Kawasaki KLX140L 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.
NOTICE
NOTICE is used to address practices not relatedtopersonalin
jury.
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.
NOTE
NOTE indicates information that may help or guide
○
you in the operation 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 with 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.
2.
Never allow your child 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 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.
7.
You must determine your child’s readiness to ride this off-road motorcycle. Your child should already be
familiar with motorcycle controls (locatio n and function) and basic riding techniques. 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.
8.
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 checkin g all items thoro ugh ly before riding the motorcycle. Also, familiarity with the motorcycle is
important should a problem occur far from help.
9.
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
theridewithyourch
may b e necessary to negotiate the terrain safely. If you are not 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 pounds). 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
©2014 Kawasaki Hea
vy Industries, Ltd.
Feb. 22, 2014. (1)
TABLE OF CONTENTS
SPECIFICATIONS............................................ 10
GENERAL INFORMATION.............................. 13
Location of Labels ......................................... 13
Location of Parts ................. .......................... 18
Side Stand ..................................................... 21
Fuel ............................................................... 21
Engine Stop Switch ....................................... 24
Starter Butto n ...................... .......................... 25
Starting the Engine ........................................ 25
Moving Off ..................................................... 28
Shifting Gears................................................ 28
Stopping the Motorcycle ................................ 29
Stopping the Engin
Break-In......................................................... 30
Daily Pre-Ride Checks .................................. 31
MAINTENANCE AND A
Periodic Maint enance Chart .......................... 33
Engine Oil ...................................................... 38
Spark Plug ..................................................... 42
Air Cleaner ......................................... ........... 43
Throttle Cab le ................................................ 48
Choke Knob................................................... 51
Idle Speed ........................... .......................... 52
e ........................ ..............
DJUSTMENT.............
30
33
Clutch ............................................................ 53
Valve Cleara nce ............................................ 55
Spark Arrester ............................................... 55
Drive Chain.................................................... 57
Handlebar ....... .................................... ........... 63
Brakes ............................................. .............. 65
Steering ................ .................................... ..... 68
Front Suspension .......................................... 70
Rear Suspension ................. .......................... 71
Wheels .............. .................................... ........ 74
Hoses Inspect ion ........................................... 77
Battery ........................................................... 78
Fuse ...................................................... ........ 82
Tightening Torques of Nuts and Bolts............ 83
Cleaning Your Motorcycle. ............................. 88
Lubrication ..................................................... 91
TROUBLESHOOTING GUIDE......................... 94
STORAGE ... .................................... ................. 96
Before Storage .................... .......................... 96
After Storage ................................................. 97
ENVIRONMENTAL PROTECTION . ................. 98
WIRING DIAGRAM
..........................................
99
10 SPECIFICATIONS
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 tank 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 @1 400 r/min (rpm) ∼ 30°BTDC@4000r/min(rpm)
Forced lubrication (wet sump)
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
Caster 27°
Trail
5-speed, const ant mesh, return shift
Wet, m u lti 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
SPECIFICATIONS 11
12 SPECIFICATIONS
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
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.)
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)
BRAKES
Type (Front & Rear)
ELECTRICAL E QU IPM
ENT
Disc
Battery 12 V 6 Ah
LTD. IX05H
rm
-8
B: KLX140B
Specifications are subject to change without notice, and may not apply to every country.
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.
els on your vehicle and un-
rate your vehicle. There-
worn, get a replacement from
NOTE
you and your dealer obtain
GENERAL INFORMATION 13
j
1. Brake Fluid (Front)
14 GENERAL INFORMATION
2. Brake Fluid (Rear)
3. Rear Shock Absorber Warning (KLX140A)
4. Important Information
5. Helmet (Thailand Model)
6. Battery Poison/Danger
GENERAL INFORMATION 15
j
16 GENERAL INFORMATION
1)
2)
3) KLX140A
4)
5) Thailand Model 6)
GENERAL INFORMATION 17
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18 GENERAL INFORMATION
Location of Parts
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
GENERAL INFORMATION 19
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9. Front For
10. Fuel Tank
11. Fu e l Tap
12. Carbure
13. Seat
14. Air Cleaner Element
15. Brake D
k
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
20 GENERAL INFORMATION
23. Muffler
24. Fuse
25. Battery
26. Rear Axl
eNut
27. Chain Adj
28. Rear Brake Fluid Reservoir
29. Oil Filler Cap/Dipstick
30. Rear Bra
uster
ke Pedal
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
Fuel Requirements:
Your Kawasaki engine is designed to use only
unleaded gasoline with a minimum octane rating
shown below. Never use gasoline with an octane rating lower than the minimum specified by
Kawasaki to prevent severe engine damage.
The octane rating of a gasoline is a measure of
its resistance to detonation or “knocking”. The term
commonly used to describe a gasoline’s octane rating is the Research Octane Number (RON).
NOTICE
If engine “knocking" or “pinging" occurs,
use a different br
octane rating. If this condition is allowed to
continue, it can lead to severe engine dam-
age.Gasoline qu
low quality or not meeting standard industry
specifications may result in unsatisfactory
performance.
and of gasoline of a higher
ality is important. Fuels of
22 GENERAL INFORMATION
Fuel Type and Octane R
Use clean, fresh unleaded gasoline with an octane
rating equal to 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
ating
NOTICE
Do not use any fuel that contains more
nol or other oxygenates than specified
etha
for E10 fuel* in this vehicle. Damage to the
engine and fuel system, or engine starting
/or performance problems may result
and
from the use of improper fuel.
*E10 means fuel containing up to 10% ethanol.
NOTE
In case of using E10 fuel, it is necessary to change
○
carburetor setting.
Filling the Tank:
Avoid filling the tank in the rain or where heav y 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. 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 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 of gasoline may cause
paint fading or damage. Be extra careful
not to spill gas
blends during refueling.
oline or gasoline oxygenates
GENERAL INFORMATION 23
Fuel Tap:
The fuel tap has three position: OFF, ON, and RES
(reserve). For normal operation, turn the fuel tap
lever to the ON posit
tap in the ON position, the last approximately 1.1 L
(0.29 US gal) of usable fuel remains can be used by
turningthetaplev
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 rem
ments or the motorcycle is stored for a long time.
ion. If the fuel runs out with the
er to the RES position.
oved for maintenance and adjust-
j
24 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.
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
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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
B.
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.
j
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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