Kawasaki KLX140 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.

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 de ath

or serious injury.

NOTICE

NOTICE is used to

latedtopersonalinjury.

NOTE indicates information that may help or guide

○

youintheopera

address practices not re-

NOTE

tion or service of the vehicle.

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 PE OPLE.

joy it to the fullest. How-

th other people.

CT THE FUTURE OF YOUR

RESPECT THE RIGHTS

WARNING

THIS VEHIC LE IS AN OFF-ROAD VEHICLE

•

ONLY AND WAS NOT MANUFACTURED FOR USE ON PUBLIC STREETS, ROADS, OR HIGH-WAYS. USEYOURBIKELEGALLY.

•

RESPECT THE ENVIRONMENT 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 child 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 long-sleeved shirt while riding.

Never allow your child 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 child.

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

Your child’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 child understands the importance of chec kin g all items thoroughly before riding the motorcycle. Also, familiarity with the motorcycle is important should a problem occur far from help.

Do not allow your child 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 child them practice advanced riding maneuvers under controlled conditions.

11. Tell someone where you and your child are planning to ride and when you Intend to return. Discuss the ride with your ch may b e necessary to negotiate the terrain safely. If you are n ot familiar with the area, lead the way and reduce your speed.

KLX140A only

not to ride beyond his or her skill lever or faster than conditions safely allow. Have

ild before you leave so he or she will know in advance what riding techniques

NOTICE

KLX140A is designed for a rider weighting less than 70 kg (154 ponds). 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 INDUSTRIES, LTD.

Motorcycle & Engine Company

vy Industries, Ltd.

Mar. 1, 2013. (1)

TABLE OF CONTENTS

SPECIFICATIONS.................. .......................... 9

GENERAL INFORMATION.............................. 12

Location of Labels ......................................... 12

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

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

Fuel Tap......................................................... 20

Fuel ............................................................... 21

Engine Stop Switch ....................................... 24

Starter Button ................................................ 25

Starting the Engine

Moving Off ..................................................... 28

Shifting Gears................................................ 28

Stopping the Motor

Stopping the Engine ............... ....................... 30

Break-In........................................... .............. 30

Daily Pre-Ride Ch

MAINTENANCE AND ADJUSTMENT............. 33

EMISSION CONTROL INFORMATION ........ 33

Periodic Mainte

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

Spark Plug ..................................................... 44

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

Throttle Cable ................................................ 51

Choke Knob................................................... 53

Idle Speed ........................... .......................... 55

Clutch ............................................................ 56

........................................

cycle................................

ecks ..................................

nance Chart ..........................

Valve Clearan ce ............................................ 57

Spark Arrester ................... ............................ 58

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

Handlebar ........ .................................... .......... 65

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

Steering ................. .................................... .... 71

Front Suspension .......................................... 73

Rear Suspension .................. ......................... 74

Wheels ............... .................................... ....... 77

Hoses Inspect ion ........................................... 80

Battery ................... .................................... .... 81

Fuse .............................................................. 85

Tightening Torque

Cleaning Your Motorcycle..... ......................... 91

Lubrication ....... .................................... .......... 94

TROUBLESHOOTING

STORAGE................... .................................... . 99

Before Storage .............................................. 99

After Storage ................................................. 100

ENVIRONMENTAL PROTECTION .................. 101

WIRING DIAGRAM .......................................... 102

YOUR WARRANTY/

..................................................................... . 103

REPORTING SAFETY DEFECTS ................... 107

MAINTENANCE R

s of Nuts and Bolts............

GUIDE.........................

OWNER SATISFACTION

ECORD ..............................

108

SPECIFICATIONS 9

SPECIFICATIONS

DIMENSIONS

Overall length 1 820 mm (71.7 in.) B: 1 895 mm (74.6 in.)

Overall width 790 mm (31.1 in.)

Overall height 1 050 mm (41.3 in.) B: 1 075 mm (42.3 in.)

Wheelbase

Road clearance

Curb Mass 93 kg (205 lb) B: 95 kg (209 lb)

Fuel t an k capacity

ENGINE

Type

Bore × stroke

Displacement

Compression ratio

Carburetor

Starting system Electric Starter

Ignition system

Ignition timing

Lubrication system

Spark plug NGK CR7HSA

Spark plug terminal Screw type

1 260 mm (49.6 in.) B: 1 285 mm (50.6 in.)

235 mm (9.3 in.) B: 255 mm (10.0 in.)

5.8 L (1.5 US gal)

SOHC, 2-valve, single-cylinder, 4-stroke, Air-cooled

58.0 × 54.4 mm (2.3 × 2.1 in.)

144 cm³ (8. 8 cu in.)

9.5 : 1

KEIHIN PB20

CDI

10° BTDC @1 40 0 r/min (rpm) ∼ 30° BTDC @4 000 r/min (rpm)

Forced lubrication (wet sump)

10 SPECIFICATIONS

TRANSMISSION

Transmission type

Clutch type

Drive system

Gear ratios:

1st gear

2nd gear

3rd gear

4th gear

5th gear

Primary reduction ratio

Final reduction ratio

Overall ratio (top gear)

Engine oil:

Capacity 1.1 L (1.2 US qt)

Type

Viscosity

FRAME

Type Tubular, semi-double cradle

Steering angle 41° to either side

Castor 27°

Trail

5-speed, return shift

Wet, multi disc

Chain drive

2.667 (40/15)

1.895 (36/19)

1.474 (28/19)

1.182 (26/22)

1.000 (24/24)

2.880 (72/25)

3.571 (50/14)

10.286

API SG, SH, SJ, SL o

SAE 10W-40

85 mm (3.3 in.) B: 96 mm (3.8 in.)

r SM with JASO MA, MA1 or MA2

Tire size, type:

Front

Rear

70/100-17 40M, IRC., B: 70/100-19 42M, IRC., LTD. IX05H

90/100-14 49M, IRC., LTD. IX05H B: 90/100-16 52M, IRC., LTD. IX05H

LTD. IX 05 H

Rim size:

Front 17 × 1.40 B: 19 × 1.40

Rear 14 × 1.60 B: 16 × 1.85

Suspension:

Front

Rear New Uni-trak

Front suspension travel

Rear wheel travel

Telescop ic fork

180 mm (7.1 in.)

swinga

Front fork oil:

Type

Amount (per fork leg

Kawasaki Fork Oil SS

)

296 mL (10.0 US oz) B: 290 mL (9.8 US oz)

-8

BRAKES

Type (Front & Rear)

ELECTRICAL EQUIPM

ENT

Disc

Battery 12 V 6 Ah

SPECIFICATIONS 11

B: KLX140B

Specifications are subject to change without notice.

12 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. Refer to the actual vehicle label for model spec ific

○

data grayed out in t

els on your vehicle and un-

rate your vehicle. There-

worn, get a replacement from

NOTE

you and your dealer obtain

he illustra tio n.

1. Brake Fluid (Front)

GENERAL INFORMATION 13

2. Brake Fluid (Rear)

3. Rear Shock Absorber Warning (KLX140A)

4. Important Information

5. Noise Emission Control Information

6. Vehicle Emission Control Information

14 GENERAL INFORMATION

7. Battery Poison/Danger

3) KLX140A

GENERAL INFORMATION 15

16 GENERAL INFORMATION

Location of Parts

GENERAL INFORMATION 17

1. Clutch Lever

2. Engine Stop Switch

3. Choke Knob

4. Front Brake Fluid Reservoir

5. Front Brake Lever

6. Throttle Grip

7. Starter Button

8. Fuel Tank Cap

18 GENERAL INFORMATION

9. Front For

10. Fuel Tank

11. Fue l Tap

12. Carbure

13. Seat

14. Air Cleaner Element

15. Brake D

tor

isc

16. Brake Cal

17. Engine Oil Drain Plug

18. Side Stand

19. Drive Ch

20. Swingarm

21. Chain Guide

22. Rear Sh

iper

ain

ock Absorber

GENERAL INFORMATION 19

23. Muffler

24. Fuse

25. Battery

26. Rear Axl

eNut

27. Chain Adj

28. Rear Brake Fluid Res ervo ir

29. Oil Filler Cap/Dipstick

30. Rear Bra

uster

ke Pedal

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 Tap

The fuel tap has three (reserve). For normal operation, turn the fuel tap lever to the ON position. If the fuel runs out with the tap in t he ON position (0.29 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 1.1 L

orcycle is stored for a long time.

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 fillin g 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.

GENERAL INFORMATION 21

Fuel

The required of fuel i

quirements”.

The capacity of the fuel tank is 5.8 L (1.5 US gal). To open the fuel tank c hose from the hole in the steering shaft 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, disconnect the breather

nk in the rain or where heavy dust

A. Fuel Tank Cap

B. Breather Hose

22 GENERAL INFORMATION

Filling the Tank:

Avoid filling the tank in the rain or where heavy dust

is blowing so that the fuel does not get contaminated.

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

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. 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 fill the tank completely to the top. As the fuel expands in a warm tank, it may 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.

Fuel R equirements:

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.

Octane Rating Method

Antiknock Index

RON + MON)

(

Minimum

Rating

NOTICE

If engine “knocking” or “pinging” occurs, use a different brand of gasoline of a higher octane rating. If th continue it can lead to severe engine damage. Gasoline quality is quality or not meeting standard industry specifications may result in unsatisfactory performance that result from the use of poor quality or non-recommended fuel may not be covered under your warran

Fuels Containing Oxygenates

Gasoline frequently contains oxygenates (alcohols and ethers) especially in areas of the U.S. and Canada which are required to sell such reformulated fuels as part of a strategy to reduce exhaust emissions.

The types and volume of fuel oxygenates approved for use in unleaded gasoline by the U.S. Environmental Protection Agency include a broad range of alcohols and ethers, but only two components have seen any significant level of commercial use.

is condition is allowed to

important. Fuels of low

. Operating problems

ty.

GENERAL INFORMATION 23

Gasoline/Alcohol Bl to 10% ethanol (alcohol produced from agricultural products such as corn), also known as “gasohol” is approved for use.

ends - 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 (MTBE). 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.

24 GENERAL INFORMATION

NOTICE

Never use gasoline with an octane rating lower than the minimum 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 thefuelsystem. Beforestorageitisrecommended that you drain all fuel from the fuel system. Se manual.

hanol must also be

ts of gasoline may cause

ueling.

e gasoline in the fuel tank.

product with “gasohol” in

e the Storage section in this

Engine Stop Switch

Theenginestopswitc

thehandlebar. Theenginestopswitchmustbeinthe

position for the moto

the switch to the

To avoid battery discharging, check that the en-

○

gine stop switch is in the dicator light (orange LED) goes off, when the motorcycle is not us

h is located on the left side of

rcycle to operate. Move

position to stop the engine.

NOTE

position and the in-

ed.

A. Engine Stop Switch B. Indicator L

ight (LED)

GENERAL INFORMATION 25

Starter Button

This motorcycle has t button operates the electric starter when the clu tch lever pulled in.

A. Starter Button

he starter button. The starter

Starting the Engine

Turn the fuel tap leve

•

A. ON Position

Shift the transm

•

This motorcycl

○

that prevents the engine from starting when the transmission is not in neutral.

r to the ON position.

ission in to neutral.

NOTE

e is equipped with a neutral switch

26 GENERAL INFORMATION

Check that the engine

•

position.

A. Engine Stop Switch

Position

stop switch is in the

WARNING

Riding with the side stand in the down position can cause a crash resulting in injury. Do not start the engine or attempt to ride the motorcycle when the side stand is down.

NOTICE

Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the bat temporarily. Wait 15 seconds between each operation of the starter to let it recover.

When engine is cold:

Pull out the choke knob.

•

A. Choke Knob

Leaving the throttle completely closed, push the

•

starter butt

on until the engine starts.

tery power will drop

cool and the battery power

NOTE

When the clutch lever is pulled, the motorcycle can

○

be started with the transmission in any gear.

A. Starter Button

Even after the engine has started, do not push

•

back immediate is thoroughly warmed up.

When the engine is already warm or on a hot day,

○

open the throttle part way instead of using the choke knob.

ly the choke knob until the engine

NOTE

GENERAL INFORMATION 27

NOTICE

Do not let the engine idle longer than five minutes, or engine overheating and damage may occur.

28 GENERAL INFORMATION

Moving Off

Check that the side st

•

Shift into 1st gear.

•

Open the throttle slowly.

•

and is up.

Shifting Gears

This motorcycle is eq shift” transmission. The neutral is located halfway between 1st and 2nd gear. “Return shift” means that when shifting up engaged before the next higher or lower gear may be selected.

To engage first gea

•

in the clutch lever and push down on the shift pedal, gently release the clutch lever, then release the shift pedal. To shift up to the next gear, pull in the clutch lever,

•

lift the shift pedal with your toes, gently release the clutch lever, an To shift down to the next gear, pull in the clutch

•

lever, push the shift pedal down as far as it will go, gently release t shift pedal.

uipped with a 5-speed “return

or down, each gear must be

r from the neutral position, pull

d then release the shift pedal.

he clutch le ver, then release the

WARNING

Downshifting to a lower gear at high speed

causes engine rpm to increase excessively,

potentially damaging the engine and it may

also cause the rear wheel to skid and cause

an accident.

NOTICE

When changing gears, press firmly on the shift pedal to ensure proper shifting. Careless, incomplete sh transmission to jump out of gear and lead to engine damage.

A. Shift Pedal

ifting can cause the

GENERAL INFORMATION 29

Stopping the Motorcycle

For maximum decelera apply both front and rear brakes. Pull in the clutch lever as the motorcycle comes to a stop. Independent use of the front o geous in certain circu ms ta nc es . Shift down progressively to ensure good engine response at all speeds.

tion, close the throttle and

r rear brake may be advanta-

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