1. DL manuals
  2. Kawasaki
  3. Other
  4. KLX 110 - BROCHURE 2009
  5. Service Manual

Kawasaki KLX 110 - BROCHURE 2009 Service Manual

Other manuals for KLX 110 - BROCHURE 2009: Brochure, Brochure, Owner's Manual, Service Manual, Service Manual
Manual is about: Motorcycle

Summary of KLX 110 - BROCHURE 2009

  • Page 1

    Klx110 klx110l motorcycle service manual.

  • Page 3: Quick Reference Guide

    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 th...

  • Page 5: Klx110

    Klx110 klx110l 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...

  • Page 6

    List of abbreviations a ampere(s) lb 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...

  • Page 7: Foreword

    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 prope...

  • Page 9: General Information

    General information 1-1 1 general information table of contents before servicing ..................................................................................................................... 1-2 model identification................................................................................

  • Page 10

    1-2 general information before servicing before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions...

  • Page 11

    General information 1-3 before servicing arrangement and cleaning of removed parts disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of removed parts after all the parts including subas...

  • Page 12

    1-4 general information before servicing tightening sequence generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can l...

  • Page 13

    General information 1-5 before servicing press for items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball bearing and needle bearing do not remove presse...

  • Page 14

    1-6 general information before servicing lubrication it is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of engine rotati...

  • Page 15

    General information 1-7 model identification klx110ca left side view klx110ca right side view frame number engine number.

  • Page 16

    1-8 general information model identification klx110da left side view klx110da right side view.

  • Page 17

    General information 1-9 general specifications items klx110ca ∼ ce, klx110da ∼ de dimensions overall length 1 560 mm (61.42 in.) overall width 650 mm (25.59 in.) overall height: klx110c 955 mm (37.60 in.) klx110d 990 mm (38.98 in.) wheelbase 1 075 mm (42.32 in.) road clearance: klx110c 215 mm (8.46 ...

  • Page 18

    1-10 general information general specifications items klx110ca ∼ ce, klx110da ∼ de valve timing: inlet: open 25° btdc close 55° abdc duration 260° exhaust: open 60° bbdc close 20° atdc duration 260° lubrication system forced lubrication (wet sump) engine oil: type api sg, sh, sj, sl or sm with jaso ...

  • Page 19

    General information 1-11 general specifications items klx110ca ∼ ce, klx110da ∼ de front tire: size 2.50-14 4p.R. Make/type irc, gs-45f, tube rear tire: size 3.00-12 4p.R. Make/type irc, gs-45f, tube rim size: front 14 × 1.40 rear 12 × 1.60 front suspension: type telescopic fork wheel travel: klx110...

  • Page 20

    1-12 general information unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass: kg × 2.205 = lb g × 0.03527 = oz units of volume: l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us)...

  • Page 21: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart .............. 2-2 torque and locking agent................. 2-4 specifications .................................... 2-8 special tools ..................................... 2-10 periodic maintenance procedur...

  • Page 22

    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. Periodic inspection frequency initial every hours(month (s)) 5 50 100 operation (1) (6) (12) see page spark plug - clean and inspect † • • ...

  • Page 23

    Periodic maintenance 2-3 periodic maintenance chart periodic replacement parts frequency initial every hours (month (s)) 5 50 100 operation (1) (6) (12) see page engine oil - change • • • 2-19 oil filter - replace • • 2-20 fuel hose - replace every 5 years 2-14 front fork oil - change • • 2-32.

  • Page 24

    2-4 periodic maintenance torque and locking agent tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening toque for t...

  • Page 25

    Periodic maintenance 2-5 torque and locking agent torque fastener n·m kgf·m ft·lb remarks clutch primary clutch hub nut (klx110c) 72 7.3 53 secondary clutch hub nut (klx110c) 72 7.3 53 clutch hub nut (klx110d) 72 7.3 53 primary gear nut (klx110d) 72 7.3 53 clutch spring bolts 5.0 0.51 44 in·lb oil s...

  • Page 26

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks brake pedal bolt 8.8 0.90 78 in·lb suspension front fork clamp bolts (upper) 20 2.0 15 front fork clamp bolts (lower) 30 3.1 22 steering stem nut 4.9 0.50 43 in·lb steering stem head nut 44 4.5 32 swingarm pivo...

  • Page 27

    Periodic maintenance 2-7 torque and locking agent basic torque for general fasteners threads dia. Torque (mm) n·m kgf·m ft·lb 5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb 6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb 8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5 10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25 12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45 14 73 ...

  • Page 28

    2-8 periodic maintenance specifications item standard service limit fuel system throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 600 ∼ 1 700 r/min (rpm) – – – air cleaner element oil high quality foam air filter oil – – – engine top end valve clearance: exhaust 0.08 ∼ 0.12 mm (0...

  • Page 29

    Periodic maintenance 2-9 specifications item standard service limit final drive drive chain slack klx110c models 11 ∼ 16 mm (0.4 ∼ 0.6 in.) – – – klx110d models 8 ∼ 13 mm (0.3 ∼ 0.5 in.) – – – drive chain 20-link length 254.0 ∼ 254.6 mm (10.00 ∼ 10.02 in.) 259 mm (10.2 in.) standard chain: make daid...

  • Page 30

    2-10 periodic maintenance special tools steering stem nut wrench: 57001-1100 valve adjusting screw holder: 57001-1217 jack: 57001-1238 spark plug wrench, hex 16: 57001-1262 fork oil level gauge: 57001-1290 filler cap driver: 57001-1454.

  • Page 31

    Periodic maintenance 2-11 periodic maintenance procedures fuel system fuel hose and connection inspection ○ the fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the inside the fuel line can cause fuel to ...

  • Page 32

    2-12 periodic maintenance periodic maintenance procedures if the throttle grip free play cannot be adjusted with the adjuster at the upper end of the throttle cable, use the lower cable adjuster at the carburetor. • remove the shroud (see shroud removal in the frame chapter). • pull off the boot [a]...

  • Page 33

    Periodic maintenance 2-13 periodic maintenance procedures idle speed adjustment notice the pilot screw [a] is set at the factory and should not be adjusted. But if necessary, set the pilot screw as follows: note ○ for us and ca models, the pilot screw cannot be ad- justed. • remove the shroud (see s...

  • Page 34

    2-14 periodic maintenance periodic maintenance procedures warning gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or flame any- where near the working areas. Do not use g...

  • Page 35

    Periodic maintenance 2-15 periodic maintenance procedures • remove: fuel tank (see fuel tank removal in the fuel system chapter) fuel hose [a] • replace the fuel hose with a new one. • fix the both ends of the fuel hose with the clamps [a] securely. • start the engine and check the fuel hose for lea...

  • Page 36

    2-16 periodic maintenance periodic maintenance procedures engine top end valve clearance inspection note ○ valve clearance must be checked and adjusted when the engine is cold (at room temperature). • remove: valve adjusting covers [a] (see camshaft sprocket re- moval in the engine top end chapter) ...

  • Page 37

    Periodic maintenance 2-17 periodic maintenance procedures spark arrester cleaning this vehicle is equipped with a spark arrester. It must be properly maintained to ensure its efficiency. Notice the spark arrester must be installed correctly and functioning properly to provide adequate fire pro- tect...

  • Page 38

    2-18 periodic maintenance periodic maintenance procedures clutch release adjustment (klx110c) • loosen the adjusting screw locknut [a]. • turn the adjusting screw [b] counterclockwise until it be- comes hard to turn. • loosen the adjusting screw until the specified value. Clutch release: 1/4 turn ou...

  • Page 39

    Periodic maintenance 2-19 periodic maintenance procedures friction and steel plates inspection • remove the clutch plates (see secondary clutch disassembly (klx110c) or clutch hub disassembly (klx110d) in the clutch chapter). • visually inspect the friction and steel plates to see if they show any s...

  • Page 40

    2-20 periodic maintenance periodic maintenance procedures warning the engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during oil change. • place an oil pan beneath the engine. • remove the engine oil drain plug [...

  • Page 41

    Periodic maintenance 2-21 periodic maintenance procedures • replace the oil filter [a] with a new one. • apply engine oil to the grommet [b]. • be sure to install the filter with the grommet facing inside. Notice inside out installation stops oil flow, causing engine seizure. • replace the o-ring [a...

  • Page 42

    2-22 periodic maintenance periodic maintenance procedures tires inspection as the tire tread wears down, the tire becomes more sus- ceptible the puncture and failure. • remove any imbedded stones or other foreign particles from the tread. • visually inspect the tire for cracks and cuts, replacing th...

  • Page 43

    Periodic maintenance 2-23 periodic maintenance procedures rim runout inspection • place the jack under the frame so that the front/rear wheel off the ground. Special tool - jack: 57001-1238 • inspect the rim for small cracks, dents, bending, or warp- ing. If there is any damage to the rim, it must b...

  • Page 44

    2-24 periodic maintenance periodic maintenance procedures final drive drive chain slack inspection • raise the rear wheel off the ground, rotate the rear wheel to find the place where the chain is tightest (because it wears unevenly). • check the wheel alignment (see wheel alignment inspec- tion in ...

  • Page 45

    Periodic maintenance 2-25 periodic maintenance procedures • tighten both chain adjuster locknuts securely. • tighten the axle nut. Torque - rear axle nut: 64 n·m (6.5 kgf·m, 47 ft·lb) • rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary. • tighten the...

  • Page 46

    2-26 periodic maintenance periodic maintenance procedures • stretch the chain taut by hanging a 10 kg (20 lb) weight [a] on the chain. • measure the length of 20 links [b] on the straight part [c] of the chain from the pin center of the 1st pin to the pin center of the 21st pin. Since the chain may ...

  • Page 47

    Periodic maintenance 2-27 periodic maintenance procedures sprocket wear inspection • visually inspect the front and rear sprocket teeth for wear and damage. If they are worn as illustrated or damaged, replace the sprocket. [a] worn tooth (engine sprocket) [b] worn tooth (rear sprocket) [c] direction...

  • Page 48

    2-28 periodic maintenance periodic maintenance procedures brake lever free play adjustment • slide the brake lever dust cover [a] out of place. • loosen the locknut [b] and turn the adjuster [c] so that the brake lever will have 4 ∼ 5 mm (0.16 ∼ 0.20 in.) of play. • if it cannot be done, use the adj...

  • Page 49

    Periodic maintenance 2-29 periodic maintenance procedures brake pedal free play adjustment • turn the adjusting nut [a] at the brake cam lever so that the pedal has proper play. • operate the pedal a few times to see that it returns to its rest position immediately upon release. • rotate the rear wh...

  • Page 50

    2-30 periodic maintenance periodic maintenance procedures brake shoe lining thickness [a] standard: front 2.10 ∼ 3.00 mm (0.08 ∼ 0.12 in.) rear 3.85 ∼ 4.15 mm (0.152 ∼ 0.163 in.) (when the wear indicator is within the usable range.) service limit: front 1.2 mm (0.05 in.) rear 2.0 mm (0.08 in.) (when...

  • Page 51

    Periodic maintenance 2-31 periodic maintenance procedures • before removing the cam lever [a], mark the position [b] of the cam lever. • remove the brake cam lever bolt [c] and nut [d], and then pull out the brake cam lever from the brake camshaft. • mount the cam lever at a new position so that the...

  • Page 52

    2-32 periodic maintenance periodic maintenance procedures brake panel lubrication • disassemble the brake panel (see brake panel disas- sembly in the brakes chapter). • clean all old grease out of the brake parts with a cloth. • apply high-temperature grease to the following. Brake shoe anchor pin [...

  • Page 53

    Periodic maintenance 2-33 periodic maintenance procedures • drain the fork oil [a] with the fork upside down. Note ○ pump the fork tube several times to discharge the oil. • pour in the specified type and amount of oil. Suspension oil - ss-8 (1 l): 44091-0007 fork oil amount: klx110c models 165 ±2.5...

  • Page 54

    2-34 periodic maintenance periodic maintenance procedures swingarm pivot inspection • raise the rear wheel off the ground with the jack. Special tool - jack: 57001-1238 • move the swingarm [a] side to side to check for worn, damaged or loose suspension pivot components. If any play is detected, chec...

  • Page 55

    Periodic maintenance 2-35 periodic maintenance procedures • loosen the front fork upper clamp bolts [a], and remove the steering stem head nut [b] and steering stem head [c]. • turn the steering stem nut [a] with the steering stem nut wrench [b] to obtain the proper adjustment. If the steering is to...

  • Page 56

    2-36 periodic maintenance periodic maintenance procedures frame frame inspection • clean the frame with steam cleaner. • visually inspect the frame [a] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. Warning a repaired frame may fail in use, possibly causing an ...

  • Page 57

    Periodic maintenance 2-37 periodic maintenance procedures • measure the gap [a] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [b] with a suitable tool to obtain the correct gap. Spark plug gap standard: 0.6 ∼ 0.7 mm (0.024 ∼ 0.028 in.) • install the spa...

  • Page 58

    2-38 periodic maintenance periodic maintenance procedures • check that the battery terminals are not corroded. If necessary, remove the battery (see battery removal in the electrical system chapter) and clean the terminals and cable ends using a solution of baking soda and water. • after attaching b...

  • Page 59

    Periodic maintenance 2-39 periodic maintenance procedures • 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. ...

  • Page 60

    2-40 periodic maintenance periodic maintenance procedures brakes: rear brake adjust nut brake lever pivot bolt brake pedal bolt torque link nuts torque link nut cotter pins suspension: front fork clamp bolts rear shock absorber mounting bolts, nuts swingarm pivot nut steering: steering stem head nut...

  • Page 61: Fuel System

    Fuel system 3-1 3 fuel system table of contents exploded view........................................................................................................................ 3-2 specifications ......................................................................................................

  • Page 62

    3-2 fuel system exploded view.

  • Page 63

    Fuel system 3-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 carburetor holder bolts 5.2 0.53 46 in·lb 2 throttle cable housing cap screws 0.6 0.06 5.3 in·lb 3. Throttle cable 4. Choke cable 5. Throttle grip 6. Carburetor cap 7. Retainer 8. Circlip 9. Jet needle 10. Throttle valve 11....

  • Page 64

    3-4 fuel system exploded view.

  • Page 65

    Fuel system 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air cleaner cover screws 1.5 0.15 13 in·lb 2 air cleaner housing bolts 3.5 0.36 31 in·lb 3 air duct clamp screw 2.0 0.20 18 in·lb 4 fuel tap mounting bolts 4.4 0.45 39 in·lb 5 screw (for seat hook) 5.0 0.51 44 in·lb 6 screw ...

  • Page 66

    3-6 fuel system specifications item standard throttle grip and cable throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) carburetor make/type keihin pb18 idle speed 1 600 ∼ 1 700 r/min (rpm) main jet #78 main air jet #180 jet needle ncfa throttle valve cutaway 3.0 slow jet #40/40 pilot screw (turns o...

  • Page 67

    Fuel system 3-7 special tool fuel level gauge: 57001-1017.

  • Page 68

    3-8 fuel system throttle grip and cable 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 wi...

  • Page 69

    Fuel system 3-9 throttle grip and cable • lubricate the cable. • apply grease to the tips of the cables. • insert the throttle valve assembly. • run the throttle cable in accordance with the cable, wire and hose routing section in the appendix chapter. • install the throttle cable to the cable housi...

  • Page 70

    3-10 fuel system throttle grip and cable choke cable installation • installation is the reverse of removal. • install the choke cable in accordance with the cable, wire and hose routing section in the appendix chapter. • after the installation, adjust the cable properly. Warning operation with impro...

  • Page 71

    Fuel system 3-11 carburetor since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carbure- tor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble can be caused by dirt, wear, maladjustment or imp...

  • Page 72

    3-12 fuel system carburetor • check the fuel level in the gauge. Service fuel level (below the bottom edge of the carburetor body) standard: 3.0 ± 1 mm (0.12 ± 0.04 in.) • screw the carburetor drain plug. • turn the fuel tap to the off position and remove the fuel level gauge. If the fuel level is i...

  • Page 73

    Fuel system 3-13 carburetor float bowl mating surface [a] float valve needle rod (contacted but unloaded) [b] float [c] float height [d] note ○ measure the height with the carburetor upside down. ○ do not push the needle rod in during the float height measurement. • install: float bowl carburetor (s...

  • Page 74

    3-14 fuel system carburetor carburetor installation • installation is the reverse of removal. • fit the slit [a] and the projection [b], and insert the throttle valve assembly [c] into the carburetor body. • replace the o-ring with a new one. • install the insulator [a] between intake pipe [b] and c...

  • Page 75

    Fuel system 3-15 carburetor • remove the following parts from the carburetor body. Idle adjusting screw [a] o-ring [b] spring [c] pilot screw [d] washer [e] spring [f] o-ring [g] o-ring [h] pilot jet [a] needle jet [b] needle jet holder [c] main jet [d] float valve needle [e] float [f] pin [g] o-rin...

  • Page 76

    3-16 fuel system carburetor • immerse all the metal parts in carburetor cleaning solu- tion. • rinse the parts in water. • after the parts are cleaned, dry them with compressed air. • blow through the air and fuel passages with compressed air. • assemble the carburetor, and install it on the motorcy...

  • Page 77

    Fuel system 3-17 carburetor • remove the float valve needle. • check the float valve needle [a]. If the needle is worn [b] as shown in the figure, replace the valve needle. • push the rod [c] in the valve needle, and then release it [d]. If the rod does not spring out, replace the valve needle. • ch...

  • Page 78

    3-18 fuel system carburetor carburetor assembly • clean the disassembly parts before assembling. • clean the fuel and air passages with high flash-point sol- vent and compressed air. • install the needle jet [a] into the carburetor so that the smaller diameter end [b] of the jet goes in first. • car...

  • Page 79

    Fuel system 3-19 air cleaner air cleaner housing removal • remove the shroud (see shroud removal in the frame chapter). • loosen the clamp screw [a] and pull out the air cleaner duct [b] from the carburetor. • remove the air cleaner housing mounting bolts [a]. • remove the air cleaner housing [b]. A...

  • Page 80

    3-20 fuel system air cleaner air cleaner element installation • installation is the reverse of removal. • 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 where th...

  • Page 81

    Fuel system 3-21 fuel tank fuel tank removal 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 l...

  • Page 82

    3-22 fuel system fuel tank fuel tap removal • remove the fuel tank (see fuel tank removal). • drain the fuel. • remove the mounting bolts [a] and take off the fuel tap [b]. Fuel tap installation • replace the o-ring [a] with a new one. • insert the filter part into the tank, and tighten the bolts. T...

  • Page 83

    Fuel system 3-23 fuel tank • turn the fuel tap to the off position. • place a suitable container beneath the carburetor drain hose [a]. • loosen the drain plug [b] from the bottom of the float bowl and check for water or dirt in the fuel. If any water or dirt comes out, clean the carburetor, fuel fi...

  • Page 85: Engine Top End

    Engine top end 4-1 4 engine top end table of contents exploded view................................... 4-2 specifications .................................... 4-6 special tools ..................................... 4-8 camshaft chain tensioner ................ 4-10 camshaft chain tensioner removal ....

  • Page 86

    4-2 engine top end exploded view.

  • Page 87

    Engine top end 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 valve adjusting cap bolts 5.2 0.53 46 in·lb 2 cylinder head bolts 12 1.2 106 in·lb s, l 3 cylinder head nuts 22 2.2 16 s rocker shaft holder plate bolts (klx110ca/da early models) 5.2 0.53 46 in·lb 4 rocker shaft holder p...

  • Page 88

    4-4 engine top end exploded view.

  • Page 89

    Engine top end 4-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 camshaft chain tensioner cap bolt 5.2 0.53 46 in·lb 2 camshaft chain tensioner mounting bolts 5.2 0.53 46 in·lb l 3 muffler cover screws 3.0 0.31 27 in·lb 4 exhaust pipe holder nuts 16 1.6 12 5 muffler mounting bolt 9.8 1...

  • Page 90

    4-6 engine top end specifications item standard service limit rocker arm, rocker arm shaft rocker arm inside diameter 10.000 ∼ 10.015 mm (0.3937 ∼ 0.3943 in.) 10.05 mm (0.396 in.) rocker arm shaft diameter 9.980 ∼ 9.995 mm (0.3929 ∼ 0.3935 in.) 9.95 mm (0.392 in.) camshaft cam height: exhaust 29.054...

  • Page 91

    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.) 53.10 mm (2.0905 in.) piston diameter 52.969 ∼ 52.981 mm (2.0854 ∼ 2.0859 in.) 52.82 mm (2.080 in.) piston/cylinder clearance 0.010 ∼ 0.022 mm (0.00039 ∼ 0...

  • Page 92

    4-8 engine top end special tools compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 piston pin puller assembly: 57001-910 valve seat cutter, 45° - 27.5: 57001-1114 valve seat cutter, 32° - 25: 57001-1118 valve seat cutter, 60° - 30: 57001-1123 valve seat cutter hold...

  • Page 93

    Engine top end 4-9 special tools valve seat cutter, 67.5° - 22: 57001-1207 compression gauge adapter, m10 × 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 filler cap driver: 57001-1454.

  • Page 94

    4-10 engine top end camshaft chain tensioner camshaft chain tensioner removal notice 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, d...

  • Page 95

    Engine top end 4-11 camshaft chain tensioner camshaft chain tensioner installation • remove the tensioner cap bolt and o-ring. • while compressing the push rod [a], turn it clockwise [b] with a standard tip screwdriver until the rod protrusion comes to about 10 mm (0.4 in.) from the tensioner body. ...

  • Page 96

    4-12 engine top end camshaft camshaft removal • remove the rocker arms (see rocker arm removal). • pull out the camshaft [a]. Camshaft installation • clean the camshaft with high flash-point solvent. • apply clean engine oil to all cam parts. • install the camshaft in the cylinder head. • install th...

  • Page 97

    Engine top end 4-13 camshaft kacr installation • install: weight [a] • insert the shaft [b] as shown. Retaining plate camshaft sprocket bolts camshaft sprocket cover kacr inspection the kawasaki automatic compression release (kacr) momentarily opens the valve on the compression stroke at very low sp...

  • Page 98

    4-14 engine top end camshaft camshaft sprocket removal • remove: camshaft sprocket cover bolts [a] camshaft sprocket cover [b] • remove the timing inspection cap [a] and rotor nut cap [b]. Special tool - filler cap driver [c]: 57001-1454 • turn the alternator rotor nut counterclockwise and align the...

  • Page 99

    Engine top end 4-15 camshaft • use a suitable tool [a] or wire to keep the chain [b] from falling down into the cylinder block. Notice 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...

  • Page 100

    4-16 engine top end camshaft • apply grease to the new o-ring [a] and install the camshaft sprocket cover [b]. • tighten: torque - camshaft sprocket cover bolts [c]: 5.2 n·m (0.53 kgf·m, 46 in·lb) notice rotation of the crankshaft with improper camshaft timing could cause the valve to contact each o...

  • Page 101

    Engine top end 4-17 camshaft camshaft chain installation • install the camshaft chain to the crankshaft, and pull up it through camshaft chain hole of the cylinder. • keep the chain. • install the camshaft chain holder. • tighten: torque - camshaft chain plate screws [a]: 5.2 n·m (0.53 kgf·m, 46 in·...

  • Page 102

    4-18 engine top end rocker arm, rocker arm shaft rocker arm removal • remove: camshaft sprocket (see camshaft sprocket removal) valve adjusting cover bolts [a] valve adjusting covers [b] • remove: rocker shaft holder plate bolts [a] rocker shaft holder plate stopper [b] • while holding the rocker ar...

  • Page 103

    Engine top end 4-19 rocker arm, rocker arm shaft rocker arm & arm shaft wear inspection • visually inspect the area on the rocker arm where the cam rubs. If there is any damage or uneven wear, replace the rocker arm. • measure the inside diameter [a] of each rocker arm with a cylinder gauge. Rocker ...

  • Page 104

    4-20 engine top end cylinder head compression measurement • warm up the engine thoroughly. • stop the engine. • remove the spark plug (see spark plug cleaning and inspection in the periodic maintenance chapter). • attach compression gauge and adapter firmly into the spark plug hole. Special tools - ...

  • Page 105

    Engine top end 4-21 cylinder head cylinder head removal • remove: muffler (see muffler removal) oil pipe (see oil pipe removal in the engine lubrication system chapter) spark plug cap [a] intake pipe bolts [b] insulator • remove: camshaft sprocket (see camshaft sprocket removal) clamp [a] (klx110d m...

  • Page 106

    4-22 engine top end cylinder head cylinder head cleaning • scrape out any carbon, and wash the head with high flash -point solvent. Cylinder head warp inspection • lay a straightedge across the lower surface of the cylinder head at several positions. • use a thickness gauge [a] to measure the space ...

  • Page 107

    Engine top end 4-23 valves valve clearance inspection • refer to valve clearance inspection in the periodic main- tenance chapter. Valve clearance adjustment • refer to valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove: cylinder head (see cylinder head removal) c...

  • Page 108

    4-24 engine top end valves valve guide removal • remove: valve (see valve removal) valve stem oil seal • heat the area around the valve guide to 120 ∼ 150°c (248 ∼ 302°f). Notice do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head and heat the oil. • ...

  • Page 109

    Engine top end 4-25 valves valve seat inspection • remove the valve (see valve removal). • check the valve seat surface [a] between the valve [b] and valve seat [c]. ○ measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, repair...

  • Page 110

    4-26 engine top end valves valve seat repair • 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° - 27.5: 57001-1114 valve seat cutter, 32° - 25: 57001-1118...

  • Page 111

    Engine top end 4-27 valves operating procedures • clean the seat area carefully. • coat the seat with machinist’s dye. • fit a 45° cutter [a] to the holder [b] and slide it into the valve guide. • press down lightly on the handle [c] and turn it right or left. Grind the seating surface only until it...

  • Page 112

    4-28 engine top end valves if the outside diameter of the seating surface is too large, make the 32° grind described below. If the outside diameter [a] of the seating surface is within the specified range, measure the seat width as described below. • grind the seat at a 32° angle [b] until the seat ...

  • Page 113

    Engine top end 4-29 valves • lap the valve to the seat using a lapper, once the seat width and outside diameter are within the ranges specified above. ○ put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○ spin the valve against the seat until...

  • Page 114

    4-30 engine top end valves valve stem diameter inspection • 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 (0.1748 in.) inlet valve ...

  • Page 115

    Engine top end 4-31 valves • repeat the measurement in a direction at a right angle to the first. If the reading exceeds the service limit, replace the guide. Note ○ the reading is not actual valve/valve guide clearance because the measuring point is above the guide..

  • Page 116

    4-32 engine top end valves.

  • Page 117

    Engine top end 4-33 cylinder, piston cylinder removal • remove: cylinder head (see cylinder head removal) lower camshaft chain guide [a] • tap the cylinder [b] lightly with a plastic mallet to separate from the crankcase. • remove the cylinder base gasket. Cylinder installation note ○ if the cylinde...

  • Page 118

    4-34 engine top end cylinder, piston piston removal • remove the cylinder (see cylinder removal). • wrap a clean cloth around the base of the piston. • use the plier [a] and remove the snap ring [b]. • remove the piston by pushing the piston pin and pulling it out. Use the piston pin puller assembly...

  • Page 119

    Engine top end 4-35 cylinder, piston note ○ if a new piston is used, check piston to cylinder clear- ance (see piston/cylinder clearance inspection), and use new piston rings. • install the piston so that the “ex” mark [a] on the piston toward exhaust side. • fit a new piston snap ring into the side...

  • Page 120

    4-36 engine top end 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 the difference between the two values. Measure the piston diameter as just described, and ...

  • Page 121

    Engine top end 4-37 cylinder, piston piston ring end gap inspection • 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. • measure the gap [b] between the ends of the ring wit...

  • Page 122

    4-38 engine top end cylinder, piston piston ring/groove clearance standard: top 0.020 ∼ 0.060 mm (0.0008 ∼ 0.0024 in.) second 0.010 ∼ 0.050 mm (0.0004 ∼ 0.0020 in.) service limit: top 0.16 mm (0.0063 in.) second 0.15 mm (0.0059 in.) piston ring thickness standard: top 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311...

  • Page 123

    Engine top end 4-39 cylinder, piston piston, piston pin, connecting rod inspection • measure the inside diameter of both piston pin holes in the piston. Piston pin hole inside diameter [a] standard: 13.001 ∼ 13.007 mm (0.5118 ∼ 05121 in.) service limit: 13.08 mm (0.515 in.) if either piston pin hole...

  • Page 124

    4-40 engine top end muffler muffler removal • remove: right side cover (see side cover removal in the frame chapter) screws [a] exhaust pipe covers [b] • remove the exhaust pipe holder nuts [a]. • remove the muffler mounting nut [a] and bolt [b]. • remove the muffler assembly [a] rearward..

  • Page 125

    Engine top end 4-41 muffler muffler installation • installation is the reverse of removal; note the following. • replace the gasket with a new one. • tighten: torque - exhaust pipe holder nuts: 16 n·m (1.6 kgf·m, 12 ft·lb) • replace the muffler mounting nut [b] with a new one. ○ tighten the muffler ...

  • Page 127: Clutch

    Clutch 5-1 5 clutch table of contents exploded view........................................................................................................................ 5-2 specifications ................................................................................................................

  • Page 128

    5-2 clutch exploded view klx110c models.

  • Page 129

    Clutch 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch cover bolts 8.8 0.9 78 in·lb 2 oil seal retaining plate screws 2.9 0.3 26 in·lb l 3 primary clutch hub nut 72 7.3 53 4 clutch spring bolts 5.0 0.51 44 in·lb 5 secondary clutch hub nut 72 7.3 53 6 clutch adjusting screw loc...

  • Page 130

    5-4 clutch exploded view klx110d models.

  • Page 131

    Clutch 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch cover bolts 8.8 0.9 78 in·lb 2 clutch hub nut 72 7.3 53 3 primary gear nut 72 7.3 53 cl: apply cable lubricant. Eo: apply engine oil. G: apply grease. R: replacement parts.

  • Page 132

    5-6 clutch specifications item standard service limit clutch (klx110c) primary clutch: primary clutch housing inside diameter 104.0 ∼ 104.2 mm (4.094 ∼ 4.102 in.) 104.5 mm (4.114 in.) primary clutch shoe groove depth 1.0 mm (0.04 in.) 0.5 mm (0.02 in.) secondary clutch: friction plate thickness 3.1 ...

  • Page 133

    Clutch 5-7 special tools bearing driver set: 57001-1129 clutch holder 1: 57001-1507 clutch holder 2: 57001-1508 gear holder: 57001-1602.

  • Page 134

    5-8 clutch clutch lever and cable (klx110d) due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the periodic maintenance chart. Warning the engine and exhaust system get extremely hot during normal operation and can cause se...

  • Page 135

    Clutch 5-9 clutch cover (klx110c) clutch cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the kick pedal (see kick pedal removal in the crankshaft/transmission chapter). ○ when the clutch cove is to be disassembled, loosen the clutch adjust...

  • Page 136

    5-10 clutch clutch cover (klx110c) • remove the screws [a] and plate [b]. • take the oil seal [c] out of the cover with a hook. Clutch cover assembly • replace the o-ring and the oil seal with new ones. • apply high-temperature grease to the oil seal lips [a]. ○ press in the new oil seal so that the...

  • Page 137

    Clutch 5-11 clutch cover (klx110d) clutch cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the kick pedal (see kick pedal removal in the crankshaft/transmission chapter). • remove the clutch cover bolts [a]. • free the clutch cable lower en...

  • Page 138

    5-12 clutch clutch cover (klx110d) release shaft installation • installation is the reverse of removal. • apply grease to the new oil seal lips. • press in the oil seal [a] until it bottoms out..

  • Page 139

    Clutch 5-13 clutch clutch removal (klx110c) • remove the clutch cover (see clutch cover removal). • pull out the clutch release lever [a]. • remove: release ball assembly [b] release cam [c] ball bearing [d] ball bearing holder [e] • loosen the primary clutch hub nut while holding the pri- mary clut...

  • Page 140

    5-14 clutch clutch • remove: collar [a] spacer [b] secondary clutch disassembly (klx110c) • remove the secondary clutch (see clutch removal). • unscrew the clutch spring bolts [a] and take off the spring plate [b] and springs [c]. • remove the clutch hub [a] and clutch wheel [b]. • remove the second...

  • Page 141

    Clutch 5-15 clutch • install the clutch wheel on the clutch hub. • 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]. • install the last friction plate [a] fitting the tangs in the grooves on the ho...

  • Page 142

    5-16 clutch clutch if the one-way clutch and race dropped from the primary clutch housing, install it as follows. ○ put the one-way clutch [a] in the clutch housing halfway with the rotation mark [b] facing out. ○ fit the race [c] into the one-way clutch with the machin- ing unevenness side facing o...

  • Page 143

    Clutch 5-17 clutch • loosen the clutch hub nut while holding the clutch steady with the gear holder. Special tool - gear holder: 57001-1602 note ○ if the clutch hub nut is difficult to loosen using a gear holder (57001-1602), use the clutch holder 2 (57001 -1508). • loosen the clutch hub nut [a], wh...

  • Page 144

    5-18 clutch clutch clutch hub disassembly (klx110d) • separate the clutch hub assembly from the clutch hous- ing. • remove: clutch spring bolts [a] clutch spring plate [b] clutch springs [c] clutch holder [d] friction plates [e] steel plates [f] friction plates [g] clutch hub assembly (klx110d) • cl...

  • Page 145

    Clutch 5-19 clutch • tighten the clutch hub nut while holding the clutch steady with the gear holder. Special tool - gear holder: 57001-1602 note ○ if the clutch hub nut is difficult to tighten using a gear holder (57001-1602), use the clutch holder 2 (57001 -1508). • tighten the clutch hub nut, whi...

  • Page 146

    5-20 clutch clutch • measure the groove depth [a]. ○ use a depth gauge, and measure at several points as shown. If 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 clu...

  • Page 147

    Clutch 5-21 clutch clutch housing finger damage inspection • visually inspect the clutch housing fingers [a] where the friction plate tangs [b] hit them. If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are ...

  • Page 149: Engine Lubrication System

    Engine lubrication system 6-1 6 engine lubrication system table of contents exploded view........................................................................................................................ 6-2 engine oil flow chart....................................................................

  • Page 150

    6-2 engine lubrication system exploded view.

  • Page 151

    Engine lubrication system 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil pipe banjo bolts 15 1.5 11 2 oil pipe clamp screw 5.2 0.53 46 in·lb 3 oil pump mounting screws (l = 25) 5.2 0.53 46 in·lb 4 oil pump mounting screw (l = 30) 5.2 0.53 46 in·lb 5 oil filter cap bolts 5.2 0.53...

  • Page 152

    6-4 engine lubrication system engine oil flow chart 1. Crankshaft 2. Oil screen 3. Oil filter 4. Camshaft 5. Oil pump 6. Oil pipe.

  • Page 153

    Engine lubrication system 6-5 specifications item standard engine oil type api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity 0.9 l (1.0 us qt) (when filter is not removed) 1.0 l (1.1 us qt) (when filter is removed) 1.1 l (1.2 us qt) (when engine is completely dry) level...

  • Page 154

    6-6 engine lubrication system special tools oil pressure gauge, 5 kgf/cm²: 57001-125 oil pressure gauge adapter, m10 × 1.25: 57001-1182 oil pressure cap: 57001-1651.

  • Page 155

    Engine lubrication system 6-7 engine oil and oil filter warning vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter accordin...

  • Page 156

    6-8 engine lubrication system engine oil and oil filter oil screen cleaning • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: clutch cover (see clutch cover removal in the clutch chapter) oil screen [a] • clean the oil screen [a] with high flash-point so...

  • Page 157

    Engine lubrication system 6-9 oil pump oil pump removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the clutch cover (see clutch cover removal in the clutch chapter). Klx110c models • remove the clutch (see clutch removal (klx110c) in the clutch cha...

  • Page 158

    6-10 engine lubrication system oil pipe oil pipe removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: banjo bolts [a] oil pipe clamp screw [b] oil pipe [c] oil pipe installation • before installation, flush out the pipe with a high flash -point solv...

  • Page 159

    Engine lubrication system 6-11 oil pressure oil pressure measurement • remove the engine guard (see engine guard re- moval/installation in the frame chapter). • remove the bolts [a] and oil filter cap [b]. • move the spring and the o-ring of the oil filter cap to the oil pressure cap. Special tool -...

  • Page 161: Engine Removal/installation

    Engine removal/installation 7-1 7 engine removal/installation table of contents exploded view........................................................................................................................ 7-2 special tool ........................................................................

  • Page 162

    7-2 engine removal/installation exploded view.

  • Page 163

    Engine removal/installation 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper engine mounting nut 54 5.5 40 r 2 middle engine mounting nut 54 5.5 40 r 3 lower engine mounting nut 54 5.5 40 r 4. Upper engine mounting bolt (l = 105) 5. Middle engine mounting bolt (l = 125) 6. Lower...

  • Page 164

    7-4 engine removal/installation special tool jack: 57001-1238.

  • Page 165

    Engine removal/installation 7-5 engine removal/installation engine removal • squeeze the brake lever slowly and hold it with a band [a]. Warning motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine. Notice be sure to hold ...

  • Page 166

    7-6 engine removal/installation engine removal/installation • remove the breather tube [a]. • free the leads from the clamp [b]. • disconnect: gear position switch lead connector [c] alternator lead connector [d] • remove the engine sprocket (see engine sprocket re- moval in the final drive chapter)...

  • Page 167: Crankshaft/transmission

    Crankshaft/transmission 8-1 8 crankshaft/transmission table of contents exploded view........................................................................................................................ 8-2 specifications ..............................................................................

  • Page 168

    8-2 crankshaft/transmission exploded view.

  • Page 169

    Crankshaft/transmission 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 shift return spring pin (bolt) 22 2.2 16 l 2 shift drum bearing retaining screws 2.5 0.25 22 in·lb l 3 drive shaft bearing retaining screw 5.2 0.53 46 in·lb l 4 crankcase bolts (l = 50) 9.8 1.0 87 in·lb s 5 crank...

  • Page 170

    8-4 crankshaft/transmission exploded view.

  • Page 171

    Crankshaft/transmission 8-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 kick pedal bolt 8.8 0.90 78 in·lb 2 shift drum position lever pivot bolt 5.2 0.53 46 in·lb l 3 shift drum position plate screw 5.2 0.53 46 in·lb 4 shift drum cam bolt 5.2 0.53 46 in·lb l 5 shift pedal bolt 5.2 0....

  • Page 172

    8-6 crankshaft/transmission specifications item standard service limit crankshaft, connecting rods connecting rod: big end radial clearance 0.005 ∼ 0.025 mm (0.0002 ∼ 0.0010 in.) 0.07 mm (0.0028 in.) big end side clearance 0.1 ∼ 0.2 mm (0.004 ∼ 0.008 in.) 0.4 mm (0.016 in.) crankshaft runout tir 0.0...

  • Page 173

    Crankshaft/transmission 8-7 special tools & sealant outside circlip pliers: 57001-144 bearing puller: 57001-158 crankcase splitting tool assembly: 57001-1098 bearing driver set: 57001-1129 crankshaft jig: 57001-1174 liquid gasket, tb1215: 92104-1065.

  • Page 174

    8-8 crankshaft/transmission crankcase crankcase splitting • remove the engine (see engine removal in the engine removal/installation chapter). • set the engine on a clean surface and hold the engine steady while parts are being removed. • remove: cylinder head (see cylinder head removal in the en- g...

  • Page 175

    Crankshaft/transmission 8-9 crankcase crankcase assembly notice right and left crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. • chip off the old gasket from the mating surfaces of the crankcase halves. • using compressed air, b...

  • Page 176

    8-10 crankshaft/transmission crankcase • fit the crankshaft into the right crankcase half using a press [a]. • install: transmission shaft assemblies [a] shift forks [b] • check that the shift drum is in neutral position. • make sure that the mating surfaces of the crankcase halves are completely fr...

  • Page 177

    Crankshaft/transmission 8-11 crankcase • install the crankcase bolts in the left and right crankcase half and tighten them, starting with the nearest ones to the crankshaft, then farther ones. Longer bolts [a] shorter bolts [b] l: apply a non-permanent locking agent. Torque - crankcase bolts: 9.8 n·...

  • Page 178

    8-12 crankshaft/transmission crankshaft, connecting rod crankshaft disassembly notice 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...

  • Page 179

    Crankshaft/transmission 8-13 crankshaft, connecting rod • check the following items are within specifications after the crankshaft assembly. Connecting rod radial clearance (see connecting rod big end radial clearance inspection) connecting rod side clearance (see connecting rod big end side clearan...

  • Page 180

    8-14 crankshaft/transmission crankshaft, connecting rod crankshaft alignment if the runout at either point exceeds the service limit, align the flywheels so that the runout falls within the service limit. • in the case of horizontal misalignment, which is the most common, strike the projecting rim o...

  • Page 181

    Crankshaft/transmission 8-15 external shift mechanism shift pedal removal • remove the shift pedal bolt [a] and take off the shift pedal [b] from the shift shaft. Shift pedal installation • install the shift pedal [a] to the shift shaft so that the up- per surface of pedal [b] is level with the uppe...

  • Page 182

    8-16 crankshaft/transmission external shift mechanism ○ check that the return spring pin [a] is not loose. If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it. Torque - return spring pin: 22 n·m (2.2 kgf·m, 16 ft·lb) ○ check that the return spring [b] and s...

  • Page 183

    Crankshaft/transmission 8-17 transmission shift drum removal • remove: clutch (see clutch removal (klx110c/d) in the clutch chapter) external shift mechanism (see external shift mecha- nism removal) shift drum allen bolt [a] cam holder [b] shift drum cam dowel pin • split the crankcase (see crankcas...

  • Page 184

    8-18 crankshaft/transmission transmission • apply 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 ○ fingers of the 1st/3rd shift fork are longer than the fin- gers of the 2nd/4th shift ...

  • Page 185

    Crankshaft/transmission 8-19 transmission ○ the output shaft gears can be identified by size; the largest diameter gear is 1st gear, and the smallest is 4th. 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 ge...

  • Page 186

    8-20 crankshaft/transmission transmission shift fork ear/gear shift fork groove wear inspection • measure the thickness [a] of the shift fork ears. If 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...

  • Page 187

    Crankshaft/transmission 8-21 ball bearing, needle bearing, and oil seal ball and needle bearing wear inspection notice do not remove the ball bearings for inspection. Re- moval may damage them. • check the ball bearings. ○ since the ball bearings are made to extremely close toler- ances, the wear mu...

  • Page 188

    8-22 crankshaft/transmission kickstarter kick pedal removal • remove: bolt [a] kick pedal [b] kick pedal installation • installation is the reverse of removal. ○ install the kick pedal as shown in the figure. [a] about 16° ○ tighten: torque - kick pedal bolt [b]: 8.8 n·m (0.90 kgf·m, 78 in·lb) kick ...

  • Page 189

    Crankshaft/transmission 8-23 kickstarter • apply molybdenum disulfide grease to the inside of the kick gear [a] and kick shaft [b]. • replace the removed circlips with new ones. ○ when assembling the ratchet gear onto the kick shaft, align the punch mark [a] on the ratchet gear with the punch mark [...

  • Page 191: Wheels/tires

    Wheels/tires 9-1 9 wheels/tires table of contents exploded view........................................................................................................................ 9-2 specifications ....................................................................................................

  • Page 192

    9-2 wheels/tires exploded view.

  • Page 193

    Wheels/tires 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spoke nipples 4.0 0.41 35 in·lb 2 front axle nut 44 4.5 32 r 3 torque link nuts 25 2.5 18 4 rear axle nut 64 6.5 47 g: apply grease. R: replacement parts wl: apply soap and water solution, or rubber lubricant..

  • Page 194

    9-4 wheels/tires specifications item standard service limit wheels (rims) rim size: front 14 × 1.40 – – – rear 12 × 1.60 – – – rim runout: axial tir 0.8 mm (0.031 in.) or less tir 2.0 mm (0.08 in.) radial tir 1.2 mm (0.047 in.) or less tir 2.0 mm (0.08 in.) front axle runout/100 mm (3.94 in.) tir 0....

  • Page 195

    Wheels/tires 9-5 special tools rim protector: 57001-1063 bearing driver set: 57001-1129 jack: 57001-1238 bearing remover shaft, 9: 57001-1265 bearing remover head, 10 × 12: 57001-1266.

  • Page 196

    9-6 wheels/tires wheels (rims) front wheel removal • stabilize the motorcycle with the jack. Special tool - jack: 57001-1238 • apply the rear brake so that the rear wheel does not turn. • remove: cotter pin [a] front axle nut [b] • raise the front wheel off the ground with the jack. • remove: front ...

  • Page 197

    Wheels/tires 9-7 wheels (rims) • replace the axle nut [b] with a new one. • insert the axle [a] from right side, and tighten the axle nut. Torque - front axle nut: 44 n·m (4.5 kgf·m, 32 ft·lb) • insert a new cotter pin [c] to the front axle, and bend it to both sides. • install the front brake cable...

  • Page 198

    9-8 wheels/tires wheels (rims) rear wheel installation • apply high-temperature grease to the oil seal [a]. • install the collar [b] on the left side of the hub. • install the rear brake panel. • engage the drive chain with the rear sprocket, and set the rear wheel to the motorcycle. • insert the ax...

  • Page 199

    Wheels/tires 9-9 wheels (rims) wheels inspection • raise the front/rear wheel off the ground with the jack. Special tool - jack: 57001-1238 • spin the wheel lightly, and check for roughness or binding. If the roughness or binding is found, replace the hub bear- ings. • visually inspect the front and...

  • Page 200

    9-10 wheels/tires wheels (rims) axle inspection • visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • place the front axle in v blocks that are 100 mm (3.94 in.) (rear axle: 110 mm (4.33 in.)) [a] apart, and set a dial gauge [b] on the axle at a point ...

  • Page 201

    Wheels/tires 9-11 tires tire removal • remove the wheel (see front/rear wheel removal). • to maintain wheel balance, mark [a] the valve stem posi- tion on the tire with chalk so that the tire can be reinstalled in the same position. • take out the valve core [b] to let out the air. • remove the valv...

  • Page 202

    9-12 wheels/tires tires ○ position the tire on the rim so that the air valve [a] is at the tire balance mark [b] (the chalk mark made during removal, or the paint mark on a new tire). • insert the valve stem into the rim, and screw the nut on loosely. • fit the rim protectors and use suitable tire i...

  • Page 203

    Wheels/tires 9-13 hub bearings hub bearing removal • remove the wheel (see front/rear wheel removal). • to remove the grease seals, pry out the grease seal using a screwdriver. • using the bearing remover shaft and bearing remover head, remove the hub bearings [a]. Special tools - bearing remover sh...

  • Page 204

    9-14 wheels/tires hub bearings bearing lubrication • remove the hub bearings on the front and rear wheel hubs. • wash the bearings with a high flash-point solvent, dry them (do not spin them while they are dry), and oil them. • spin each bearings by hand to check its condition. If it is noisy, does ...

  • Page 205: Final Drive

    Final drive 10-1 10 final drive table of contents exploded view........................................................................................................................ 10-2 specifications ...................................................................................................

  • Page 206

    10-2 final drive exploded view.

  • Page 207

    Final drive 10-3 exploded view torque no fastener n·m kgf·m ft·lb remarks 1 engine sprocket cover bolts 5.2 0.53 46 in·lb 2 chain guide roller mounting bolt 23 2.3 17 3 rear sprocket nuts 44 4.5 32 r 4 rear axle nut 64 6.5 47 5. Klx110d models g: apply grease. Ho: apply heavy oil. R: replacement par...

  • Page 208

    10-4 final drive specifications item standard service limit drive chain drive chain slack: klx110c models 11 ∼ 16 mm (0.4 ∼ 0.6 in.) – – – klx110d models 8 ∼ 13 mm (0.3 ∼ 0.5 in.) – – – drive chain 20-link length 254.0 ∼ 254.6 mm (10.00 ∼ 10.02 in.) 259 mm (10.2 in.) standard chain: make daido – – –...

  • Page 209

    Final drive 10-5 special tools outside circlip pliers: 57001-144 bearing driver set: 57001-1129.

  • Page 210

    10-6 final drive drive chain drive chain slack inspection • refer to the drive chain slack inspection in the periodic maintenance chapter. Drive chain slack adjustment • refer to the drive chain slack adjustment in the periodic maintenance chapter. Wheel alignment inspection • check that the notch [...

  • Page 211

    Final drive 10-7 drive chain • remove the clip [a] from the master link using pliers, and remove the chain from the rear sprocket. • take the chain off the motorcycle, being careful that the chain does not get dirty from contact with the ground. Drive chain installation warning for safety, use only ...

  • Page 212

    10-8 final drive drive chain ○ the upper bolt is longer than the other ones. • tighten: torque - engine sprocket cover bolts [a]: 5.2 n·m (0.53 kgf·m, 46 in·lb).

  • Page 213

    Final drive 10-9 sprockets engine sprocket removal • remove the engine sprocket cover (see drive chain re- moval). • remove the circlip [a] and the engine sprocket [b] with the drive chain [c]. Special tool - outside circlip pliers: 57001-144 • take off the sprocket from the chain. Engine sprocket i...

  • Page 214

    10-10 final drive sprockets rear sprocket warp inspection • refer to the rear sprocket warp inspection in periodic maintenance chapter. Coupling bearing removal • pull out the coupling collar from the left. • remove the oil seal. • using the bearing driver set [a] or some other suitable tool, remove...

  • Page 215: Brakes

    Brakes 11-1 11 brakes table of contents exploded view........................................................................................................................ 11-2 specifications .............................................................................................................

  • Page 216

    11-2 brakes exploded view.

  • Page 217

    Brakes 11-3 exploded view cl: apply cable lubricant. G: apply grease. R: replacement parts si: apply silicone grease..

  • Page 218

    11-4 brakes exploded view.

  • Page 219

    Brakes 11-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake pedal bolt 8.8 0.90 78 in·lb 2 torque link nuts 25 2.5 18 3 brake cam lever bolt 7.0 0.71 62 in·lb g: apply grease. R: replacement parts.

  • Page 220

    11-6 brakes specifications item standard service limit brake lever and pedal brake lever free play 4 ∼ 5 mm (0.16 ∼ 0.20 in.) – – – brake pedal free play 20 ∼ 30 mm (0.79 ∼ 1.18 in.) – – – brake drum, brake shoes shoe lining thickness: front 2.10 ∼ 3.00 mm (0.08 ∼ 0.12 in.) 1.2 mm (0.05 in.) rear 3....

  • Page 221

    Brakes 11-7 special tools inside circlip pliers: 57001-143 jack: 57001-1238.

  • Page 222

    11-8 brakes brake lever and cable brake lever free play inspection • refer to the brake lever free play inspection in the pe- riodic maintenance chapter. Brake lever free play adjustment • refer to the brake lever free play adjustment in the pe- riodic maintenance chapter. Brake cable removal • free...

  • Page 223

    Brakes 11-9 brake pedal and rod brake pedal free play inspection • refer to brake pedal free play inspection in the periodic maintenance chapter. Brake pedal free play adjustment • refer to brake pedal free play adjustment in the periodic maintenance chapter. Brake pedal and rod removal • remove the...

  • Page 224

    11-10 brakes brake panel and drum brake lining wear inspection • refer to brake lining wear inspection in the periodic maintenance chapter. Cam lever angle inspection • refer to cam lever angle inspection in the periodic main- tenance chapter. Cam lever angle adjustment • refer to cam lever angle ad...

  • Page 225

    Brakes 11-11 brake panel and drum • mark the position [a] of the cam lever before removal so that it can be installed later in the same position. • remove the brake cam lever bolt [b] and nut [c], and then pull out the brake cam lever [d] from the brake camshaft. • pull out the brake camshaft from t...

  • Page 226

    11-12 brakes brake panel and drum • face the triangle mark [a] on the cam surface towards the center of the panel and install the camshaft in the panel. Warning ineffective brakes can cause a serious accident resulting in serious injury death. Improper instal- lation will cause ineffective braking. ...

  • Page 227

    Brakes 11-13 brake panel and drum camshaft wear inspection • measure the shaft diameter [a]. If it is worn down to less than the service limit, replace the shaft. • measure the inside diameter [b] of the camshaft hole. If it is worn past the service limit, replace the brake panel. Camshaft diameter ...

  • Page 229: Suspension

    Suspension 12-1 12 suspension table of contents exploded view........................................................................................................................ 12-2 specifications .....................................................................................................

  • Page 230

    12-2 suspension exploded view.

  • Page 231

    Suspension 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork clamp bolts (upper) 20 2.0 15 2 front fork clamp bolts (lower) 30 3.1 22 3 steering stem head nut 44 4.5 32 4 fork bottom bolts 20 2.0 15 5. Ca model only r: replacement parts.

  • Page 232

    12-4 suspension exploded view.

  • Page 233

    Suspension 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber mounting bolt (upper) 39 4.0 29 2 rear shock absorber mounting nut (upper) 39 4.0 29 r 3 rear shock absorber mounting nut (lower) 39 4.0 29 r 4 swingarm pivot nut 78 8.0 58 r 5 torque link nuts 25 2.5 18 ...

  • Page 234

    12-6 suspension specifications item standard service limit front fork air pressure atmospheric pressure – – – rebound damping adjustment non-adjustable – – – compression damping adjustment non-adjustable – – – suspension oil kawasaki ss-8 or equivalent – – – amount (klx110c) 165 ±2.5 ml (5.58 ±0.085...

  • Page 235

    Suspension 12-7 special tools fork cylinder holder handle: 57001-183 fork cylinder holder adapter: 57001-1011 front fork oil seal driver: 57001-1219 jack: 57001-1238.

  • Page 236

    12-8 suspension front fork front fork oil change • refer to the front fork oil change in the periodic main- tenance chapter. Front fork removal • remove: number plate (see number plate removal in the frame chapter) front wheel (see front wheel removal in the wheels/tires chapter) • loosen the upper ...

  • Page 237

    Suspension 12-9 front fork front fork disassembly (each fork leg) • remove the cap. • loosen the front fork upper clamp bolt [a]. • remove the snap ring [b] while pressing the top plug [c], and then remove the top plug with o-ring. • remove the front fork (see front fork removal). • thoroughly clean...

  • Page 238

    12-10 suspension front fork • separate the inner tube [a] from the outer tube [b] by pulling them out. • take the cylinder base [a] out of the outer tube [b]. • remove the retaining ring [a] from the outer tube. • remove the oil seal [b], using a standard tip screwdriver if necessary. Front fork ass...

  • Page 239

    Suspension 12-11 front fork • insert the cylinder base [a] in the cylinder unit [b]. ○ the cylinder base must be installed with the tapered side [c] facing upward. • insert the inner tube and cylinder unit as a set into the outer tube. • apply a non-permanent locking agent to the bottom allen bolt a...

  • Page 240

    12-12 suspension front fork inner tube inspection • visually inspect the inner tube [a]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal and dust seal, replace the oil seal and dust seal whenever the inner tube is replaced. Notice if the inner tube...

  • Page 241

    Suspension 12-13 rear shock absorber rear shock absorber removal • remove: seat (see seat removal in the frame chapter) fuel tank (see fuel tank removal in the fuel system chapter) • raise the rear wheel off the ground with the jack. Special tool - jack: 57001-1238 notice when pulling out the mounti...

  • Page 242

    12-14 suspension rear shock absorber rear shock absorber inspection • remove the rear shock absorber (see rear shock ab- sorber removal). • visually inspect the following items. Oil leakage crack or dent if there is any damage to the rear shock absorber, replace it. • visually inspect the rubber bus...

  • Page 243

    Suspension 12-15 swingarm swingarm removal • raise the rear wheel off the ground with the jack. Special tool - jack: 57001-1238 • remove: drive chain (see drive chain removal in the final drive chapter) rear wheel (see rear wheel removal in the wheels/tires chapter) • remove: drive chain cover bolts...

  • Page 245: Steering

    Steering 13-1 13 steering table of contents exploded view........................................................................................................................ 13-2 special tools ..........................................................................................................

  • Page 246

    13-2 steering exploded view.

  • Page 247

    Steering 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar holder bolts 25 2.5 18 2 steering stem head nut 44 4.5 32 3 steering stem nut 4.9 0.50 43 in·lb t 4 front fork clamp bolts (upper) 20 2.0 15 5 front fork clamp bolts (lower) 30 3.1 22 ad: apply adhesive cement. G: ap...

  • Page 248

    13-4 steering special tools bearing puller adapter: 57001-136 steering stem bearing driver: 57001-137 steering stem bearing driver adapter, 32: 57001-292 head pipe outer race press shaft: 57001-1075 head pipe outer race driver, 51.5: 57001-1076 steering stem nut wrench: 57001-1100 head pipe outer ra...

  • Page 249

    Steering 13-5 steering steering inspection • refer to the steering inspection in the periodic mainte- nance chapter. Steering adjustment • refer to the steering adjustment in the periodic mainte- nance chapter..

  • Page 250

    13-6 steering steering stem steering stem, stem bearing removal • remove: front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) • remove: number plate (see number plate removal in the frame chapter) handlebar holder bolts [a] h...

  • Page 251

    Steering 13-7 steering stem • to remove the outer races [a] pressed into the head pipe [b], insert a bar [c] into the head pipe, and hammer evenly around the circumference of the opposite race to drive it out. Note ○ if either steering stem bearing is damaged, it is recom- mended that both the upper...

  • Page 252

    13-8 steering steering stem • apply grease liberally to the upper outer race in the head pipe so that the steel balls will stick in place during stem insertion, and install upper steel balls. • insert the steering stem [a] carefully through the head pipe so that the steel balls on the steering stem ...

  • Page 253

    Steering 13-9 steering stem • tighten: torque - steering stem head nut [a]: 44 n·m (4.5 kgf·m, 32 ft·lb) front fork clamp bolts (upper) [b]: 20 n·m (2.0 kgf·m, 15 ft·lb) front fork clamp bolts (lower) [c]: 30 n·m (3.1 kgf·m, 22 ft·lb) • install the other removed parts (see appropriate chap- ters). W...

  • Page 254

    13-10 steering handlebar handlebar removal • remove: number plate (see number plate removal in the frame chapter) screws [a] brake lever holder [b] brake lever assembly [c] • slide out the dust cover [a]. • loosen the screws [b] and remove the throttle cable hous- ing [c] together with the throttle ...

  • Page 255

    Steering 13-11 handlebar • remove: handlebar holder bolts [a] handlebar holders [b] handlebar [c] handlebar installation • apply adhesive to the inside of the left handlebar grip. • install the left handlebar grip so that the projection of grip aligns with the punch mark of the handlebar. • mount th...

  • Page 256

    13-12 steering handlebar • install the brake lever [a]. ○ position the brake lever so that the mating surface [b] aligns with the punch mark [c] of the handlebar. • install the number plate (see number plate installation in the frame chapter). • route the cables and leads correctly (see cable, wire,...

  • Page 257: Frame

    Frame 14-1 14 frame table of contents exploded view........................................................................................................................ 14-2 special tool .................................................................................................................

  • Page 258

    14-2 frame exploded view.

  • Page 259

    Frame 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 footpeg bracket bolts 25 2.5 18 2 sidestand bolt 9.8 1.0 87 in·lb 3 sidestand nut 29 3.0 21 r g: apply grease. R: replacement parts.

  • Page 260

    14-4 frame exploded view.

  • Page 261

    Frame 14-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear reflector bracket screws 7.4 0.75 65 in·lb 2 screw (for seat hook) 5.0 0.51 44 in·lb 3 screw (for rubber band hook) 5.0 0.51 44 in·lb 4. Ca model only.

  • Page 262

    14-6 frame special tool jack: 57001-1238.

  • Page 263

    Frame 14-7 frame frame inspection • refer to the frame inspection in the periodic mainte- nance chapter. Engine guard removal/installation • remove: bolts [a] footpeg bracket bolts [b] engine guard [c] • installation is the reverse of removal; note the following. • tighten: torque - footpeg bracket ...

  • Page 264

    14-8 frame shroud shroud removal • remove: side covers (see side cover removal) seat (see seat removal) bolts [a] (both sides) screw [b] fuel tank cap [c] shroud [d] shroud installation • installation is the reverse of removal..

  • Page 265

    Frame 14-9 seat seat removal • remove the seat mounting bolts [a] on both sides. • take off the seat [b] backward. Seat installation • installation is the reverse of removal. ○ insert the hooks [a] under the washer [b] and the bracket [c]..

  • Page 266

    14-10 frame side covers side cover removal • remove the bolts [a]. • pull the side cover [b] outward to clear the stopper. Side cover installation • installation is the reverse of removal. ○ install the collars to the side cover. ○ insert the tab [a] into the slot [b]. ○ insert the projection [c] in...

  • Page 267

    Frame 14-11 number plate number plate removal • remove the band [a] from the handlebar. • remove the bolt [b] and take off the number plate [c] upward. Number plate installation • install the collar [a] to the number plate. • fit the holes [a] at the bottom of number plate onto the bolt threads [b] ...

  • Page 268

    14-12 frame fenders front fender removal • remove the bolts [a] and take off the front fender [b]. Front fender installation • installation is the reverse of removal; note the following. ○ install the collars [a] to the front fender [b]. ○ install the longer bolts to the front [a] and the shorter bo...

  • Page 269

    Frame 14-13 fenders • remove the bolts [a]. • remove the bolts [a] and take off the rear fender [b]. • installation is the reverse of removal. ○ run the cables and leads correctly (see cable, wire, and hose routing section in the appendix chapter). Rear flap removal/installation • remove: right side...

  • Page 270

    14-14 frame footpegs and bracket footpeg removal/installation • remove: cotter pin [a] pivot pin [b] spring [c] footpeg [d] • installation is reverse of removal; note the following. • replace the cotter pin with a new one. • apply grease to the sliding area of the footpeg. • bend the longer side of ...

  • Page 271

    Frame 14-15 sidestand sidestand removal • raise the rear wheel off the ground with the jack. Special tool - jack: 57001-1238 • remove: spring [a] sidestand bolt [b] sidestand nut [c] sidestand [d] sidestand installation • apply grease to the sliding area [a] of the sidestand [b]. • replace the sides...

  • Page 273: Electrical System

    Electrical system 15-1 15 electrical system table of contents exploded view................................... 15-2 specifications .................................... 15-6 special tools and sealant ................. 15-7 wiring diagram.................................. 15-8 precautions................

  • Page 274

    15-2 electrical system exploded view.

  • Page 275

    Electrical system 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 regulator mounting screw 5.2 0.53 46 in·lb 2 ignition coil mounting bolt 2.9 0.30 26 in·lb 3 gear position switch screws 2.9 0.30 26 in·lb 4 spark plug 13 1.3 115 in·lb 5. Battery 6. Starter relay 7. Ic igniter 8. Mai...

  • Page 276

    15-4 electrical system exploded view.

  • Page 277

    Electrical system 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 starter motor terminal screw 2.0 0.20 18 in·lb 2 terminal cover plate screws 2.0 0.20 18 in·lb 3 brush holder plate screws 0.9 0.09 8.0 in·lb 4 end cover screws 4.4 0.45 39 in·lb 5 starter motor mounting screws 5.2 0....

  • Page 278

    15-6 electrical system specifications item standard service limit battery type sealed battery (wet) – – – model name fth4l-bs – – – capacity 12 v 3 ah – – – voltage 12.6 v or more – – – gross weight 1.4 kg (3.1 lb) – – – electrolyte volume 0.18 l (10.98 cu in.) – – – charging system crankshaft senso...

  • Page 279

    Electrical system 15-7 special tools and sealant rotor puller m18 × 1.5, m16 × 1.5: 57001-1099 rotor puller, m16/m18/m20/m22 × 1.5: 57001-1216 flywheel holder: 57001-1313 hand tester: 57001-1394 peak voltage adapter: 57001-1415 needle adapter set: 57001-1457 flywheel puller, m28 × 1.0: 57001-1471 li...

  • Page 280

    15-8 electrical system wiring diagram klx110ca model.

  • Page 281

    Electrical system 15-9 wiring diagram klx110da model.

  • Page 282

    15-10 electrical system wiring diagram klx110cb models ∼.

  • Page 283

    Electrical system 15-11 wiring diagram klx110db models ∼.

  • Page 284

    15-12 electrical system precautions there are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ the electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the...

  • Page 285

    Electrical system 15-13 electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clea...

  • Page 286

    15-14 electrical system battery battery removal • remove: seat (see seat removal in the frame chapter) left side cover (see side cover removal in the frame chapter) battery holder bolts [a] • slide the battery, and disconnect the negative (–) cable [b] and then positive (+) cable [c]. Notice be sure...

  • Page 287

    Electrical system 15-15 battery notice do not remove the aluminum sealing sheet [a] from the filler ports [b] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. Danger sulfuric acid in battery electrolyte can cause severe burns. To prevent bur...

  • Page 288

    15-16 electrical system battery • check the electrolyte flow. If no air bubbles [a] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [b] a few times. Note ○ be careful not to have the battery fall down. • keep the container in place. Don’t...

  • Page 289

    Electrical system 15-17 battery initial charge • newly activated sealed batteries require an initial charge. Standard charge: 0.9 a × 5 ∼ 10 hours if using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: battery mate...

  • Page 290

    15-18 electrical system battery danger batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri- ous injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before tu...

  • Page 291

    Electrical system 15-19 battery • determine the battery condition after refresh charge. ○ determine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below. Criteria judgement 12.6 v or higher good 12.0 ∼ lower th...

  • Page 292

    15-20 electrical system charging system alternator cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: left side cover (see side cover removal in the frame chapter) seat (see seat removal in the frame chapter) engine sprocket cover (see engin...

  • Page 293

    Electrical system 15-21 charging system alternator rotor removal • remove: alternator cover (see alternator cover removal) starter idle gear and washers • wipe oil off the outer circumference of the rotor. • hold the alternator rotor steady with the flywheel holder [a], and remove the alternator rot...

  • Page 294

    15-22 electrical system charging system • hold the rotor steady with the flywheel holder [a], tighten the rotor nut [b]. Torque - alternator rotor nut: 53.9 n·m (5.50 kgf·m, 39.8 ft·lb) special tool - flywheel holder: 57001-1313 • install the alternator cover (see alternator cover installa- tion). S...

  • Page 295

    Electrical system 15-23 charging system • check the alternator output voltage, do the following pro- cedures. ○ remove: left side cover (see side cover removal in the frame chapter) seat (see seat removal in the frame chapter) ○ clear the leads from the clamp [a]. ○ connect a tester to the connector...

  • Page 296

    15-24 electrical system charging system charging voltage inspection • remove: seat (see seat removal in the frame chapter) left side cover (see side cover removal in the frame chapter) • check the battery condition (see charging condition in- spection). • warm up the engine to obtain actual alternat...

  • Page 297

    Electrical system 15-25 charging system • with the kawasaki hand tester, measure the internal re- sistance in both directions between the terminals. Special tool - hand tester: 57001-1394 if the reading is not the specified value, replace the reg- ulator/rectifier. Internal resistance @20°c (68°f) u...

  • Page 298

    15-26 electrical system charging system charging system troubleshooting • recharge the battery if it is discharged..

  • Page 299

    Electrical system 15-27 charging system charging system circuit (klx110ca/da models) 1. Load 2. Main fuse 10 a 3. Battery 12 v 3 ah 4. Regulator/rectifier 5. Alternator charging system circuit (klx110cb/db models ∼ ) 1. Load 2. Main fuse 10 a 3. Battery 12 v 3 ah 4. Regulator/rectifier 5. Alternator.

  • Page 300

    15-28 electrical system starter motor clutch starter motor clutch/starter motor clutch gear removal • remove: alternator rotor (see alternator rotor removal) • remove the bolts [a] and take off the starter motor clutch [b] from the rotor. Special tool - flywheel holder [c]: 57001-1313 • pull the sta...

  • Page 301

    Electrical system 15-29 starter motor clutch starter motor clutch inspection • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: alternator cover (see alternator cover removal) starter motor idle gear [a] • turn the torque limiter [a] by hand. The starter ...

  • Page 302

    15-30 electrical system ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Crankshaft sensor removal • refer to the stator remov...

  • Page 303

    Electrical system 15-31 ignition system measuring coil resistance if the arcing tester is not available, the coil can be checked for a broken or badly shorted winding with an ohmmeter. However, an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. ...

  • Page 304

    15-32 electrical system ignition system ignition coil primary peak voltage check • disconnect the spark plug cap from the spark plug, but do not remove the spark plug. • connect the good spark plug [a] to the spark plug cap, then touch the engine with it. Note ○ measure the voltage with each lead co...

  • Page 305

    Electrical system 15-33 ignition system crankshaft sensor peak voltage check • to check the peak voltage, do the following procedures. ○ disconnect the alternator lead connector from the main harness (see alternator cover removal). Note ○ measure the voltage with each lead connected cor- rectly. The...

  • Page 306

    15-34 electrical system ignition system.

  • Page 307

    Electrical system 15-35 ignition system ignition system circuit (klx110ca/da models) 1. Engine stop switch 2. Engine starter button 3. Main fuse 10 a 4. Battery 12 v 3 ah 5. Crankshaft sensor 6. Ic igniter 7. Ignition coil 8. Spark plug.

  • Page 308

    15-36 electrical system ignition system ignition system circuit (klx110cb/db models ∼ ) 1. Engine stop switch 2. Engine starter button 3. Main fuse 10 a 4. Battery 12 v 3 ah 5. Crankshaft sensor 6. Ic igniter 7. Ignition coil 8. Spark plug.

  • Page 309

    Electrical system 15-37 electrical starter system starter motor removal notice do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • remove: exhaust pipe cover (see muffler removal in the engine top end chapter) • slide out the rubber cap [a]. • remove: star...

  • Page 310

    15-38 electrical system electrical starter system note ○ hold the carbon brush leads [a], using the suitable tool [b] as shown. • pull out the carbon brush spring [a]. • remove the brush holder screws [b] with lockwashers and flat washers. • remove the (–) carbon brush [c]. • remove the terminal cov...

  • Page 311

    Electrical system 15-39 electrical starter system starter motor assembly • smooth the commutator surface if necessary with fine emery paper (more than #600). • blow or wipe the parts of the starter motor to clean the dust or any carbon particles. • replace the oil seal with a new one. • apply engine...

  • Page 312

    15-40 electrical system electrical starter system • hold the (–) carbon brush in the brush holder so that a suitable tool [a] could hold the (–) carbon brush lead [b] as shown. • install the (+) carbon brush spring. • hold the (+) carbon brush lead with a suitable tool. • apply high-temperature grea...

  • Page 313

    Electrical system 15-41 electrical starter system • measure the outer diameter [a] of the commutator [b]. Replace the starter motor with a new one if the commu- tator diameter is less than the service limit. Commutator diameter standard: 22.0 mm (0.87 in.) service limit: 21.5 mm (0.85 in.) armature ...

  • Page 314

    15-42 electrical system electrical starter system • connect a digital meter [a] and 12 v battery [b] to the starter relay [c] as shown in the figure. If the relay does not work as specified, the relay is defec- tive. Replace the relay. Klx110ca/da models [d] klx110cb/db models ∼ [e] starter relay in...

  • Page 315

    Electrical system 15-43 electrical starter system electrical starter system circuit (klx110ca/da models) 1. Engine stop switch 2. Engine starter button 3. Starter motor 4. Starter relay 5. Main fuse 10 a 6. Battery 12 v 3 ah 7. Starter lockout switch (klx110d models) 8. Gear position switch.

  • Page 316

    15-44 electrical system electrical starter system electrical starter system circuit (klx110cb/db models ∼ ) 1. Engine stop switch 2. Engine starter button 3. Starter motor 4. Starter relay 5. Main fuse 10 a 6. Battery 12 v 3 ah 7. Starter lockout switch (klx110d models) 8. Gear position switch.

  • Page 317

    Electrical system 15-45 switches and sensors switch inspection • using a digital meter, check to see that only the con- nections shown in the table have continuity (about zero ohms). If the switch has an open or short, repair it or replace it with a new one. Gear position switch removal • disconnect...

  • Page 318

    15-46 electrical system fuses main fuse 10 a removal • remove: seat (see seat removal in the frame chapter) left side cover (see side cover removal in the frame chapter) • remove the main fuse [a]. Main fuse 10 a inspection • remove the fuse (see main fuse 10 a removal) and in- spect the fuse elemen...

  • Page 319: Appendix

    Appendix 16-1 16 appendix table of contents cable, wire, and hose routing .............................................................................................. 16-2 troubleshooting guide ...........................................................................................................

  • Page 320

    16-2 appendix cable, wire, and hose routing.

  • Page 321

    Appendix 16-3 cable, wire, and hose routing 1. Brake cable 2. Throttle cable 3. Battery positive (+) cable 4. Route the starter motor cable through the inside of engine mount. 5. Igniter.

  • Page 322

    16-4 appendix cable, wire, and hose routing.

  • Page 323

    Appendix 16-5 cable, wire, and hose routing 1. Left switch housing lead connector 2. Clamps 3. Alternator lead connector 4. Battery negative (–) cable 5. Damper 6. Fuse 7. Starter relay leads 8. Gear position switch lead connector 9. Starter motor cable 10. Frame ground lead terminal 11. Ignition co...

  • Page 324

    16-6 appendix cable, wire, and hose routing.

  • Page 325

    Appendix 16-7 cable, wire, and hose routing 1. Throttle cable 2. Clutch cable (klx110d models) 3. Route the clutch cable in front of the band of number plate. 4. Starter lockout switch lead (klx110d models) 5. Left switch housing lead 6. Clamps 7. Route the brake cable in front of the number plate. ...

  • Page 326

    16-8 appendix cable, wire, and hose routing.

  • Page 327

    Appendix 16-9 cable, wire, and hose routing 1. Clamps 2. Regulator/rectifier 3. Throttle cable 4. Clutch cable (klx110d models) 5. Engine ground lead terminal.

  • Page 328

    16-10 appendix troubleshooting guide this is not an exhaustive list, giving every 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. Engine doesn’t start, starting difficulty: starter motor not rotating:...

  • Page 329

    Appendix 16-11 troubleshooting guide compression low: spark plug loose cylinder head not sufficiently tightened down no valve clearance cylinder, piston worn piston ring bad (worn, weak, broken or sticking) piston ring/groove clearance excessive cylinder head gasket damaged cylinder head warped cyli...

  • Page 330

    16-12 appendix troubleshooting guide clutch operation faulty: clutch slipping: no clutch release play (klx110c) no clutch lever play (klx110d) clutch cable maladjusted (klx110d) clutch inner cable sticking (klx110d) friction plate worn or warped steel plate worn or warped clutch spring broken or wea...

  • Page 331

    Appendix 16-13 troubleshooting guide 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., not properly mounted or tightened abnormal exhaust color: wh...

  • Page 332

    Model application year model beginning frame no. 2010 klx110ca jkalxsc1 □ ada71826 jkalx110ccda71829 2010 klx110da jkalxsd1 □ ada71830 2011 klx110cb jkalxsc1 □ bda76725 jkalx110ccda77275 2011 klx110db jkalxsd1 □ bda76735 2012 klx110cc jkalxsc1 □ cda81071 jkalx110ccda81841 2012 klx110dc jkalxsd1 □ cd...