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Kawasaki KLX 110 - BROCHURE 2009 Service Manual
Summary of KLX 110 - BROCHURE 2009
Page 1
Klx110 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 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 divisi...
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
Emission control information to protect the environment in which we all live, kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the california air resources board. 1. Crankcase emission control system this system el...
Page 8
Tampering with noise control system prohibited federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle ...
Page 9: 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 11: General Information
General information 1-1 1 general information table of contents before servicing ..................................................................................................................... 1-2 model identification................................................................................
Page 12
1-2 general information before servicing before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descrip- tions have been included wherever necessary. Nevertheless,...
Page 13
General information 1-3 before servicing (11)press when using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (12)ball bearing and needle bearing do not remove a ball bearing or a needle ...
Page 14
1-4 general information before servicing (19)inspection when parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion crack hardening warp bent dent scratch wear co...
Page 15
General information 1-5 model identification klx110-a1 left side view klx110-a1 right side view.
Page 16
1-6 general information general specifications items klx110-a1 ∼ dimensions overall length 1 555 mm (61.2 in.) overall width 660 mm (26.0 in.) overall height 955 mm (37.6 in.) wheelbase 1 065 mm (41.9 in.) road clearance 190 mm (7.5 in.) seat height 650 mm (25.6 in.) dry mass klx110-a1 ∼ a8f 64 kg (...
Page 17
General information 1-7 general specifications items klx110-a1 ∼ drive train primary reduction system: type gear, centrifugal reduction ratio 3.048 (64/21) (klx110-a1) 3.409 (75/22) (klx110-a2 ∼) clutch type centrifugal & wet, multi disc transmission: type 3-speed, constant mesh, return shift gear r...
Page 18
1-8 general information torque and locking agent the following tables lists the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “remarks” column mean: l: apply a non-permanent locking agent to the threads. S: tighten the ...
Page 19
General information 1-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks crankshaft/transmission crankcase screws 5.2 0.53 46 in·lb l(1) s bearing retainer screw 5 mm 2.9 0.3 26 in·lb bearing retainer screw 6 mm 5.2 0.53 46 in·lb shift return spring pin 22 2.2 16 l shift drum allen b...
Page 20
1-10 general information torque and locking agent torque fastener n·m kgf·m ft·lb remarks electrical system gear position switch screw 2.9 0.3 26 in·lb spark plug 13 1.3 113 in·lb magneto flywheel nut 10 mm (klx110-a1) 42 4.3 31 magneto flywheel nut 12 mm (klx110-a2 ∼) 54 5.5 40 exciter coil mountin...
Page 21
General information 1-11 special tools and sealants oil pressure gauge, 5 kgf/cm²: 57001-125 steering stem bearing driver: 57001-137 inside circlip pliers: 57001-143 outside circlip pliers: 57001-144 bearing puller: 57001-158 fork cylinder holder handle: 57001-183 compression gauge, 20 kgf/cm²: 5700...
Page 22
1-12 general information special tools and sealants fork cylinder holder adapter: 57001-1011 fuel level gauge: 57001-1017 oil seal & bearing remover: 57001-1058 rim protector: 57001-1063 bead breaker assembly: 57001-1072 crankcase splitting tool assembly: 57001-1098 steering stem nut wrench: 57001-1...
Page 23
General information 1-13 special tools and sealants valve seat cutter holder bar: 57001-1128 bearing driver set: 57001-1129 valve spring compressor adapter, 20: 57001-1154 crankshaft jig: 57001-1174 oil pressure gauge adapter, m10 × 1.25: 57001-1182 bearing puller stud: 57001-1190 valve seat cutter,...
Page 24
1-14 general information special tools and sealants valve adjusting screw holder: 57001-1217 front fork oil seal driver: 57001-1219 jack: 57001-1238 spark plug wrench, hex 16: 57001-1262 bearing remover shaft, 9: 57001-1265 bearing remover head, 10 × 12: 57001-1266 fork oil level gauge: 57001-1290 f...
Page 25
General information 1-15 special tools and sealants valve guide arbor, 4.5: 57001-1331 valve guide reamer, 4.5: 57001-1333 hand tester: 57001-1394 peak voltage adapter: 57001-1415 flywheel puller, m28 × 1.0: 57001-1471 clutch holder 1: 57001-1507 clutch holder 2: 57001-1508 oil pressure cap: 57001-1...
Page 26
1-16 general information special tools and sealants kawasaki bond(liquid gasket - black): 92104-1003.
Page 27
General information 1-17 cable, wire and hose routing dummy page.
Page 28
1-18 general information cable, wire and hose routing.
Page 29
General information 1-19 cable, wire and hose routing 1. Throttle cable 2. Engine stop switch lead 3. Band 4. Handlebar 5. Frame 6. Carburetor 7. Clamp 8. Air vent hose 9. Regulator/rectifier 10. Igniter 11. Crankcase breather hose 12. Magneto leads 13. Gear position switch leads 14. Main harness 15...
Page 30
1-20 general information cable, wire and hose routing.
Page 31
General information 1-21 cable, wire and hose routing 1. Frame 2. Align the damper center with the frame hole. 3. Apply adhesive to diagonal line portion. 4. Clamp 5. Run the carburetor drain hose into a hole of the engine guard. 6. Ignition coil lead 7. Inlet fuel hose 8. Crankcase breather hose 9....
Page 32
1-22 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 33: Periodic Maintenance
Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart .............. 2-2 specifications .................................... 2-3 periodic maintenance procedures..... 2-5 fuel system.................................... 2-5 fuel hose and connections inspection......
Page 34
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. Frequency initial every operation 5 hours (1 month) 50 hours (6 months) 100 hours (12 months) see page engine oil-change • • • 2-11 (e)spar...
Page 35
Periodic maintenance 2-3 specifications item standard service limit fuel system throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 250 ∼ 1 350 r/min (rpm) – – – air cleaner element oil high quality foam air filter oil – – – engine top end valve clearance: exhaust 0.04 ∼ 0.08 mm (0...
Page 36
2-4 periodic maintenance specifications special tools - valve adjusting screw holder: 57001-1217 jack: 57001-1238 fork oil level gauge: 57001-1290 steering stem nut wrench: 57001-1100
Page 37
Periodic maintenance 2-5 periodic maintenance procedures fuel system fuel hose and connections inspection • check the fuel hose [a] for the following. Fuel leakage loose or improperly positioned line clamp [b] deteriorated or damaged line replace the fuel hose if any fraying, cracks or bulges are no...
Page 38
2-6 periodic maintenance periodic maintenance procedures throttle grip free play inspection 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 han...
Page 39
Periodic maintenance 2-7 periodic maintenance procedures idle speed inspection • start the engine and warm it up thoroughly. • turn the handlebar from side to side while idling the en- gine. If handlebar movement changes the idle speed, the throt- tle cable may be improperly adjusted or incorrectly ...
Page 40
2-8 periodic maintenance periodic maintenance procedures warning clean the element in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use ...
Page 41
Periodic maintenance 2-9 periodic maintenance procedures • turn the camshaft sprocket plate [a] counterclockwise and align the line [b] on the camshaft sprocket with the projection [c] on the mating surface of the cylinder head. • measure the clearance of each valve by inserting a thick- ness gauge ...
Page 42
2-10 periodic maintenance periodic maintenance procedures • scrape carbon deposits off the spark arrester [a]. • install the spark arrester and torque the spark arrester mounting bolts. Torque - spark arrester mounting bolts: 8.8 n·m (0.9 kgf·m, 78 in·lb) • install the muffler cover. Clutch clutch a...
Page 43
Periodic maintenance 2-11 periodic maintenance procedures oil level inspection • to check the oil level, start the engine and run it for sev- eral minutes at idle speed. This fills the oil filter with oil. Then stop the engine and wait several minutes until the oil settles. • if the motorcycle has j...
Page 44
2-12 periodic maintenance periodic maintenance procedures note ○ do not add any chemical additive to the oil. Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch. ○ although 10w-40 engine oil is the recommended oil for most ...
Page 45
Periodic maintenance 2-13 periodic maintenance procedures wheel bearing inspection • raise the front wheel off the ground. • turn the end of handlebar to left or right fully, feel the excessive play for front wheel bearing by pushing and pulling [a] the tire. • spin the wheel lightly and check for r...
Page 46
2-14 periodic maintenance periodic maintenance procedures final drive chain slack inspection • support the mortorcycle perpendicular to the ground. Note ○ clean the drive chain if it is dirty, and lubricate it if it appears dry. • rotate the rear wheel to find the position where the chain is tightes...
Page 47
Periodic maintenance 2-15 periodic maintenance procedures • insert a new cotter pin [a]. Note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axel, tighten the nut clockwise [b] up to next alignment. ○ it should be within 30 degree. ○ loosen once...
Page 48
2-16 periodic maintenance periodic maintenance procedures • stretch the chain taut by hanging a 98 n (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 pin center of the 1st pin to pin center of the 21st pin. Since the chain may we...
Page 49
Periodic maintenance 2-17 periodic maintenance procedures chain slipper wear inspection • visually inspect the chain slipper [a] on the swingarm and replace it if worn or damaged. Brakes brake lever, brake pedal free play inspection • check the front brake lever free play [a] when the brake is light...
Page 50
2-18 periodic maintenance periodic maintenance procedures front brake lever free play adjustment • loosen the locknut at the front brake lever, screw the ad- juster fully in, and tighten the locknut. • loose the nuts [a] at the lower end of the brake cable. • turn the nuts at the lower end of the fr...
Page 51
Periodic maintenance 2-19 periodic maintenance procedures • check that the brake cam lever [a] comes to an 80° ∼ 90° angle [b] with the brake rod or cable [c] when the brake is fully applied. If it does not, adjust the brake cam lever angle. Cam lever angle standard: 80° ∼ 90° warning since a cam le...
Page 52
2-20 periodic maintenance periodic maintenance procedures cam lever angle adjustment caution do not depress the brake pedal deeply in order to separate the brake rod from the brake cam lever joint, this may extend the brake spring beyond its allowable spring extension. Rotate the rear brake panel cl...
Page 53
Periodic maintenance 2-21 periodic maintenance procedures suspension fork oil level adjustment (simplify) • using the jack under the frame, and stabilize the motor- cycle. Special tool - jack: 57001-1238 • remove the number plate. • remove the cap from the top of the fork tubes, and push down the to...
Page 54
2-22 periodic maintenance periodic maintenance procedures • check both top plug o-ring [a] for damage and replace them if necessary. • push down the top plug and install the circlip. • assemble the other fork tube in the same way as de- scribed above. • install the parts removed. Front fork inner tu...
Page 55
Periodic maintenance 2-23 periodic maintenance procedures • check the rubber bushings [a]. If they are worn, cracked, hardened, or otherwise dam- aged, replace them. Swingarm pivot inspection • check for wear or damage to the shock absorber and the swing arm mount pivot point while compressing [a] t...
Page 56
2-24 periodic maintenance periodic maintenance procedures steering steering inspection • using the jack, raise the front wheel off the ground. Special tool - jack: 57001-1238 • with the front wheel pointing straight ahead, alternately nudge each end of the handlebar. The front wheel should swing ful...
Page 57
Periodic maintenance 2-25 periodic maintenance procedures • mount the handlebar holders [b] so that the arrows [c] on the holder point at the front [a]. ○ align the punch mark [d] on the handlebar to the mating surface of each clamps of the handlebar. • tighten the clamp bolts, front first and then ...
Page 58
2-26 periodic maintenance periodic maintenance procedures general lubrication lubrication • before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • lubricate the points listed below with indicated lubricant. Note ○ whenever the vehicl...
Page 59
Periodic maintenance 2-27 periodic maintenance procedures nut, bolt and fastener tightness tightness inspection • check the tightness of bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Note ○ for the engine fasteners, check the tightness of them...
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 1. Throttle cable 2. Throttle grip 3. Carburetor cap 4. Spring 5. Retainer 6. Circlip 7. Jet needle 8. Throttle valve 9. Choke cable 10. Idle adjusting screw 11. Spring 12. Air screw 13. Pilot jet 14. Float valve needle 15. Main jet 16. Float g: apply grease. O: apply o...
Page 64
3-4 fuel system exploded view.
Page 65
Fuel system 3-5 exploded view 1. Fuel tank cap 2. Fuel tank 3. Fuel tap 4. Air cleaner housing 5. Element 6. Fuel tank cover (klx110a8f ∼, united states and canada models) ad: apply adhesive. G: apply grease. O: high-quality foam-air filter oil. T1: 4.9 n·m (0.5 kgf·m, 43 in·lb): klx110-a3 ∼ a: klx1...
Page 66
3-6 fuel system specifications item standard service limit throttle grip and cable throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – carburetor make/type keihin pb18 – – – main jet #80 – – – main air jet #180 – – – jet needle ncfa – – – throttle valve cutaway #3.0 – – – pilot jet #38/38 – – –...
Page 67
Fuel system 3-7 throttle grip and cable free play inspection • refer to the throttle grip free play inspection in the pe- riodic maintenance chapter. Free play adjustment • refer to the throttle grip free play adjustment in the periodic maintenance chapter. Throttle cable and choke cable installatio...
Page 68
3-8 fuel system carburetor idle speed inspection • refer to the idle speed inspection in the periodic main- tenance chapter. Idle speed adjustment • refer to the idle speed adjustment in the periodic main- tenance chapter. Fuel level inspection warning gasoline is extremely flammable and can be expl...
Page 69
Fuel system 3-9 carburetor • read the fuel level in the gauge and compare it to the specification. Fuel level 3.0 ±1 mm (0.12 ±0.04 in.) below the bottom edge of carburetor body • screw in the carburetor drain plug. • turn the fuel tap to the off position and remove the fuel level gauge. If the fuel...
Page 70
3-10 fuel system carburetor float removal • remove the carburetor and disassembly the float bowl. • drive out the pivot pin [a] and remove the float [b] and float valve as a set. Fuel system cleanliness inspection warning gasoline is extremely flammable and can be ex- plosive under certain condition...
Page 71
Fuel system 3-11 carburetor • unscrew the cap [a] and pull out the throttle cable lower end with the throttle valve, spring and jet needle as a set. Warning if dirt or dust allowed to pass through into the car- buretor, the throttle may become stuck, possibly causing an accident. Caution if dirt get...
Page 72
3-12 fuel system carburetor caution do not use compressed air on an assembled carbu- retor, or the float may be deformed by the pressure. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbu- retor with a cleaning solution. This will prevent damage to or d...
Page 73
Fuel system 3-13 carburetor • remove the following parts from the carburetor body. Idle adjusting screw [a] o-ring [b] spring [c] air 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-ring ...
Page 74
3-14 fuel system carburetor carburetor inspection 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 pi...
Page 75
Fuel system 3-15 carburetor • check the main jet [a], needle jet holder [b] and pilot jet [c] for any damage. If they are damaged, replace them with new ones. • remove the throttle valve [a] and jet needle. • inspect the outside of the throttle valve for scratches and abnormal wear. If the valve is ...
Page 76
3-16 fuel system air cleaner air cleaner housing removal • remove the left shroud. • loosen the air cleaner duct clamp [a]. • unscrew the air cleaner mounting bolts [a] and remove the air cleaner housing [b]. Air cleaner housing installation • installation is the reverse of the removal. • install th...
Page 77
Fuel system 3-17 air cleaner • stuff a clean, lint-free towel into the carburetor so that no dirt is allowed to enter the carburetor. • wipe out the inside of the air cleaner housing [a] and the wire screen [b] with a clean damp towel. Caution check inside of the inlet tract and carburetor for dirt....
Page 78
3-18 fuel system 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 79
Fuel system 3-19 fuel tank fuel tap inspection • refer to the fuel tap inspection in the periodic mainte- nance chapter. Fuel tank and tap cleaning warning clean the tank in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area. Because of the danger o...
Page 81: Engine Top End
Engine top end 4-1 4 engine top end table of contents exploded view................................... 4-2 specifications .................................... 4-6 camshaft chain tensioner ................ 4-8 camshaft chain tensioner removal .................................... 4-8 camshaft chain te...
Page 82
4-2 engine top end exploded view.
Page 83
Engine top end 4-3 exploded view 1. Intake pipe 2. Valve adjusting cover 3. Valve guide 4. Rocker arm shaft stopper 5. Camshaft sprocket cover 6. Cylinder head 7. Rocker arm 8. Rocker arm shaft 9. Valve adjusting screw 10. Valve adjusting screw locknut 11. Split keepers 12. Valve spring 13. Valve sp...
Page 84
4-4 engine top end exploded view.
Page 85
Engine top end 4-5 exploded view 1. Camshaft chain tensioner 2. Piston 3. Piston pin 4. Cylinder 5. Muffler 6. Damper (klx110-a1) 7. Exhaust pipe holder nuts t1: 5.2 n·m (0.53 kgf·m, 46 in·lb) t2: 8.8 n·m (0.9 kgf·m, 78 in·lb) eo: apply engine oil. L: apply non-permanent locking agent. R: replacemen...
Page 86
4-6 engine top end specifications item standard service limit camshaft camshaft: cam height: exhaust 29.021 mm ∼ 29.201 mm (1.1426 ∼ 1.1496 in.) 28.92 mm (1.139 in.) inlet 28.984 mm ∼ 29.164 mm (1.1411 ∼ 1.1482 in.) 28.88 mm (1.137 in.) rocker arms, shaft: rocker arm inside diameter 10.000 ∼ 10.015 ...
Page 87
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 (2.091 in.) piston outside diameter 52.981 ∼ 52.993 mm (2.0859 ∼ 2.0863 in.) 52.83 mm (2.080 in.) piston/cylinder clearance 0.010 ∼ 0.022 mm (0.00...
Page 88
4-8 engine top end camshaft chain tensioner camshaft chain tensioner removal caution 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 89
Engine top end 4-9 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 suitable screwdriver until the rod protrusion comes to about 10 mm from the tensioner body. Caution do not ...
Page 90
4-10 engine top end camshaft chain tensioner replacement chain tensioner installation ○ a replacement chain tensioner (spare parts) has a push rod holder plate. • apply a non-permanent locking agent to the threads of the tensioner mounting bolts. • install the tensioner on the cylinder block, and ti...
Page 91
Engine top end 4-11 camshaft sprocket camshaft sprocket removal • remove: left shroud engine sprocket cover (see final drive chapter) magneto cover (see electrical system chapter) • remove the camshaft sprocket cover bolts [a] and take off the cover [b]. • turn the crankshaft counterclockwise until ...
Page 92
4-12 engine top end camshaft sprocket camshaft sprocket installation • check crankshaft position to see that the "t" mark [a] on the magneto flywheel aligns with the index mark [b] on the crankcase. • remember to pull the camshaft chain taut before rotating the crankshaft. • pull the lower side of t...
Page 93
Engine top end 4-13 camshaft sprocket camshaft chain removal • drain the engine oil. • remove: left shroud camshaft chain tensioner camshaft sprocket cylinder head magneto cover (see electrical system chapter) magneto flywheel (see electrical system chapter) woodruff key (see electrical system chapt...
Page 94
4-14 engine top end rocker arm, rocker arm shaft rocker arm removal • remove left shroud camshaft sprocket cover camshaft chain tensioner camshaft sprocket bolts [a] camshaft sprocket [b] valve adjusting cover bolts [a] valve adjusting covers [b] rocker arm shaft stopper screws [c] rocker arm shaft ...
Page 95
Engine top end 4-15 rocker arm, rocker arm shaft rocker arm & arm shaft wear • visually inspect where the cam and valve stem wear on each arm. If there is any damage or uneven wear, replace the arm. ○ measure the inside diameter [a] of each rocker arm with a cylinder gauge. Rocker arm inside diamete...
Page 96
4-16 engine top end camshaft camshaft removal • remove: left shroud camshaft chain tensioner camshaft sprocket rocker arms • pull out the camshaft [a]. Camshaft installation • clean the camshaft with a high-flash-point solvent. • apply clean engine oil to all cam parts. • install the camshaft in the...
Page 97
Engine top end 4-17 cylinder head compression measurement • warm up the engine thoroughly • stop the engine. • remove the spark plug and attach compression gauge and adapter firmly into the spark plug hole. Special tools - compression gauge: 57001-221 [a] compression gauge adapter, m10 × 1.0: 57001-...
Page 98
4-18 engine top end cylinder head cylinder head removal • remove the right and left shrouds. • remove the exhaust pipe holder nuts [a], and muffler mounting bolt [b] and then the muffler with the exhaust pipe holder. • remove the oil pipe banjo bolts [a], screws [b], and take off the oil pipe [c]. •...
Page 99
Engine top end 4-19 cylinder head cylinder head installation • check to see that the two dowel pins [a] are in place on the cylinder. • install a new cylinder head gasket [b]. • fit the cylinder head onto the cylinder block using a screwdriver or wire to keep the chain from falling down into the cyl...
Page 100
4-20 engine top end valve/valve guide valve removal • remove: cylinder head rocker arm & rocker arm shaft camshaft • using the valve spring compressor assembly to press down the valve spring retainer, remove the split keeper. Special tools - valve spring compressor assembly: 57001 -241 [a] valve spr...
Page 101
Engine top end 4-21 valve/valve guide valve guide installation ○ valve guides are identical. • lightly oil the valve guide outer surface. • heat the cylinder head around the valve guide hole to about 120° ∼ 150°c (250° ∼ 302°f). • drive the valve guide in from the top of the cylinder head until the ...
Page 102
4-22 engine top end valve/valve guide 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:...
Page 103
Engine top end 4-23 valve/valve guide operating procedures • clean the seat area carefully. • coat the seat with machinist’s dye. • fit a 45° cutter to the holder and slide it into the valve guide. • press down lightly on the handle and turn it right or left. Grind the seating surface only until it ...
Page 104
4-24 engine top end valve/valve guide ○ to make the 32° grind, fit a 32° cutter to the holder, and slide it into the valve guide. ○ turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. Caution the 32° cutter removes material very quickly. Check the sea...
Page 105
Engine top end 4-25 valve/valve guide valve head thickness inspection • measure the thickness of valve head. Valve head thickness [a] standard: exhaust valve 1.15 ∼ 1.45 mm (0.0453 ∼ 0.0571 in.) inlet valve 0.85 ∼ 1.15 mm (0.0335 ∼ 0.0453 in.) service limit: exhaust valve 0.5 mm (0.02 in.) inlet val...
Page 106
4-26 engine top end valve/valve guide valve to guide clearance measurement if a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • insert a new valve [a] into the valve guide [b] and set a dial ...
Page 107
Engine top end 4-27 valve/valve guide.
Page 108
4-28 engine top end cylinder, piston cylinder removal • remove the cylinder head. • take out the cylinder block with lower camshaft chain guide, and remove the gasket. There are knock pins on the cylinder base. • wrap a clean cloth [a] around the base of the piston so that no parts or dirt will fall...
Page 109
Engine top end 4-29 cylinder, piston piston removal • remove the cylinder. • remove: pliers [a] snap ring [b] • remove the piston by pushing its pin pull out the side that the snap ring was removed. Use the piston pin puller assembly [a] if the pin is tight. Special tool - piston pin puller assembly...
Page 110
4-30 engine top end cylinder, piston note ○ if a new piston is used, check piston to cylinder clear- ance (see piston/cylinder clearance), and use new pis- ton rings. • install the piston so that the ex mark [a] on the piston faces to exhaust side. • fit a new piston snap ring into the side of the p...
Page 111
Engine top end 4-31 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 112
4-32 engine top end 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 113
Engine top end 4-33 cylinder, piston piston ring groove width standard: top 0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.) second 0.80 ∼ 0.82 mm (0.0315 ∼ 0.0323 in.) service limit: top 0.90 mm (0.035 in.) second 0.90 mm (0.035 in.) if the clearance exceeds the service limit, remove the pis- ton rings, and me...
Page 114
4-34 engine top end cylinder, piston measure the inside diameter [a] of the connecting rod small end. Connecting rod small end inside diameter standard: 13.003 ∼ 13.014 mm (0.5119 ∼ 0.5124 in.) service limit 13.05 mm (0.5138 in.) if the inside diameter exceeds the service limit, replace the connecti...
Page 115
Engine top end 4-35 muffler muffler removal • unscrew the muffler mounting bolt [a]. • remove the exhaust pipe holder nuts [a]. • pull out the muffler mounting bolt and remove the muffler assembly. Muffler installation • check the gasket and replace it if damaged. • after tightening the mounting bol...
Page 117: Clutch
Clutch 5-1 5 clutch table of contents exploded view (klx110-a1) .................................................................................................. 5-2 exploded view (klx110-a2 ∼ ) .............................................................................................. 5-4 speci...
Page 118
5-2 clutch exploded view (klx110-a1).
Page 119
Clutch 5-3 exploded view (klx110-a1) 1. Clutch cover 2. Primary clutch shoe linings 3. Outer race 4. One-way clutch 5. Primary clutch housing 6. Clutch spring plate 7. Clutch spring 8. Secondary clutch hub 9. Friction plate 10. Steel plate 11. Clutch wheel 12. Clutch housing 13. Clutch adjusting scr...
Page 120
5-4 clutch exploded view (klx110-a2 ∼ ).
Page 121
Clutch 5-5 exploded view (klx110-a2 ∼ ) 1. Clutch cover 2. Primary clutch shoe linings 3. Race 4. One-way clutch 5. Primary clutch housing 6. Clutch spring plate 7. Clutch spring 8. Secondary clutch hub 9. Friction plate 10. Steel plate 11. Clutch wheel 12. Clutch housing 13. Clutch adjusting screw ...
Page 122
5-6 clutch specifications item standard service limit primary clutch primary clutch housing inside 104.0 ∼ 104.2 mm 104.5 mm (4.114 in.) diameter (4.094 ∼ 4.102 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 ∼ 3.3 mm (0.12 ∼ 0....
Page 123
Clutch 5-7 clutch cover clutch cover and oil screen removal • drain the engine oil (see engine lubrication system). • remove: kick pedal [a] footpeg [b] engine guard [c] brake pedal (hanging) [d] • remove: clutch cover screws [a] (klx110-a1 ∼ a7f) clutch cover bolts [a] (klx110a8f ∼) clutch cover [b...
Page 124
5-8 clutch clutch cover clutch cover and oil screen installation • clean any metal particles and other dirt out of the oil screen. • using compressed air, blow out any particles which may obstruct the oil passage [a] in the clutch cover. • check that the ball bearing is in place. The shield side of ...
Page 125
Clutch 5-9 clutches clutch removal • remove the clutch cover (see this chapter). • remove: release ball assembly [a] release cam [b] ball bearing [c] ball bearing holder [d] • remove the primary clutch hub nut [a], while holding the primary clutch steady with the primary clutch holder [b]. Special t...
Page 126
5-10 clutch clutches • install: needle bearing [a] primary clutch housing [b] needle bearing [c] primary clutch sleeve [d] klx110-a2 ∼ if the primary clutch housing disassembled, assemble it as follows. ○ install the gear [b] to the primary clutch housing [a]. ○ install the spring [c] to the holder ...
Page 127
Clutch 5-11 clutches • install the plate with the line mark [a] facing out, noting the proper position. • install the primary clutch shoe linings. • tighten the primary clutch nut while holding the primary clutch steady with the primary clutch holder. Special tool - primary clutch holder: 57001-1507...
Page 128
5-12 clutch clutches secondary clutch assembly • install the friction plates [a] and steel plates [b] on the secondary clutch hub [c], starting with a friction plate and alternating them. ○ the grooves [d] on the friction plate surfaces are cut tan- gentially and radially. Install the friction plate...
Page 129
Clutch 5-13 clutches primary clutch shoe lining wear inspection • remove the primary clutch hub (see clutch removal). • visually inspect the primary clutch shoe linings [a] for un- even wear, discoloration, missing friction material, cracks or other damage. If any of the linings are damaged, replace...
Page 130
5-14 clutch clutches ○ check that the rollers [a] in the one-way clutch is installed as shown when viewed from the right side of the engine. Clutch plate wear and damage inspection • visually inspect the friction and steel plates for uneven wear, discoloration, missing friction material, cracks, or ...
Page 131
Clutch 5-15 clutches secondary clutch hub spline damage inspection • visually inspect where the teeth on the steel plates wear against the clutch hub splines. If there are notches worn into the clutch hub splines [a], replace the clutch hub. Also, replace the steel plates if their teeth are damaged....
Page 132
5-16 clutch kickstarter kickstarter removal • remove the clutch cover. • remove the return spring [a] with pliers. • remove: spring guide [b] • remove the kick shaft assembly [c], twisting it counter- clockwise. • there is a thrust washer between the kick shaft end and the crankcase. Kickstarter ins...
Page 133
Clutch 5-17 kickstarter kickstarter inspection • visually inspect the parts and portion listed below. Kick shaft return spring [a] ratchet gear spring [b] ratchet portion [c] of the kick gear [d] and ratchet gear [e] if there is any kind of damage, replace the damaged part. • measure the kick shaft ...
Page 134
5-18 clutch external shift mechanism external shift mechanism removal • remove: clutch cover (see clutch cover removal) primary clutch (see clutch removal) secondary clutch (see clutch removal) shift pedal clamp bolt [a] shift pedal [b] • move the shift mechanism arm out of its position on the end o...
Page 135
Clutch 5-19 external shift mechanism • install the shift pedal [a] to the shift shaft so that the pedal upper surface [b] is level with the footpeg upper surface [c]..
Page 137: Engine Lubrication System
Engine lubrication system 6-1 6 engine lubrication system table of contents exploded view........................................................................................................................ 6-2 specifications ..........................................................................
Page 138
6-2 engine lubrication system exploded view.
Page 139
Engine lubrication system 6-3 exploded view 1. Oil pump 2. Oil screen 3. Oil pipe 4. Copper washer 5. Crankcase breather tube 6. Oil filter 7. Drain plug t1: 5.2 n·m (0.53 kgf·m, 46 in·lb) t2: 15 n·m (1.5 kgf·m, 11 ft·lb) t3: 29 n·m (3.0 kgf·m, 21 ft·lb) g: apply grease. R: replacement parts.
Page 140
6-4 engine lubrication system specifications item standard service limit engine oil grade api se, sf or sg – – – api sh or sj with jaso ma, ma1 or ma2 (klx110-a1 ∼ a6f) api sh, sj or sl with jaso ma, ma1 or ma2 (klx110a7f ∼) viscosity sae 10w-40 – – – capacity: when engine is completely dry 1.1 l (1...
Page 141
Engine lubrication system 6-5 engine oil flow chart 1. Camshaft 2. Oil pipe 3. Cylinder head 4. Primary clutch housing 5. Clutch cover 6. Crankshaft 7. Oil filter 8. Bypass valve 9. Oil pump 10. Oil screen 11. Oil passage (cylinder head) 12. Oil passage (camshaft) 13. Oil passage (right engine cover...
Page 142
6-6 engine lubrication system engine oil oil level inspection • refer to the oil level inspection in the periodic mainte- nance chapter. Oil changing • refer to the oil changing in the periodic maintenance chapter..
Page 143
Engine lubrication system 6-7 oil filter element/oil screen oil filter element replacement • refer to the oil filter element replacement in the peri- odic maintenance chapter. Oil screen cleaning • drain the engine oil. • remove the clutch cover (see clutch chapter). • pull out the oil screen [a]. ○...
Page 144
6-8 engine lubrication system engine oil pump engine oil pump removal • remove the clutch cover (see clutch chapter). • remove the primary and secondary clutch assemblies (see clutch chapter). • turn the crankshaft so that the engine oil pump screws [a] can be removed through the pump gear holes, an...
Page 145
Engine lubrication system 6-9 oil pipe oil pipe removal • remove the banjo bolts [a] and oil pipe clamp screw [b]. Oil pipe installation • before installation, flush out the pipe with a high-flash -point solvent. • discard the used copper washers and install new washers on each side of the pipe fitt...
Page 146
6-10 engine lubrication system oil pressure measurement oil pressure measurement • remove the oil filter cap (see oil filter element replace- ment in the periodic maintenance chapter), and attach the oil pressure cap [a], adapter [b] and gauge [c]. Special tools - oil pressure gauge, 5 kgf/cm²: 5700...
Page 147: Engine Removal/installation
Engine removal/installation 7-1 7 engine removal/installation table of contents exploded view........................................................................................................................ 7-2 engine removal/installation .........................................................
Page 148
7-2 engine removal/installation exploded view.
Page 149
Engine removal/installation 7-3 exploded view 1. Footpeg mounting bolts g. Apply grease. T1: 54 n·m (5.5 kgf·m, 40 ft·lb) t2: 23 n·m (2.3 kgf·m, 17 ft·lb).
Page 150
7-4 engine removal/installation engine removal/installation engine removal • drain the engine oil (see engine lubrication chapter). • squeeze the brake lever slowly and hold it with a band [a]. Warning be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It coul...
Page 151
Engine removal/installation 7-5 engine removal/installation • remove the bolts [a] and the engine guard [b]. • remove the brake pedal return spring [a]. • support the rear part of the frame on the jack [a]. • support the engine with a suitable stand [a]. • remove the bolts [a] and take off the front...
Page 152
7-6 engine removal/installation engine removal/installation • remove the three engine mounting bolts [a] and dis- mount the engine. Engine installation • support the engine with a suitable stand and set it at the correct position. • install the lower [a], middle [b] and upper [c] engine mounting bol...
Page 153: Crankshaft / Transmission
Crankshaft / transmission 8-1 8 crankshaft / transmission table of contents exploded view........................................................................................................................ 8-2 specifications ..........................................................................
Page 154
8-2 crankshaft / transmission exploded view.
Page 155
Crankshaft / transmission 8-3 exploded view 1. Left crankcase half 2. Right crankcase half 3. Shift fork 4. Shift rod 5. Shift drum cam 6. Shift drum 7. Gear position switch 8. Drive shaft 9. Output shaft 10. Ball-bearing 11. Bushing (klx110-a2 ∼ ) 12. Woodruff key (klx110-a1) t1: 2.9 n·m (0.3 kgf·m...
Page 156
8-4 crankshaft / transmission specifications item standard service limit crankshaft, connecting rods connecting rod: big end radial clearance 0.009 ∼ 0.023 mm 0.07 mm (0.0028 in.) (klx110-a1) (0.0004 ∼ 0.0009 in.) big end radial clearance 0.006 ∼ 0.020 mm 0.07 mm (0.0028 in.) (klx110-a2 ∼ ) (0.0002 ...
Page 157
Crankshaft / transmission 8-5 crankcase splitting crankcase splitting • remove the engine (see 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 engine top end chapter) cylinder (see engine...
Page 158
8-6 crankshaft / transmission crankcase splitting warning clean the engine parts in a well-ventilated area, and take care that there are no sparks or flame any- where near the working area; this includes any ap- pliance with a pilot light. Do not use gasoline or a low-flash-point solvent to clean pa...
Page 159
Crankshaft / transmission 8-7 crankcase splitting • install: shift drum [a] transmission shaft assemblies [b] shift forks [c] • check that the shift drum is in neutral position. • make sure that the mating surfaces of the crankcase halves are completely free of oil or contamination. • apply liquid g...
Page 160
8-8 crankshaft / transmission crankshaft, connecting rod crankshaft disassembly and assembly caution 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 equipmen...
Page 161
Crankshaft / transmission 8-9 crankshaft, connecting rod • apply engine oil to the big end bearing. • press the crank halves onto the crankpin, noting the crankpin direction until connecting rod side clearance is within specification as shown. Side clearance [a]: 0.1 ∼ 0.2 mm (0.004 ∼ 0.008 in.) cra...
Page 162
8-10 crankshaft / transmission crankshaft, connecting rod crankshaft runout inspection • set the crankshaft in a flywheel alignment jig or on v blocks, and place a dial gauge [a] against the points indi- cated. • turn the crankshaft slowly. The maximum difference in gauge readings is the crankshaft ...
Page 163
Crankshaft / transmission 8-11 crankshaft, connecting rod • in the case of both horizontal and vertical misalignment, correct the horizontal misalignment first. • recheck big end side clearance after aligning crankshaft (see connecting rod big end side clearance). Note ○ if crankshaft alignment cann...
Page 164
8-12 crankshaft / transmission transmission transmission and shift mechanism removal • split the crankcase (see crankcase splitting). • pull out the shift rods and take out the shift forks. • remove the drive and output shaft assemblies as a set. • holding the shift drum with suitable bar, unscrew t...
Page 165
Crankshaft / transmission 8-13 transmission apply engine oil [g] ○ always install circlips so that the opening is aligned with a spline groove. To install a circlip without damage, first fit the circlip onto the shaft expanding it just enough to install it, and then use a suitable gear to push the c...
Page 166
8-14 crankshaft / transmission transmission shift fork bending inspection • visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. [a] 90° shift fork ear/gear shift fork groo...
Page 167
Crankshaft / transmission 8-15 transmission gear dog/gear dog hole damage inspection • visually inspect the gear dogs [a] and gear dog holes [b]. Replace any damaged gears or gears with excessively worn dogs or dog holes. Ball and needle bearing wear inspection caution do not remove the bearings for...
Page 169: Wheels/tires
Wheels/tires 9-1 9 wheels/tires table of contents exploded view........................................................................................................................ 9-2 specifications ....................................................................................................
Page 170
9-2 wheels/tires exploded view.
Page 171
Wheels/tires 9-3 exploded view 1. Nipple 2. Spoke 3. Front tire 4. Rim 5. Front axle 6. Rear tire 7. Rear axle t1: 44 n·m (4.5 kgf·m, 32 ft·lb) t2: 64 n·m (6.5 kgf·m, 47 ft·lb) t3: 1.2 n·m (0.12 kgf·m, 10 in·lb) t4: 25 n·m (2.5 kgf·m, 18 ft·lb) g: apply high-temperature grease. R: replacement parts ...
Page 172
9-4 wheels/tires specifications item standard service limit wheels rim size: front 14 × 1.40 – – – rear 12 × 1.60 – – – rim runout (with tire installed): axial tir 0.8 mm (0.03 in.) or less tir 2 mm (0.08 in.) radial tir 1.0 mm (0.04 in.) or less tir 2 mm (0.08 in.) axle runout/100 mm (rear: 110 mm)...
Page 173
Wheels/tires 9-5 wheels (rims) front wheel removal • remove: cotter pin [a] front axle nut [b] • using a jack, raise the front wheel off the ground. • remove: front brake cable end [c] front axle [d] front wheel front brake panel collar front wheel installation • apply high-temperature grease to the...
Page 174
9-6 wheels/tires wheels (rims) • remove: adjusting nut [a] cotter pin [b] rear torque link nut [c] rear torque link bolt [d] cotter pin [e] rear axle nut [f] caution do not depress the brake pedal deeply with the brake rod inserted into the brake cam lever joint, this may elongate the spring beyond ...
Page 175
Wheels/tires 9-7 wheels (rims) • insert a new cotter pin [a]. Note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axel, tighten the nut clockwise [b] up to next alignment. ○ it should be within 30 degree. ○ loosen once and tighten again when the...
Page 176
9-8 wheels/tires tires air pressure inspection/adjustment • remove the valve cap. • using tire air pressure gauge [a], measure the tire pres- sure when the tires are cold. Adjust the tire air pressure to suit track conditions and rider preference, but do not stray too far from the recom- mended pres...
Page 177
Wheels/tires 9-9 tires tire removal • remove the wheel from the motorcycle (see wheels re- moval). • 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. • remo...
Page 178
9-10 wheels/tires tires tire installation • inspect the rim and tire, and replace them if necessary. • install the tube. • apply a soap and water solution, or rubber lubricant to the rim flange and tire beads. • position the tire on the rim so that the valve [a] is at the tire balance mark [b] (the ...
Page 179
Wheels/tires 9-11 hub bearing 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 sha...
Page 180
9-12 wheels/tires hub bearing 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 n...
Page 181: Final Drive
Final drive 10-1 10 final drive table of contents exploded view........................................................................................................................ 10-2 specifications ...................................................................................................
Page 182
10-2 final drive exploded view.
Page 183
Final drive 10-3 exploded view 1. Engine sprocket cover 2. Engine sprocket 3. Swingarm 4. Chain slipper 5. Chain guide 6. Locknut 7. Adjusting nut 8. Chain adjuster 9. Drive chain 10. Coupling damper 11. Rear axle 12. Chain tension guide 13. Torque link 14. Chain cover t1: 25 n·m (2.5 kgf·m, 18 ft·l...
Page 184
10-4 final drive specifications item standard service limit drive chain make/type – – – (klx110-a1) did 420mbk1 (klx110-a2 ∼ a4/a6f ∼) did 420dx link (klx110-a1) 88 links link (klx110-a2 ∼) 86 links drive chain slack 0 ∼ 5 mm (0 ∼ 0.2 in.) – – – 20 link length 254.0 ∼ 254.6 mm (10.00 ∼ 10.02 in.) 25...
Page 185
Final drive 10-5 drive chain chain slack inspection • refer to the chain slack inspection in the periodic main- tenance chapter. Chain slack adjustment • refer to the chain slack adjustment in the periodic main- tenance chapter. Drive chain removal • remove: drive chain cover engine sprocket cover •...
Page 186
10-6 final drive sprockets, coupling engine sprocket removal • remove: bolts [a] engine sprocket cover [b] • remove the circlip [a] and take off the sprocket [b] with drive chain [c]. • pull the collar and o-ring off the output shaft. Special tool - outside circlip pliers: 57001-144 engine sprocket ...
Page 187
Final drive 10-7 sprockets, coupling rear sprocket removal • remove the rear wheel (see wheels/tires chapter). • unscrew the rear sprocket bolts [a], and remove the rear sprocket [b]. Rear sprocket installation • install the rear sprocket facing the tooth number making [a] outward. • tighten the rea...
Page 188
10-8 final drive sprockets, coupling coupling bearing installation • inspect the bearing, and replace it if necessary. • press in the bearing so that the marked side faces out until it is bottomed. • replace the oil seal with a new one. • press in the oil seal so that the seal surface is flush with ...
Page 189: Brakes
Brakes 11-1 11 brakes table of contents exploded view........................................................................................................................ 11-2 specifications .............................................................................................................
Page 190
11-2 brakes exploded view.
Page 191
Brakes 11-3 exploded view 1. Brake lever 2. Brake cable 3. Cam lever 4. Brake panel 5. Brake shoe 6. Camshaft 7. Brake lever pivot nut 8. Front brake adjuster t1: 44 n·m (4.5 kgf·m, 32 ft·lb) c: apply cable lubricant. G: apply grease. Si: apply silicone grease..
Page 192
11-4 brakes exploded view.
Page 193
Brakes 11-5 exploded view 1. Brake pedal 2. Brake rod 3. Adjusting nut 4. Brake shoe 5. Camshaft 6. Cam lever t1: 8.8 n·m (0.9 kgf·m, 78 in·lb) t2: 64 n·m (6.5 kgf·m, 47 ft·lb) t3: 7 n·m (0.7 kgf·m, 60 in·lb) g: apply grease. R: replacement parts..
Page 194
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 195
Brakes 11-7 brake lever, brake pedal brake lever, brake pedal free play inspection • refer to the brake lever, brake pedal free play inspec- tion in the periodic maintenance chapter. Front brake free play adjustment • refer to the front brake lever free play adjustment in the periodic maintenance ch...
Page 196
11-8 brakes brake lever, brake pedal brake pedal return spring [a] brake pedal mounting bolt [b] brake pedal [c] with rod [d] cotter pin and washer [a] rod [b] o-rings [c] brake pedal and rod installation • brake pedal and rod installation is the reverse of removal. • bend the cotter pin [a] securel...
Page 197
Brakes 11-9 brake panel and drum brake lining wear inspection • refer to the brake lining wear inspection in the periodic maintenance chapter. Cam lever angle adjustment • refer to the cam lever angle adjustment in the periodic maintenance chapter. Brake panel removal • remove the front or rear whee...
Page 198
11-10 brakes brake panel and drum • remove the wheel and separate the brake panel from the wheel. • using a clean cloth around the linings to prevent grease or oil from getting on them, remove and install the brake shoes [a] by pulling up on the center of the linings. • pull the brake camshaft out f...
Page 199
Brakes 11-11 brake panel and drum brake shoe lining wear inspection • visually inspect the linings for uneven wear, and file or sand down any high spots. With a wire brush, remove any foreign particles imbedded in the lining surface. Wash off any oil or grease with a high-flash-point solvent. Do not...
Page 200
11-12 brakes brake panel and drum brake shoe springs inspection • visually inspect the brake shoe springs for breaks or dis- tortion. If the springs are damaged in any way, replace them. • measure [a] the free length of the brake shoe springs. If either is stretched beyond the service limit, replace...
Page 201: Suspension
Suspension 12-1 12 suspension table of contents exploded view........................................................................................................................ 12-2 specifications .....................................................................................................
Page 202
12-2 suspension exploded view.
Page 203
Suspension 12-3 exploded view 1. Circlip 2. Top plug 3. O-ring 4. Fork spring 5. Cylinder unit 6. Inner tube 7. Dust seal 8. Retaining ring 9. Oil seal 10. Outer tube 11. Gasket 12. Allen bolt 13. Steering stem head 14. Steering stem t1: 20 n·m (2.0 kgf·m, 15 ft·lb) t2: 29 n·m (3.0 kgf·m, 22 ft·lb) ...
Page 204
12-4 suspension exploded view.
Page 205
Suspension 12-5 exploded view 1. Pivot shaft 2. Swingarm 3. Rear shock absober 4. Rubber bushing 5. Flap: note the installing direction. T1: 78 n·m (8.0 kgf·m, 58 ft·lb) t2: 25 n·m (2.5 kgf·m, 18 ft·lb) t3: 39 n·m (4.0 kgf·m, 29 ft·lb) g: apply grease. R: replacement parts ca: canada model.
Page 206
12-6 suspension specifications item standard service limit front fork oil viscosity showa ss-8 or equivalent – – – oil capacity (completely dry) 163 ±2.5 ml (5.51 ±0.08 us oz) – – – oil level – – – (fully compressed, spring removed) 89 ±2 mm (3.50 ±0.08 in.) (from top of inner tube) – – – fork sprin...
Page 207
Suspension 12-7 front fork fork oil level check (simplify) • refer to the fork oil level adjustment (simplify) in the periodic maintenance chapter. Oil change/oil level adjustment (each fork leg) • remove the front fork (see this chapter). • remove the following. Top plug fork spring warning the top...
Page 208
12-8 suspension front fork front fork removal • remove the front brake cable clamp [a]. • remove the front brake cable [b]. • remove the front wheel (see wheels/tires chapter). • remove the number plate. • loosen the upper and lower fork clamp bolts [a]. • with a twisting motion, work the fork leg d...
Page 209
Suspension 12-9 front fork • remove the cylinder unit [a] and spring [b] from the 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]. S...
Page 210
12-10 suspension front fork front fork assembly (each fork) • assembly is the reverse of disassembly. • replace the following parts removed with a new one. Retaining ring oil seal bottom allen bolt washer • inspect the following and replace them with new ones if damaged. Inner tube (see inner tube i...
Page 211
Suspension 12-11 front fork dust seal/oil seal inspection • inspect the dust seal [b] for any signs of deterioration or damage. Replace it if necessary. • replace the oil seal [a] with a new one whenever it has been removed. Spring tension inspection • since a spring becomes shorter as it weakens, c...
Page 212
12-12 suspension rear shock absorber removal • using the jack under the frame, raise the rear wheel off the ground. Special tool - jack: 57001-1238 • remove the shock absorber mounting bolt [a], nut and pull off the shock absorber [b]. • to remove the rubber bushings [a], tap out the bushing with a ...
Page 213
Suspension 12-13 swingarm swingarm removal • using the jack under the frame, raise the rear wheel off the ground. Special tool - jack: 57001-1238 • remove: rear wheel (see wheels/tires chapter) left side cover (see frame chapter) drive chain rear shock absorber lower end • remove the pivot shaft nut...
Page 215: Steering
Steering 13-1 13 steering table of contents exploded view........................................................................................................................ 13-2 specifications .........................................................................................................
Page 216
13-2 steering exploded view.
Page 217
Steering 13-3 exploded view 1. Handlebar holder 2. Handlebar 3. Steering stem head nut 4. Steering stem head 5. Stem locknut 6. Upper steel balls 7. Head pipe 8. Lower steel balls 9. Steering stem 10. Lower inner race 11. Lower outer race 12. Upper outer race 13. Upper inner race 14. Stem cap 15. Fr...
Page 218
13-4 steering specifications special tools - steering stem bearing driver: 57001-137 steering stem nut wrench: 57001-1100 jack: 57001-1238 bearing driver set: 57001-1129 bearing puller: 57001-158 bearing puller stud: 57001-1190 bearing puller adapter: 57001-317.
Page 219
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. Steering stem removal • remove: front wheel (see wheels/tires chapter) front brake cable ...
Page 220
13-6 steering steering • install the stem head and washer, and tighten the stem head nut lightly. • settle the bearing in place as follows; ○ tighten the stem locknut to 39 n·m (4.0 kgf·m, 29 ft·lb) of torque. (to tighten the steering stem locknut to the specified torque, hook the wrench [a] on the ...
Page 221
Steering 13-7 steering • remove the lower inner race on the steering stem with a bearing puller [a]. Special tools - bearing puller: 57001-158 bearing puller stud: 57001-1190 [b] bearing puller adapter: 57001-317 [c] steering stem race installation notes • apply engine oil to the outer races, and th...
Page 222
13-8 steering handlebar handlebar removal • remove: engine stop switch [a] throttle grip assembly [b] brake lever holder [c] handlebar clamps [d] handlebar [e] handlebar installation • apply adhesive cement to the inside of the left handlebar grip [a]. • mount the handlebar holders [b] so that the a...
Page 223
Steering 13-9 handlebar • install the engine stop switch. ○ position the engine stop switch so that its edge [a] is aligned with the punch mark [b] on the handlebar..
Page 225: Electrical System
Electrical system 14-1 14 electrical system table of contents exploded view........................................................................................................................ 14-2 specifications .......................................................................................
Page 226
14-2 electrical system exploded view.
Page 227
Electrical system 14-3 exploded view 1. Engine stop switch 2. Main harness 3. Regulator/rectifier 4. Igniter 5. Exciter coil 6. Crankshaft sensor 7. Flywheel 8. Magneto cover 9. Spark plug 10. Gear position switch 11. Ignition coil 12. Frame 13. Damper (klx110-a1) t1: 42 n·m (4.3 kgf·m, 31 ft·lb): k...
Page 228
14-4 electrical system specifications item standard service limit magneto regulator/rectifier resistance in the text – – – ignition system – – – crankshaft sensor resistance 50 ∼ 200 Ω (blue/yellow← →ground) – – – air gap 0.7 mm (0.028 in.) ignition coil: primary winding resistance 0.19 ∼ 0.23 Ω – –...
Page 229
Electrical system 14-5 wiring diagram.
Page 230
14-6 electrical system precautions there are a number of important precautions that need to follow during 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...
Page 231
Electrical system 14-7 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, clean...
Page 232
14-8 electrical system magneto flywheel magneto cover removal • drain the engine oil. • remove: shift pedal engine sprocket cover (see final drive chapter) • pull off the magneto connector [a]. • remove: magneto cover screws [a] (klx110-a1 ∼ a7f) magneto cover bolts [a] (klx110a8f ∼) magneto cover [...
Page 233
Electrical system 14-9 magneto flywheel magneto cover assembly • run the magneto lead [a] as shown. • torque: plate screws [b]: 5.2 n·m (0.53 kgf·m, 46 in·lb) exciter coil mounting screws [c]: 5.2 n·m (0.53 kgf·m, 46 in·lb) crankshaft sensor mounting screws [d]: 2.9 n·m (0.3 kgf·m, 26 in·lb) magneto...
Page 234
14-10 electrical system magneto flywheel magneto flywheels inspection • there are three types of magneto problems: short, open (wire burned out), or loss in flywheel magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in flywheel magnet...
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Electrical system 14-11 ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. Caution do not disconnect the electrical connections whil...
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14-12 electrical system ignition system ignition coil removal • remove: left side cover spark plug cap • disconnect the ignition coil leads [a]. • unscrew the bolt [b] and remove the ignition coil [c]. Ignition coil installation • installation is the reverse of removal. • apply silicone grease to th...
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Electrical system 14-13 ignition system if the hand tester reads as specified, the ignition coil wind- ings are probably good. However, if the ignition system still does not perform as it should after all other com- ponents have been checked, replace the coil with one known to be good. • check the s...
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14-14 electrical system ignition system • connect the peak voltage adapter [a] between the termi- nal of primary lead (black) and ground connection of the unit with the lead of the ignition coil [b] connected. Special tools - peak voltage adapter: 57001-1415 type: kek-54-9-b hand tester: 57001-1394 ...
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Electrical system 14-15 ignition system exciter coil peak voltage check: • disconnect the connector of the main harness from the igniter. • to check the peak voltage, do the following procedures. Note ○ measure the voltage with each lead connected cor- rectly. The correct value may not be obtained i...
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14-16 electrical system ignition system.
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Electrical system 14-17 switches switch inspection • using the hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). Special tool - hand tester: 57001-1394 if the switch has an open or short, repair it or replace it with a new one. Engine stop sw...
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14-18 electrical system switches gear position switch inspection: • remove the gear position switch head and examine the contact points for presence of oxidation, oil or dirt, etc. Clean the contact points, and ensure that the switch finger is working correctly. • establish that the switch finger [a...
Page 243: Troubleshooting
Troubleshooting 15-1 15 troubleshooting table of contents troubleshooting guide ........................................................................................................... 15-2.
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15-2 troubleshooting troubleshooting guide note ○ 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: engine won’t t...
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Troubleshooting 15-3 troubleshooting guide spark plug cap shorted or not in good con- tact spark plug incorrect ignition coil trouble crankshaft sensorl trouble stator coil shorted or open igniter trouble fuel/air mixture incorrect: main jet clogged or wrong size jet needle or needle jet worn jet ne...
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15-4 troubleshooting troubleshooting guide drive shaft, output shaft, and/or gear splines worn overshifts: shift drum set lever spring weak or broken shift pawl spring weak or broken abnormal engine noise: knocking: carbon built up in combustion chamber fuel poor quality or incorrect overheating spa...
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Troubleshooting 15-5 troubleshooting guide right/left front fork oil level uneven rear shock absorber and/or swingarm bent shock absorption unsatisfactory: (too hard) front fork oil excessive front fork oil viscosity too high front fork bent tire air pressure too high (too soft) front fork oil visco...
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Model application year model beginning frame no. 2002 klx110-a1 jkalxsa1 □ 2a000001 or jkalx110aaa000001 2003 klx110-a2 jkalxsa1 □ 3da08133 or jkalx110aada08133 2004 klx110-a3 jkalxsa1 □ 4da14318 2005 klx110-a4 jkalxsa1 □ 5da21001 or jkalx110aada23033 2006 klx110a6f jkalxsa1 □ 6da31790 or jkalx110aa...