a cylinder note the following OThere are two sizes of oversize pistons available Over size pistons require oversize rings Oversize Pistons and Rings 0 5 mm 0 0197 in Oversize 1 0 mm 0 0394 in Oversize OBefore boring a cylinder first measure the exact diame ter of the service data section oversize piston and then according to the standard clearance in the determine the rebore diameter However if the amount of boring nec essary would make the inside diameter greater than 1 0 mm oversize the cylinder block must be replaced OCylinder inside diameter must not vary more than 0 01 mm at any point OBe wary of measurements taken immediately after boring since the heat affects cylinder diameter Oln the case of a rebored cylinder and oversize piston the service limit for the cylinder is the diameter that the cylin der was bored to plus 0 1 mm and the service limit for the piston is the oversize piston original diameter minus 0 20 mm If the exact figure for the rebored diameter is unknown it can be roughly determined
168. the hub back and forth A while checking for plays roughness or binding If bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for damage or leakage lf the seal is damaged or is leaking replace the bearing 6J06001BSi 6J06004BSi C 6J06010581 6J06040681 9 12 WHEELS TIRES Hub Bearing Bearing Lubrication e Remove the hub bearings on the front and rear wheel hubs e Wash the bearings with a high flash point solvent dry them do not spin them while they are dry and oil them e Spin each bearings by hand to check its condition lf it is noisy does not spin smoothly or has any rough spots it must be replaced e f the same bearing is to be used again re wash it with a high flash point solvent and dry it e Pack each bearings with good quality bearing grease A before installation Turn each bearing around by hand a few times to make sure the grease is distributed uni formly inside the bearing and wipe the old grease out of the bearing housings on the wheel hub before bearing in stallation e Install the bearings 6J08010781 FINAL DRIVE 10 1 Final Drive Table of Contents leie e RTE 10 2 Specifications im Rm 10 4 Biel e EI 10 5 EINEN 10 5 Chain SlackJAdjusltmerib caetero lt td e aeaaea aaao aia Aa actenla Eaa aE danse pde bags 10 5 Drive Chain HRemoval EEEE 10 5 Drive Chain Insta
169. these parts with new ones every time they are removed Although the pre viously mentioned gasket O ring ball bearing needle bearing grease seal oil seal circlip and cotter pin have not been so designated in their respective text they are replacement parts 18 Electrical Leads All the electrical leads are either one color or two color A two color lead is identified first by the primary color and then the stripe color For example a yellow lead with thin red stripes is referred to as a yellow red lead it would be a red yellow lead if the colors were reversed Unless instructed otherwise electrical leads must be connected to leads of the same color Two Color Electrical Lead cross section Color Indicated on the Lead Color Indicated on the Wiring Diagram Yellow Red Rem 6B02069BW C 1 4 GENERAL INFORMATION Before Servicing 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or deteri orated performance replace the dam
170. this will ex tend the brake spring beyond its allowable spring extension e Tighten the rear axle nut Torque Rear Axle Nut 64 N m 6 5 kgf m 47 ft Ib e Install the torque link A so that its R mark B faces rearward WHEELS TIRES 9 7 Wheels Rims e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axel tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole e Tighten the torque link nuts 107000851 6 Torque Torque Link Nut 25 N m 2 5 kgf m 18 ft lb e Bend the cotter pin A over the nut B HJ07002BSi C e Insert the cotter pins A through the torque link bolts B and spread its ends e Insert the cotter pin through the axle nut to rear axle and spread its ends e Adjust Drive Chain Slack see Final Drive chapter Brake Pedal Free Play see Brakes chapter 6J04023BS1i Axle Inspection e Visually inspect the front and rear axle for damages xIf the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm Rear Axle 110 mm A apart and set a dial gauge on the axle at a point halfway between the blocks e Turn the axle to measure the runout The difference be tween the highest and lowest dial readings is the amount of runout
171. tions or especially after using a high pressure water spray perform the general lubri cation Pivots Lubricate with Motor Oil Brake Pedal Brake Rod Joint Drive Chain Points Lubricate with Grease A Throttle Cable Upper End Choke Cable Lower End Brake Cable Upper End Side Stand Pivot Steering Stem Bearing Brake Lever Pivot Kick Pedal Pivot Cables Lubricate with Rust Inhibitor Throttle Cable Choke Cable Front Brake Cable e With the cable disconnected at the both ends the cable should move freely A within the cable housing If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 6C04011451 C 6004020281 PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Nut Bolt and Fastener Tightness Tightness Inspection e Check the tightness of bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature If there are loose fasteners retorque them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it lf cotter pins are
172. ur the solvent out of the tank e Remove the fuel tap from the tank by taking out the bolts e Clean the fuel tap filter screen in a high flash point sol vent e Pour high flash point solvent through the tap in all lever positions e Dry the tank and tap with compressed air e Install the tap in the tank Torque Fuel Tap Bolts 4 9 N m 0 5 kgf m 43 in Ib KLX110 A3 e Install the fuel tank ENGINE TOP END 4 1 Engine Top End Table of Contents Exploded View 4 2 Valve Clearance Inspection 4 21 Specifications eeeeeessss 4 6 Valve Clearance Adjustment 4 21 Camshaft Chain Tensioner 4 8 Valve Seat Inspection 4 21 Camshaft Chain Tensioner Valve Seat Repair 4 22 Hemoval i 4 8 Valve Head Thickness Inspection 4 25 Camshaft Chain Tensioner Valve Stem Bend Inspection 4 25 Installation 4 9 Valve Stem Diameter Inspection 4 25 Replacement Chain Tensioner Valve Guide Inside Diameter Installation ssss 4 10 Inspechon ce eeeeeeeeeeteereeeee 4 25 Camshaft Sprocket 4 11 Valve to Guide Clearance Camshaft Sprocket Removal 4 11 Measurement oannanennennnnnneaa 4 26 Camshaft Sprocket Installation 4 12 Cylinder Piston 4 28 Camshaft Chain Removal 4 13 Cylinder Removal 4 28 Cam
173. utch chapter e Pull out the oil screen A OClean the screen with high flash point solvent and then dry it OClean the screen thoroughly whenever the engine oil is changed NOTE OWhile cleaning the screen check for any metal particles that engine indicate internal damage A WARNING Clean the oil screen in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean the oil screen A fire or explosion could re sult Replace the screen with a new one if it is damaged e Install Oil Screen Clutch Cover 6 8 ENGINE LUBRICATION SYSTEM Engine Oil Pump Engine Oil Pump Removal e Remove the clutch cover see Clutch chapter e Remove the primary and secondary clutch assemblies see Clutch chapter e Turn the crankshaft so that the engine oil pump screws A can be removed through the pump gear holes and remove the screws and oil pump B Engine Oil Pump Installation e Replace the O rings with new ones if they are damaged e Check to see that the knock pin A and O rings B are in place e Install the oil pump and screws OWhen installing the oil pump be sure the oil pump gear A and pump drive gear B on the crankshaft mesh properly Torque Oil Pump Mounting Screw 5 2 N m 0 53 kgf m 46 in Ib Engine Oil Pump Inspection e
174. washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder B and holder bar C in position operate the cutter A in one hand Do not apply too much force to the diamond position NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash the cutter with washing oil and apply a thin layer of engine oil before storing Marks Stamped on the cutter The marks stamped on the back ofthe cutter A represent the following OO E TAE Cutter angle B 309 Latest Outer diameter of cutter C GE15011081 C GE15011881 ENGINE TOP END 4 23 Valve Valve Guide Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter to the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced A Grind the seat at a 45 angle to enlarge the width of the seating surface B 32 Cu
175. xIf the throttle grip free play cannot be adjusted with the adjuster at the upper end of the throttle cable use the cable adjuster A at the carburetor e Pull the boot off ofthe carburetor top Make the necessary free play adjustment at the lower cable adjuster tighten the locknut B and install the boot e Check if the throttle grip moves smoothly from full 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 cable e With the engine idling turn the handlebar both ways and check if handlebar movement changes the idling speed If so the throttle cable may be improperly adjusted or incorrectly routed or damaged Be sure to correct any of these conditions before riding A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition PERIODIC MAINTENANCE 2 7 Periodic Maintenance Procedures Idle Speed Inspection e Start the engine and warm it up thoroughly e Turn the handlebar from side to side while idling the en gine lf handlebar movement changes the idle speed the throt tle cable may be improperly adjusted or incorrectly routed or it may be damaged Be sure to correct any of these conditions before riding A WARNING Operation with an improperly adjusted inco
176. xhaust system is cold before cleaning the spark arrester The exhaust system becomes very hot soon after the engine is started e Remove the muffler cover e Unscrew the mounting bolts A and pull out the spark arrester B 2 10 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Scrape carbon deposits off the spark arrester A e Install the spark arrester and torque the spark arrester mounting bolts Torque Spark Arrester Mounting Bolts 8 8 N m 0 9 kgf m 78 in Ib e Install the muffler cover Clutch Clutch Adjustment e Loosen the adjusting screw locknut A e Turn the adjusting screw B counterclockwise until it be comes hard to turn and then back it out a quarter turn e Tighten the locknut without changing the adjusting screw position e Start the engine and inspect the conditions of clutch while shifting the pedal a few times Torque Adjusting Screw Locknut 19 N m 1 9 kgf m 14 ft Ib Engine Lubrication System In order for the transmission and clutch to function prop erly always maintain the engine oil at the proper level and change the oil periodically A WARNING Motorcycle operation with insufficient deteri orated or contaminated engine oil will cause accelerated wear and may result in transmission seizure accident and injury PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedures Oil Level Inspection e To check the oil level start the e
177. xle nut Torque Rear Axle Nut 64 N m 6 5 kgf m 47 ft Ib PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axel tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut B e Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary e Tighten the rear torque link nut securely Torque Rear Torque Link Nut 25 N m 2 5 kgf m 18 ft Ib e Insert a new cotter pin for the rear torque link nut and spread its ends A WARNING If the axle and torque link nuts are not securely tightened and the cotter pins are not installed an unsafe riding condition may result e Check the rear brake play referring to brakes section in this chapter Chain Wear Inspection e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links e Also inspect the sprockets for unevenly or excessively worn teeth and damaged teeth NOTE OSprocket wear is exaggerated for illustration see Sprocket Wear Inspection in this chapter xIf there is any irregularity replace the drive chain and sprockets e If the chain appears dry lubricate it e Remove the chain
178. y clutch housing Primary Clutch Housing Inside Diameterr Standard 104 0 104 2 mm 4 094 4 102 in Service Limit 104 5 mm 4 114 in GF08040151 C CLUTCH 5 13 Clutches Primary Clutch Shoe Lining Wear Inspection e Remove the primary clutch hub see Clutch Removal e Visually inspect the primary clutch shoe linings A for un even wear discoloration missing friction material cracks or other damage xIf any of the linings are damaged replace the primary clutch hub e Measure the groove depth A OUse a depth gauge and measure at several points as shown lf any measurement is less than the service limit replace the primary clutch hub Primary Clutch Shoe Groove Depth Standard 1 0 mm 0 04 in Service Limit 0 5 mm 0 02 in One Way Clutch Inspection e Remove the clutch cover see Clutch Cover Removal e Turn the primary clutch housing by hand When view from the right side of the engine the primary clutch housing should turn counter clockwise freely A but should not turn clockwise xIf the one way clutch does not operate as it should or if it makes noise go to the next steps ORemove the primary clutch OCheck that the one way clutch is installed so that the ro tation mark faces out OVisually inspect the one way clutch A and the outer race B in the primary clutch housing If there is any worn or damaged part replace it KL110 A2
179. y source of flame or sparks this includes any appliance with a pilot light e Remove the carburetor and hold them in true vertical po sition on a stand e Put the fuel tank on a bench and connect the fuel tap to the carburetor using a suitable hose e Prepare a rubber hose A e Connect the fuel gauge B to the carburetor float bowl with the rubber hose Special Tool Fuel Level Gauge 57001 1017 e Hold the gauge vertically against the side of the carburetor body so that the middle line C is several millimeters higher than the bottom edge of the carburetor body e Turn the fuel tap to the ON position to feed fuel to the carburetor then turn out the carburetor drain plug a few turns e Wait until the fuel level D in the gauge settles e Keeping the gauge vertical slowly lower the gauge until the middle line is even with the bottom edge E of the carburetor body NOTE ODo not lower the middle line below the bottom edge of the carburetor body If the gauge is lowered and then raised again the fuel level measure shows somewhat higher than the actual fuel level If the gauge is lowered too far dump the fuel out of it into suitable container and start the procedure over again 6C08012482 C FUEL SYSTEM 3 9 Carburetor e Read the fuel level in the gauge and compare it to the specification Fuel Level 3 0 1 mm 0 12 0 04 in below the bottom edge of carburetor body e Screw
180. ylinder compression is higher than usable range Cylinder compression is lower than usable range Diagnosis Carbon accumulation on piston and in combustion chamber possibly due to damaged valve stem oil seal and or damaged position oil rings This may be indicated by white exhaust smoke Incorrect cylinder head gasket cylinder base gasket thickness Gas leakage around cylinder head Bad condition of valve seating Incorrect valve clearance Incorrect piston cylinder clearance Piston seizure Remedy Action Remove the carbon deposits and replace damaged parts if necessary Replace the gasket with a standard part Replace damaged gasket and check cylinder head warp Repair if necessary Adjust the valve clearance Replace the piston and or cylinder Inspect the cylinder and liner and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or piston ring grooves Replace the piston and or the piston rings e Remove the compression gauge adapter and install the spark plug Torque Spark Plug 13 N m 1 3 kgf m 113 in Ib 4 18 ENGINE TOP END Cylinder Head Cylinder Head Removal e Remove the right and left shrouds e Remove the exhaust pipe holder nuts A and muffler mounting bolt B and then the muffler with the exhaust pipe holder e Remove the oil pipe banjo bolts A screws B and take off the oil pipe C e Remove the spa

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