Kawasaki KLX110L 2015 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.

formation you’re looking for.

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

lated to personal injury.

NOTE indicates information that may help or guide

○

you in the opera

address practices not re-

NOTE

tion or service of the vehicle.

IMPORTANT

Off-road motorcycling is a wonderful sport, andwehopeyouwillen 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

THIS VEHICLE IS AN OFF-ROAD VEHICLE

•

ONLY AND WAS NOT MANUFACTURED FOR USE ON PUBLIC STREETS, ROADS, OR HIGHWAYS. USE YOUR MOTORCYCLE LEGALLY.

•

RESPECT THE ENVIRONMENT AND THE

•

RIGHTS OF OTHER PEOPLE.

IMPORTANT NOTE TO PAR

Your youngster’s saf a properly maintained vehicle. As with 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 n g-sle eved shirt while riding.

Never allow your youngster to carry a passenger. This motorcycle is designed for an OPERATOR ONLY.

This motorcycle is designed for off-road riding and should never be operated on public roads or paved surfaces.

This motorcycle was not designed for hard riding such as motocross.

Always obey local off-road riding laws and regulations. Obtain permission to ride on private property.

You, the parent (and most likely “riding instructor/mechanic” 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.

You must determine your youngster’s readiness to ride this off-road motorcycle. Your youngster should already be familiar with motorcycle controls (location and function) a nd basic riding techniques. Your youngster should also be physically large enough, and strong enough to be able to straddle the motorcycle a nd hold it up, plus be able to pick up it u p if it is on its side.

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 checking all item s thoroughly before riding the motorcycle. Also, familiarity with the motorcycle is important should a problem occur far from help.

Do not allow your youngster to ride unsupervised. 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 be nec e ssary 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.

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM

To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing system. T h do not remove the se systems, or alter them in any way which result s in an increase in noise level.

ey are designed to give optim um performance while maintaining a low noise level. Please

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 superior reliability, and performance. By g iving 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 limita tio ns, and above all, how to operate it safety.

Due to improvements in design and performance made during production, in some cases there may be minor discrepancies between the actual vehicle and the illustrations and text in this manual.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

vy Industries, Ltd.

Mar. 15, 2014. (1)

TABLE OF CONTENTS

SPECIFICATIONS............................................ 10

GENERAL INFORMATION.............................. 14

Location of Labels ......................................... 14

Location of Parts ................. .......................... 17

Side Stand ..................................................... 20

Fuel ............................................................... 20

Fuel Requirements:.................................... 20

Filling the Tank: .......................................... 21

Fuel Tap:..................................................... 23

Throttle Limiting S

Engine Stop Switch ....................................... 25

Starter Butto n ...................... .......................... 26

Kick Pedal ..................................................... 26

Starting the Engine ........................................ 27

Moving Off ..................................................... 30

Shifting Gears................................................ 31

Stopping the Motorcycle ................................ 32

Stopping the Engine ...................................... 33

Break-In.......... .................................... ........... 33

Daily Pre-Ride Checks .................................. 34

MAINTENANCE AND ADJUSTMENT............. 36

Periodic Maint

Engine Oil ...................................................... 40

Spark Plug ..................................................... 45

Air Cleaner ......................................... ........... 46

crew..................................

enance Chart ..........................

Throttle Cable ................................................ 52

Carburetor ....................................... .............. 54

Clutch ............................................................ 55

Valve Cleara nce ............................................ 57

Spark Arrester ............................................... 57

Drive Chain.................................................... 60

Handlebar ....... .................................... ........... 66

Brakes ............................................. .............. 67

Steering ................ .................................... ..... 72

Front Suspension .......................................... 75

Rear Suspension ................. .......................... 76

Wheels .............. .................................... ........ 76

Hoses Inspect ion ........................................... 79

Battery ........................................................... 79

Fuse ...................................................... ........ 83

Tightening Torq u

Cleaning Your Motorcycle. ............................. 88

Lubrication ..................................................... 90

TROUBLESHOOTIN

STORAGE ... .................................... ................. 102

Before Storage .................... .......................... 102

After Storage ................................................. 103

ENVIRONMENTAL PROTECTION . ................. 104

WIRING DIAGRAM .......................................... 105

es of Nuts and Bolts............

G GUIDE........ .................

10 SPECIFICATIONS

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 Digital DC-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)

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 10.832 at Top gear

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)

API SG, SH, SJ, SL

SAE 10W-40

or SM with JASO MA, MA1 or MA2

SPECIFICATIONS 11

12 SPECIFICATIONS

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

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.)

GS-45F

Front Fork Oil:

Type

Kawasaki Fork Oil SS8

Amount (Per One Unit):

KLX110C 165 mL (5.6 US oz.)

KLX110D

182mL(6.2USoz.)

BRAKES

Type:

Front Drum brake

Rear Drum brake

ELECTRICAL EQUIPMENT

Battery 12V3Ah

Specifications are subject to change without notice, and may not apply to every country.

SPECIFICATIONS 13

14 GENERAL INFORMATION

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 de a ler and install it in the correct position.

The sample warnin g labels in this section have

○

part numbers to help the correct replacement.

els on your vehicle and un-

rate your vehicle. There-

worn, get a replacement from

NOTE

you and your dealer obtain

1. Rear Shock Absorber Warning

2. Important Information (Australia model)

3. Helmet (Thailand model)

GENERAL INFORMATION 15

16 GENERAL INFORMATION

2) Australia model

3) Thailand model

Location of Parts

GENERAL INFORMATION 17

1. Clutch Lever (KLX110D Model)

2. Engine Stop Switch

3. Front Brake Lever

4. Throttle Grip

5. Starter Button

6. Fuel Tank Cap

18 GENERAL INFORMATION

7. Front Fork

8. Brake Cable

9. Choke Knob

10. Fuel Tap

11. Brake Cam Lever

12. Air Cleaner

13. Oil Filter Cap

14. Engine Oil Drain Bolt

15. Shift Pedal

16. Chain Slipper

17. Side Stand

18. Swingarm

19. Drive Chain

GENERAL INFORMATION 19

20. Muffler

21. Rear Shock Absorber

22. Seat

23. Fuel Tank

24. Throttle Limiting Screw

25. Kick Pedal

26. Rear Brake Pedal

27. Oil Level Inspection Window

28. Carburetor

20 GENERAL INFORMATION

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

Fuel Requirements:

Your Kawasaki engine is designed to use only unleaded gasoline wit shown below. Never use gasoline with an octane rating lower than the minimum specified by Kawasaki to prevent

The octane rating of a gasoline is a measure of its resistance to detonation or “knocking”. The term commonly used to des ing is the Research Octane Number (RON).

h a minimum octane rating

severe engine damage.

cribe a gasoline’s octane rat-

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 dam-

age. Gasoline quality is important. Fuels of

low quality or not meeting standard industry

specifications may result in unsatisfactory

performance.

Fuel Type and Octane Rating

Use clean, fresh unleaded gasoline with an octane rating equal t

o or higher than that shown in the table.

Fuel Type

Ethanol Content

Minimum Octane Rating

Unleaded Gasoline

E10 or less

Research Octane Number (RON) 91

NOTICE

Do not use any fuel that contains more ethanol or other oxygenates than specified for E10 fuel* in this vehicle. Damage to the engine and fuel system, or engine starting and/or performance problems may result from the use of improper fuel.

*E10 means fuel containing up to 10% ethanol.

ling the Tank:

Fil

The capacity of the fuel tank is 3.6 L (1.0 US gal). To open the fuel tank cap, pull out the breather hose from the hole in the number plate, and turn the tank cap counterclockwise. After refueling, make sure the f iller cap is closed securely.

GENERAL INFORMATION 21

A. Fuel Tank Cap B. Breather Hose

Avoid filling the tank in the rain or where heavy dust

is blowing so that the fuel does not get contaminated.

22 GENERAL INFORMATION

A. Tank Cap B. Fuel Tank C. Top Level D. Filler Neck

WARNING

Gasoline is extremely flammable and can be explosive 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. Never f ill the tank so the fuel level rises into the filler neck. If the tank is overfilled, heat may cause the fuel to expand and overflow through the vents in the tank cap. After refueling, make sure the fuel tank cap is closed securely. If gasoline is spilled on the fuel tank, wipe it off immediately.

NOTICE

Certain ingredients in gasoline may cause paint fading or damage. Be extra careful not to spill gaso blends during refueling.

line or gasoline oxygenates

Fuel Tap:

The fuel tap has three position; OFF, ON, and RES (reserve). For normal operat ion , turn the fuel tap lever to the ON position. If the fuel runs out with the tap in the ON position, the last approximately 0.4 L (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 motorcycle is stored for a long time.

GENERAL INFORMATION 23

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.

24 GENERAL INFORMATION

Throttle Limiting S crew

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 open s to either 3/8 or 1/2 of full throttle.

Kawasaki recommend throttle limiting scre w step-by-step as follo ws; The 3/8 degree screw can be used for the be ginning 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

strictingtheturningdegreeof

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-

GENERAL INFORMATION 25

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

the handlebar. The engine stop switch must be in the

position for the moto

the switch to the

h is located on the le ft 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

A. Engine Stop Switch B. Indicator L

ed.

ight (LED)

position and the or-

26 GENERAL INFORMATION

Starter Button

This motorcycle has t

A. Starter Button

he starter button.

Kick Pedal

This motorcycle is eq system. When using the kick pedal, make sure that the transmission is in neutral.

A. Kick Pedal

uipped with a kick starting

Starting the Engine

GENERAL INFORMATION 27

Check that the engine

•

position.

stop switch is in the

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

A. Engine Stop Switch

Position

28 GENERAL INFORMATION

If the engine is cold,

•

A. Choke Knob

When the engine is already warm or on hot days,

○

open the throttle part way instead of using the choke, and then

Leaving the throttle completely closed, push the

•

starter butto

For KLX110D mo

○

pulled, the motorcycle can be started with the transmission in any gear.

n until the engine starts.

pull out the choke knob.

NOTE

start the engine.

NOTE

del; when the clutch lever is

A. Starter Button

NOTICE

Do not operate the starter continuously for

more than 5 seconds, or the starter will

overheat and the battery power will drop

temporarily. Wait 15 seconds between each

operation of the starter to let it cool and the

battery power recover.

NOTE

For KLX110C model; when using the kick pedal,

○

makesurethatthetransmissionisinneutral. For KLX110D model; when using the kick pedal,

○

make sure that the transmission is in neutral, and do not pull in the clutch lever.

GENERAL INFORMATION 29

A. Kick Pedal

NOTE

If the engine is flooded, crank the engine over with

○

the throttle fully open until the engine starts. The KLX110D model is equipped with a starter

○

lockout switch. This switch prevents the electric starter from operating when the clutch is engaged and the transmission is not in neutral.

A. Clutch Lever B. Starter Lockout Switch

Gradually push the choke knob back a little at

•

a time as necessary to keep the engine running properly during warm-up. When the engin

•

without using the choke, push the choke knob all the way back.

If you drive the motorcycle before the engine is

○

warmed up, pu as soon as you start moving.

e is warmed up enough to idle

NOTE

sh the choke knob all the way back

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