Kawasaki KLX110 L 2013 Owner's manual

Quick Reference Guide
GENERAL INFORMATION j
This Quick Reference Guide will assist you in
finding the in
A Table of Contents is included after the
Foreword.
MAINTENANCE AND ADJUSTMENT j
TROUBLESHOOTING GUIDE j
STORAGE j
IMPORTANT INFORMATION
This vehicle is designed for the operator only, no passengers.
This vehicle is an off-road motorcycle only and was not manufactured for use on public streets, roads or
highways. Respect the environment and the rights of other people.
Read owner’s manual.
Whenever you see the symbols shown below, heed their instructions! Always follow safe operat­ing and maintenance
practices.
DANGER
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING
WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
NOTICE
NOTICE is used to address practices not re­latedtopersonalin
NOTE indicates information that may help or guide
you in the operation or service of the vehicle.
jury.
NOTE
IMPORTANT
Off-road motorcycling is a wonderful sport, and we hope you will en ever, if improperly conducted, this sport has the potential to cause environmental problems as well as conflicts wi Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not occur. TO PROTE SPORT, MAKE SURE YOU USE YOUR MOTOR­CYCLE LEGALLY, SHOW CONCERN FOR THE ENVIRONMENT, AND OF OTHER PEOPLE.
joy it to the fullest. How-
th other people.
CT THE FUTURE OF YOUR
RESPECT THE RIGHTS
WARNING
THISVEHICLEISANOFF-ROADVEHICLE
ONLY AND WAS NOT MANUFACTURED FOR USE ON PUBLIC STREETS, ROADS, OR HIGHWAYS. USE YOUR MOTORCYCLE LEGALLY.
RESPECT THE EN VIRONMENT AND THE
RIGHTS OF OTHER PEOPLE.
IMPORTANT NOTE TO PAR
Your youngster’s saf a properly maintained vehicle. As w ith any moving vehicle there are possible safety risks; be sure to heed these precautions.
1. Always equip your youngster with suitable protective gear and riding apparel. Be sure he or she always wears a helmet, over-the-ankle footwear or sturdy boots, eye protection, groves, long pants, and a lo ng -sleeved shirt while riding.
2.
Never allow your youngster to carry a passenger. This motorcycle is designed for an OPERATOR ONLY.
3.
This motorcycle is designed for off-road riding and should never be operated on public roads or paved surfaces.
4.
This motorcycle was not designed for hard riding such as motocross.
5.
Always obey local off-road riding laws and regulations. Obtain permission to ride on private property.
6.
You, the parent (and most likely “riding instru cto r/m echanic” as well), must be familiar with motorcycle controls and maintenance requirements plus riding techniques. Read and understand the owner’s manual provided with the motorcycle. Review all instructions and warnings with your youngster.
7.
You must determine your youngster’s readiness to ride this off-road motorcycle. Your youngster should already be familiar with motorcycle co ntrols (location and function) and basic riding techniques. Your youngster should also be physically large enough, and strong enough to be able to straddle the motorcycle and hold it up , plus be ab le to pick up it up if it is on its side.
8.
Your youngster’s safety depends in part on the good mechanical condition of the motorcycle. Be sure to follow the maintenance and adjustment requirements contained in the Periodic Maintenance Chart, Daily Pre-ride Inspection, and After-Race Check Points. Be sure your youngster understands the importance of che cking all item s thoroughly before riding the motorcycle. Also, familiarity with the motorcycle is important should a problem occur far from help.
9.
Do not allow your youngster to ride unsupervised. He or she should always ride in the company of an experienced adult.
ety will depend on your commitment to always provide a safe riding environment and
ENTS ABOUT SAFE RIDING
10.
Encourage your young Have them practice advanced riding maneuvers under controlled conditions.
11. Tell someone where you and your youngster are planning to ride and when you intend to return. Discuss the ride wit techniques may b e necessary to negotiate the terrain safely. If you are not familiar with the area , lead the way and reduce your speed.
ster not to ride beyond his or her skill level or faster than conditions safely allow.
h your youngster before you leave so he or she will know in advance what riding
NOTICE
This motorcycle is designed for a rider weighting less than 70 kg (154 lb). Exceeding this limit could damage the motorcycle.
WARNING
Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemi­cals known to the State of California to cause cancer and birth defects or other reproductive harm.
FOREWORD
We wish to thank you for choosing this Kawasaki motorcycle. It is the end product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for super ior reliability, and performance. By giving your motorcycle the proper care and maintenance outlined in this manual, you will be helping to ensure it a long, trouble-free life.
Before starting to ride your motorcycle, please read this manual thoroughly in order to know your motorcycle’s capabilities, its lim itations, and above all, how to operate it safety.
Due to improvements in design and performance m ade during production, in some cases there may be minor discrepancies between the actual vehicle and the illustrations and text in this manual.
KAWASAKI HEAVY I NDUSTRIES, LTD.
Motorcycle & Engine Company
© 2013 Kawasaki Hea
vy Industries, Ltd.
Mar. 15, 2013. (1)
TABLE OF CONTENTS
SPECIFICATIONS.................. .......................... 11
GENERAL INFORMATION.............................. 15
LOCATION OF LABELS................................ 15
Location of Parts ........................................... 18
Side Stand ..................................................... 21
Fuel Tap......................................................... 21
Fuel ............................................................... 22
Throttle Limi ting Screw.................................. 25
Engine Stop Switch ....................................... 26
Starter Button ................................................ 27
Kick Pedal ..................................................... 28
Starting the Engine ........................................ 28
Moving Off ..................................................... 32
Shifting Gears................................................ 32
Stopping the Motorcycle ................................ 34
Stopping the Engi
Break-In........................................... .............. 35
Daily Pre-Ride Checks .................................. 36
MAINTENANCE AND
EMISSION CONTROL INFORMATION ........ 38
Periodic Maintenance Chart .......................... 41
Engine Oil ...................................................... 45
Spark Plug ..................................................... 50
Air Cleaner ......................................... ........... 52
Throttle Cabl
ne ..................... .................
ADJUSTMENT.............
e................................................
34
38
57
Carburetor ........................................ ............. 59
Clutch ............................................................ 60
Valve Clearan ce ............................................ 62
Spark Arrester ................... ............................ 63
Drive Chain.................. .................................. 65
Handlebar ........ .................................... .......... 71
Brakes .............................................. ............. 72
Steering ................. .................................... .... 77
Front Suspension .......................................... 80
Rear Suspension .................. ......................... 81
Wheels ............... .................................... ....... 81
Hoses Inspect ion ........................................... 84
Battery ................... .................................... .... 84
Fuse .............................................................. 88
Tightening Torques of Nuts and Bolts............ 89
Cleaning Your Mot
Lubrication ....... .................................... .......... 95
TROUBLESHOOTING GUIDE......................... 99
STORAGE................... .................................... . 107
Before Storage .............................................. 107
After Storage ................................................. 108
ENVIRONMENTAL
WIRING DIAGRAM .......................................... 110
YOUR WARRANTY/OWNER SATISFACTION 112 MAINTENANCE R
orcycle..............................
PROTECTION..................
ECORD ..............................
93
109
116

SPECIFICATIONS

DIMENSIONS
Overall Length 1 560 mm (61.4 in.)
Overall Width 650 mm (25.6 in.)
Overall Height:
KLX110C 955 mm (37.6 in.)
KLX110D
Wheelbase
Road Clearance:
KLX110C 215 mm (8.5 in.)
KLX110D
Curb Mass 76 kg (168 lb)
Fuel Tank Capacity 3.6 L (1.0 US gal)
ENGINE
Type
Bore × Stroke 53.0 × 50 .6 mm (2.1 × 2.0 in.)
Displacement
Compression Ratio
Fuel System Carburetor KEIHIN PB18
Starting System
Ignition System SHINDENGEN CDI
Ignition Timing
990 mm (39.0 in.)
1 075 mm (42.3 in.)
265 mm (10.4 in.)
4-stroke, SOHC, single-cylinder, air-cooled
112 cm³ (6.8 cu in.)
9.5:1
Electric starter and kick starter
10° BTDC @1 300 r/min (rpm) 31° BTDC @4 000 r/min (rpm)
SPECIFICATIONS 11
12 SPECIFICATIONS
Lubrication System Forced lubrication (wet sump)
Spark Plug NGK CR6HSA
TRANSMISSION
Transmission Type
Clutch Type:
KLX110C Centrifugal and wet, multi disc
KLX110D Wet, multi disc
Driving System Chain drive
Gear Ratio:
1st
2nd
3rd
4th
Primary Reduction Ratio
Final Reduction Ratio
Overall Drive Rat
Engine Oil:
Type
Viscosity
Capacity 1.1 L (1.2 US qt)
FRAME
Type Backbone
Steering Angle 45° to either side
io
4-speed, constant mesh, return shift
3.000 (36/12)
1.938 (31/16)
1.350 (27/20)
1.087 (25/23)
3.409 (75/22)
2.923 (38/13)
10.832 @Top gear
API SG, SH, SJ, SL
SAE 10W-40
, SM with JASO MA, MA1 or MA2
Caster:
KLX110C 24.8°
KLX110D
Trail:
KLX110C 50 mm (2.0 in.)
KLX110D
Tire Size/Type:
Front
Rear
Rim Size:
Front 14 × 1.40
Rear 12 × 1.60
Suspension:
Front
Rear
Front Suspension Travel:
KLX110C 110 mm (4.3 in.)
KLX110D
Rear Wheel Travel
KLX110C 110 mm (4.3 in.)
KLX110D
Front Fork Oil:
Type
:
24.2°
47 mm (1.9 in.)
2.50-14 4P.R./IRC
3.00-12 4P.R./IRC
Telescopic fork
Swingarm (mono-shock)
140 mm (5.5 in.)
132 mm (5.2 in.)
Kawasaki Fork Oi
SPECIFICATIONS 13
GS-45F
GS-45F
l SS8
14 SPECIFICATIONS
Amount (Per One Unit):
KLX110C 165 mL (5.6 US oz.)
KLX110D
BRAKES
Type:
Front Drum brake
Rear Drum brake
ELECTRICAL EQUIPMENT
Battery 12 V 3 Ah
Specifications are subject to change without notice.
182mL(6.2USoz.)

GENERAL INFORMATION

LOCATION OF LABELS

All warning labels which are on your vehicle are repeated here. Read lab derstand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may ope fore, it is very important that all warning labels be on your vehicle in the locations shown. If any label is missing, damaged, or your Kawasaki dealer and install it in the correct po­sition.
The sample warning labels in this section have
part numbers to help the correct replacement. Refer to the actual vehicle label for model specific
datagrayedoutint
els on your vehicle and un-
rate your vehicle. There-
worn, get a replacement from
NOTE
you and your dealer obtain
he illustration.
GENERAL INFORMATION 15
j
1. Rear Shock Absorber Warning
16 GENERAL INFORMATION
2. Important Informati
3. Vehicle Emission Co
4. Noise Emission Cont
on
ntrol Information
rol Information
1)
3)
GENERAL INFORMATION 17
j
2)
4)
18 GENERAL INFORMATION

Location of Parts

1. Clutch Lever (KLX110D Model)
2. Engine Stop Switch
3. Front Brake Lever
4. Throttle Grip
5. Starter Button
6. Fuel Tank Cap
GENERAL INFORMATION 19
j
7. Front For
8. Brake Cable
9. Choke Knob
10. Fuel Tap
11. Brake Cam Lever
k
12. Air Clean
13. Oil Filter Cap
14. Engine Oil Drain Bolt
15. Shift Pe
16. Chain Slipper
er
dal
17. Side Stan
18. Swingarm
19. Drive Chain
d
20 GENERAL INFORMATION
20. Muffler
21. Rear Shock Absorber
22. Seat
23. Fuel Tan
k
24. Throttle
25. Kick Pedal
26. Rear Brake Pedal
Limiting Screw
27. Oil Level Window
28. Carburetor
Inspection
GENERAL INFORMATION 21
j

Side Stand

The motorcycle is equ
A. Side Stand
Do not sit on the motorcycle while it is on its side stand. Always kic on the motorcycle.
ipped with a side stand.
k the stand fully up before sitting
WARNING
Riding with the side stand down could cause
an accident resulting in serious injury or
death. Always be sure the side stand is fully
raised before riding.

Fuel Tap

The fuel tap has three (reserve). For normal operation, turn the fuel tap lever to t he ON position. If the fuel runs out with the tap in the ON position (0.11 US gal) of usable fuel remains can be used by turning the tap lever to the RES position.
A. Fuel Tap
B. ON Position
C. OFF Position
D. RES Position
Turn the fuel tap lever to OFF position when the fuel tank is removed for maintenance and adjust­ments or the mot
position; OFF, ON, and RES
, the last approximately 0.4 L
orcycleisstoredforalongtime.
22 GENERAL INFORMATION
NOTE
Since riding dista n ce is limited when on RES, re-
fuel at the earliest opportunity. Make certain that the fuel tap lever is turned to ON
(not RES), after filling up the fuel tank.
WARNING
Practice operating the fuel tap with the mo­torcycle stopped. To prevent an accident you should be able to operate the fuel tap while riding without taking your eyes off the road. Be careful not to touch the hot engine while operating the fuel tap.

Fuel

The required of fuel i
quirement”.
The capacity of the fuel tank is 3.6 L (1.0 US gal). To open the fuel tank c from the hole in the number plate and turn the tank cap counterclockwise.
Avoid filling the ta is blowing so that the fuel does not get contaminated.
s specified under “Fuel Re-
ap, pull out the breather hose
nk in the rain or where heavy dust
A. Fuel Tank Cap
B. Breather Hose
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Move the en-
gine stop switch to the 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. Never fill the tank completely to the top. If the tank is filled completely to the top, heat may cause the fuel to expand and overflow through the vents in the tank cap. After re­fueling, make sure the tank cap is closed se­curely. If gasoline is spilled on the fuel tank, wipe it off immediately.
Fuel Requireme
nt -
Fuel Type
Use clean, fresh unleaded gasoline with a mini­mum Antiknock Index of 87. The Antiknock Index is posted on service station pumps in the U.S.A. The octane rating of a gasoline is a measure of its re­sistance to detonation or “knocking”. The Antiknock Index is an average of the Research Octane Num­ber (RON) and the Motor Octane Number (MON) as shown in the table below.
position. Do not
GENERAL INFORMATION 23
Octane Rating Method
Antiknock Index
(RON + MON)
2
Minimum
Rating
87
NOTICE
If engine “knocking” or “pinging” occurs, use a different brand of gasoline of a higher octane rating. If this condition is allowed to continue it can lead to severe engine damage. Gasoline quality is important. Fuels of low quality or not meeting standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or nonrecom­mended fuel may not be covered under your warranty.
Fuels Containing Oxygenates
Gasoline frequently contains oxygenates (alco-
ls and ethers) especially in areas of the U.S. and
ho Canada which are required to sell such reformu­lated fuels as part of a strategy to reduce exhaust
issions.
em
The types and volume of fuel oxygenates ap-
proved for use in unleaded gasoline by the U.S.
nvironmental Protection Agency include a broad
E
j
24 GENERAL INFORMATION
range of alcohols and nents have seen any significant level of commercial use.
Gasoline/Alcohol B to 10% ethanol (alcohol produced from agricultural products such as corn), also known as “gasohol” is approved for use.
ethers, but only two compo-
lends - Gasoline containing up
NOTICE
Avoid using blends of unleaded gasoline and
methanol (wood alcohol) whenever possible,
and never use “gasohol” containing more
than 5% methanol. Fuel system damage and
performance problems m ay result.
Gasoline/Ether Blends - The most common ether is methyl tertiary butyl ether (MTB E). You may use gasolinecontainingupto15%MTBE.
NOTE
Other oxygenates approved for use in unleaded
gasoline include TAME (up to 16.7%) and ETBE (up to 17.2%). Fuel containing these oxygenates canalsobeusedinyourKawasaki.
NOTICE
Never use gasoline with an octane rat­ing lower than the mini mum specified by Kawasaki. Never use “gasohol” with more than 10% ethanol, or more than 5% methanol. Gaso­line containing met blended with cosolvents and corrosion inhibitors. Certain ingredien paint fading or damage. Be extra careful not to spill gasoline or gasoline oxygenate blends during ref When not operating your Kawasaki for 30 to 60 days, mix a fuel stabilizer (such as STA-BIL) with th Fuel stabilizer additives inhibit oxidation of the fuel which minimizes gummy deposits. Never store this the fuel system. Before storage it is recom­mended that you drain all fuel from the fuel system. See the ual.
hanol must also be
ts of gasoline may cause
ueling.
e gasoline in the fuel tank.
product with “gasohol” in
Storage section in this man-

Throttle Limiting S crew

GENERAL INFORMATION 25
j
A screw-type throttl equipped to this motorcycle to decrease the maxi­mum engine power for a novice rider. The limiting screws function by re the throttle grip so that it opens to either 3/8 or 1/2 of full throttle.
Kawasaki recommend throttle limiting screw step-by-step as follows; The 3/8degreescrewcanbeusedforthebeginning rider, 1/2 degree s and no throttle limiting screw for riders with more advanced skills.
Changing the position of the throttle limiting screw
should only be don
The longer screw is the 3/8 degree limiter, the
short screw is th
e limiting screw can be
stricting the turning degree of
s raising the level of the
crew for the semi-skilled rider,
NOTE
e at the parents’ discretion.
e 1/2 degree limiter.
A. 3/8 Degree Screw 47 mm (1.9 in.) B. 1/2 Degree Screw 42 mm (1.7 in.)
Check that the throttle grip has 2 ~ 3 mm (0.08 ~
0.12 in.) of play and turns smoothly. Remove the blank screw and locknut installed to
the housing. Install the locknut of the blank screw to the throttle
limiting screw. Screw the th
tle housing and tighten the locknut.
rottle limiting screw fully into the throt-
26 GENERAL INFORMATION

Engine Stop Switch

A. Throttle Limiting Screw B. Throttle Grip C. Locknut
NOTICE
Use only the Kawasaki screws supplied with the motorcycle. Substituting non standard screws can damage the throttle housing.
NOTE
Store the uninstalled throttle limiting screw in a
location where they will not be lost. Do not operate the motorcycle without inserting
the throttle limiting screw or blank screw into the throttle housing. This is to keep dirt or water from entering the throttle housing.
Theenginestopswitc
thehandlebar. Theenginestopswitchmustbeinthe
position for the moto
the switch to the
h is located on the left side of
rcycle to operate. Move
position to stop the engine.
NOTE
To avoid battery discharging, check that the en-
gine stop switch is in the ange indicator light (LED) goes off, when the mo­torcycle is not us
ed.
position and the or-

Starter Button

GENERAL INFORMATION 27
j
A. Engine Stop Switch
B. Indicator Light (LED)
This motorcycle has t
A. Starter Button
he starter button.
28 GENERAL INFORMATION

Kick Pedal

This motorcycle is eq system. When using the kick pedal, make sure that thetransmissionisinneutral.
A. Kick Pedal
uipped with a kick starting

Starting the Engine

Turn the fuel tap leve
A. Fuel Tap B. ON Position
Shift the transmission into neutral.
This motorcycle is equipped with a gear position
switch that pre the transmission is not in neutral.
vents the engine from starting when
r to the ON position.
NOTE
Check that the engine
position.
stop switch is in the
GENERAL INFORMATION 29
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A. Choke Knob
A. Engine Stop Switch
B.
If the engine is cold, pull out the choke knob.
Position
NOTE
When the engine is already warm or on hot days,
open the throttle part way instead of using the choke, and then start the engine.
Leaving the throttle completely closed, push the
starter button until the engine starts.
NOTE
For KLX110D model; when the clutch lever is
pulled, the motorcycle can be started with the transmission in any gear.
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