2011 Kawasaki KLX140 Owners Manual

2011 Kawasaki KLX140 Manual

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  • 2011 Kawasaki KLX140 | Owners Manual - Page 1
  • 2011 Kawasaki KLX140 | Owners Manual - Page 2
  • 2011 Kawasaki KLX140 | Owners Manual - Page 3
    Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION MAINTENANCE AND ADJUSTMENT TROUBLESHOOTING GUIDE STORAGE j j j j A Table of Contents is included after the Foreword.
  • 2011 Kawasaki KLX140 | Owners Manual - Page 4
    IMPORTANT INFORMATION KLX models are designed for the operator only, no passengers. • Kawasaki This motorcycle designed for competition only on a closed course. • Not intended for is use on public streets. • Read your owner's manual, it contains important information. •
  • 2011 Kawasaki KLX140 | Owners Manual - Page 5
    Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. DANGER DANGER
  • 2011 Kawasaki KLX140 | Owners Manual - Page 6
    improperly conducted, this sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not occur. TO PROTECT THE FUTURE OF YOUR
  • 2011 Kawasaki KLX140 | Owners Manual - Page 7
    techniques. Read and understand the owner's manual provided with the motorcycle. Review all instructions and warnings with your child. You riding the motorcycle. Also, familiarity with the motorcycle is important should a problem occur far from help. Do not allow your child to ride unsupervised.
  • 2011 Kawasaki KLX140 | Owners Manual - Page 8
    10. Encourage your child not to ride beyond his or her skill lever or faster than conditions safely allow. Have them practice advanced riding maneuvers under controlled conditions. 11. Tell someone where you and your child are planning to ride and when you Intend to return. Discuss the ride with
  • 2011 Kawasaki KLX140 | Owners Manual - Page 9
  • 2011 Kawasaki KLX140 | Owners Manual - Page 10
    . By giving your motorcycle the proper care and maintenance outlined in this manual, you will be helping to ensure it a long, trouble-free life. Before starting to ride your motorcycle, please read this manual thoroughly in order to know your motorcycle's capabilities, its limitations, and above
  • 2011 Kawasaki KLX140 | Owners Manual - Page 11
    Inspection ...76 Battery ...77 Fuse ...81 Tightening Torques of Nuts and Bolts...82 Cleaning Your Motorcycle...87 Lubrication...90 TROUBLESHOOTING GUIDE...93 STORAGE ...95 Before Storage ...95 After Storage ...96 ENVIRONMENTAL PROTECTION ...97 WIRING DIAGRAM ...98 YOUR WARRANTY/OWNER SATISFACTION
  • 2011 Kawasaki KLX140 | Owners Manual - Page 12
    10 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall length Overall width Overall height Wheelbase Road clearance Curb Mass Fuel tank capacity ENGINE Type Bore × stroke Displacement Compression ratio Carburetor Starting system Ignition system Ignition timing Lubrication system Spark plug Spark plug
  • 2011 Kawasaki KLX140 | Owners Manual - Page 13
    SPECIFICATIONS 11 TRANSMISSION Transmission type Clutch type Drive system Gear ratios: 1st gear 2nd gear 3rd gear 4th gear 5th gear Primary reduction ratio Final reduction ratio Overall ratio (top gear) Engine oil: Capacity Grade 1.1 L (1.2 US qt) Kawasaki Performance 4-Stroke Motorcycle Oil*
  • 2011 Kawasaki KLX140 | Owners Manual - Page 14
    12 SPECIFICATIONS Castor Trail Tire size, type: Front Rear Rim size: Front Rear Suspension: Front Rear Front suspension travel Rear wheel travel Front fork oil: Type Capacity (per fork leg) BRAKES Type (Front & Rear) ELECTRICAL EQUIPMENT Battery B: KLX140B 12 V 6 Ah Disc SHOWA SS8GO or equivalent
  • 2011 Kawasaki KLX140 | Owners Manual - Page 15
    SPECIFICATIONS 13 *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki. Specifications are subject to change without notice.
  • 2011 Kawasaki KLX140 | Owners Manual - Page 16
    14 GENERAL INFORMATION j GENERAL INFORMATION Location of Parts 1. Clutch Lever 2. Engine Stop Switch 3. Choke Knob 4. Front Brake Fluid Reservoir 5. Front Brake Lever 6. Throttle Grip 7. Starter Button 8. Fuel Tank Cap
  • 2011 Kawasaki KLX140 | Owners Manual - Page 17
    GENERAL INFORMATION 15 j 9. Front Fork 10. Fuel Tank 11. Fuel Tap 12. Carburetor 13. Seat 14. Air Cleaner Element 15. Brake Disc 16. Brake Caliper 17. Engine Oil Drain Plug 18. Side Stand 19. Drive Chain 20. Swingarm 21. Chain Guide 22. Rear Shock Absorber
  • 2011 Kawasaki KLX140 | Owners Manual - Page 18
    16 GENERAL INFORMATION j 23. Muffler 24. Fuse 25. Battery 26. Rear Axle Nut 27. Chain Adjuster 28. Rear Brake Fluid Reservoir 29. Oil Filler Cap/Dipstick 30. Rear Brake Pedal
  • 2011 Kawasaki KLX140 | Owners Manual - Page 19
    GENERAL INFORMATION 17 j Side Stand The motorcycle is equipped with a side stand. Fuel Tap The fuel tap has three position: OFF, ON, and RES (reserve). For normal operation, turn the fuel tap lever to the ON position. If the fuel runs out with the tap in the ON position, the last approximately 1.1
  • 2011 Kawasaki KLX140 | Owners Manual - Page 20
    18 GENERAL INFORMATION NOTE j żSince riding distance is limited when on RES, refuel at the earliest opportunity. żMake certain that the fuel tap lever is turned to ON (not RES), after filling up the fuel tank. WARNING Practice operating the fuel tap with the motorcycle stopped. To prevent an
  • 2011 Kawasaki KLX140 | Owners Manual - Page 21
    a minimum Antiknock Index of 87. The Antiknock Index is posted on service station pumps in the U.S.A. The octane rating of a gasoline is a meeting standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or non-recommended
  • 2011 Kawasaki KLX140 | Owners Manual - Page 22
    drain all fuel from the fuel system. See the Storage section in this manual. NOTICE Avoid using blends of unleaded gasoline and methanol (wood alcohol) gasohol" containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is
  • 2011 Kawasaki KLX140 | Owners Manual - Page 23
    GENERAL INFORMATION 21 j Engine Stop Switch The engine stop switch is located on the left side of the handlebar. The engine stop switch must be in the position for the motorcycle to operate. Move position to stop the engine. the switch to the Starter Button This motorcycle has the starter button.
  • 2011 Kawasaki KLX140 | Owners Manual - Page 24
    22 GENERAL INFORMATION j Starting the Engine that the engine stop switch is in the • Check position. • Turn the fuel tap lever to the ON position. A. ON Position A. Engine Stop Switch Position B. • Shift the transmission into neutral. NOTE WARNING Riding with the side stand in the down
  • 2011 Kawasaki KLX140 | Owners Manual - Page 25
    GENERAL INFORMATION 23 NOTICE Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power will drop temporarily. Wait 15 seconds between each operation of the starter to let it cool and the battery power recover. When engine is cold: Pull out
  • 2011 Kawasaki KLX140 | Owners Manual - Page 26
    24 GENERAL INFORMATION j NOTICE Do not let the engine idle longer than five minutes, or engine overheating and damage may occur. Moving Off that the side stand is up. • Check Shift into gear. • Open the 1st throttle slowly. •
  • 2011 Kawasaki KLX140 | Owners Manual - Page 27
    GENERAL INFORMATION 25 NOTICE Shifting Gears This motorcycle is equipped with a 5-speed "return shift" transmission. The neutral is located halfway between 1st and 2nd gear. "Return shift" means that when shifting up or down, each gear must be engaged before the next higher or lower gear may be
  • 2011 Kawasaki KLX140 | Owners Manual - Page 28
    26 GENERAL INFORMATION j Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Pull in the clutch lever as the motorcycle comes to a stop. Independent use of the front or rear brake may be advantageous in certain circumstances. Shift down
  • 2011 Kawasaki KLX140 | Owners Manual - Page 29
    GENERAL INFORMATION 27 j Break-In The first one hour that the motorcycle is ridden is designed as the break-in period. If the motorcycle is not used carefully during this period, you may very well end up with a "broken down" instead of a "broken in" motorcycle after the long use. Do not start
  • 2011 Kawasaki KLX140 | Owners Manual - Page 30
    28 GENERAL INFORMATION j Daily Pre-Ride Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure a safe, reliable ride. If any irregularities are found during these checks, refer to the appropriate section and
  • 2011 Kawasaki KLX140 | Owners Manual - Page 31
    GENERAL INFORMATION 29 Frame Tires ...Overall condition good No wear or damage Air pressure correct Air valve cap installed Spokes ...No looseness Drive Chain ...Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ...Function properly Lever and pedal play correct No
  • 2011 Kawasaki KLX140 | Owners Manual - Page 32
    30 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT The maintenance and adjustments outlined in this chapter must be carried out in accordance with the Periodic Maintenance Chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be
  • 2011 Kawasaki KLX140 | Owners Manual - Page 33
    following repair recommendations specified in the appropriate Kawasaki Service Manual. MAINTENANCE Proper maintenance is necessary to ensure that the recommended maintenance is carried out according to the instructions in this Owner's Manual at your own expense. You should keep a maintenance record
  • 2011 Kawasaki KLX140 | Owners Manual - Page 34
    32 MAINTENANCE AND ADJUSTMENT TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED: Federal regulations and California State law prohibit 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
  • 2011 Kawasaki KLX140 | Owners Manual - Page 35
    the motorcycle in good running condition. † : Replace, add, adjust, clean or torque if necessary. (K) : Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer. ż : Emission-related Item 1. Periodic Inspection (Engine Related Item) FREQUENCY OPERATION Initial 5 hours
  • 2011 Kawasaki KLX140 | Owners Manual - Page 36
    and rim runout - check † C H A S S I S (K) Drive chain wear - check † Drive chain - inspect and adjust † Drive chain - lubricate Drive chain guide and slipper - inspect † Front fork - inspect and clean † Nuts, bolts, fasteners - inspect † Steering play - inspect † (K) Steering stem bearing - grease
  • 2011 Kawasaki KLX140 | Owners Manual - Page 37
    MAINTENANCE AND ADJUSTMENT 35 FREQUENCY OPERATION Battery - inspect † Battery terminal - inspect † Chassis parts - lubricate Side stand - inspect † C H A S S I S (K) Wheel bearing - check † (K) Swingarm and Uni-track linkage pivot - inspect (K) Swingarm and Uni-track linkage pivot - grease (K) Rear
  • 2011 Kawasaki KLX140 | Owners Manual - Page 38
    36 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement (Engine and Chassis Related Item) Initial FREQUENCY OPERATION Engine oil - change Oil filter - replace (K) Brake hose - replace (K) Fuel hose - replace (K) Brake fluid - change (K) Brake master cylinder cup and dust seal - replace (K) Brake
  • 2011 Kawasaki KLX140 | Owners Manual - Page 39
    transmission seizure, accident, and injury. Check the oil level before each ride and change the oil according to the periodic maintenance chart in the Owner's Manual. • and reinsert it by screwing. Check the engine oil level on the dipstick. The oil level should come up between the low and high
  • 2011 Kawasaki KLX140 | Owners Manual - Page 40
    38 MAINTENANCE AND ADJUSTMENT the oil level is too high, remove the excess oil • If through the oil filler opening using a syringe or WARNING Motor oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling. the oil
  • 2011 Kawasaki KLX140 | Owners Manual - Page 41
    MAINTENANCE AND ADJUSTMENT 39 the oil filter element with a new one. • Replace Apply the oil to the grommet. • Install the grease oil filter element with the grommet to• ward the engine. the oil has completely drained out, install the • After drain plug with its new gasket. Proper torque for it is
  • 2011 Kawasaki KLX140 | Owners Manual - Page 42
    riding area. CR7HSA *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki. A. Gap B. Outer Electrode
  • 2011 Kawasaki KLX140 | Owners Manual - Page 43
    MAINTENANCE AND ADJUSTMENT 41 If the plug is oily or has carbon built up on it, clean it (preferably with a sandblaster) and then clean off any abrasive particles. The plug may also be cleaned using a high-flash-point solvent and a wire brush or other suitable tool. If the spark plug electrodes are
  • 2011 Kawasaki KLX140 | Owners Manual - Page 44
    42 MAINTENANCE AND ADJUSTMENT Air Cleaner A clogged air cleaner restricts the air intake, increases fuel consumption, reduces engine power, and can cause spark plug fouling. Inspect the air intake system, which includes the air filter and air duct to the carburetor, and the duct clamps and
  • 2011 Kawasaki KLX140 | Owners Manual - Page 45
    MAINTENANCE AND ADJUSTMENT 43 the wing bolt, and take out the air cleaner • Remove element. j A. Air Cleaner Cover B. Bolts A. Air Cleaner Element B. Wing Bolt a clean, lint-free towel on the air cleaner • Cover housing to keep dirt from entering the carburetor. out the inside of the air cleaner
  • 2011 Kawasaki KLX140 | Owners Manual - Page 46
    44 MAINTENANCE AND ADJUSTMENT WARNING A clogged air cleaner may allow dirt and dust to enter the carburetor and the throttle may stick resulting in a hazardous operating condition. Clean the air filter according to the periodic maintenance chart; more often if the vehicle is used in extremely dusty
  • 2011 Kawasaki KLX140 | Owners Manual - Page 47
    MAINTENANCE AND ADJUSTMENT 45 than too little. Finally pat the inside of the element with a paper towel to remove any excess oil. Before installation, check the element for damage such as tears, hardening, or shrinkage. If damaged, replace the element. Apply grease to all mating surfaces and to the
  • 2011 Kawasaki KLX140 | Owners Manual - Page 48
    46 MAINTENANCE AND ADJUSTMENT an air cleaner element with its pointing end • Install facing toward the rear of the motorcycle. Oil Draining j the hose or plug to see if any oil or water • Inspect has run down. A. Pointing end the wing bolt. • Install the air cleaner cover. • Install • Install
  • 2011 Kawasaki KLX140 | Owners Manual - Page 49
    MAINTENANCE AND ADJUSTMENT 47 Throttle Cable Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle cable in accordance with the Periodic Maintenance Chart. Check that the throttle grip has 2 a 3 mm (0.08 a 0.12 in.) of play
  • 2011 Kawasaki KLX140 | Owners Manual - Page 50
    48 MAINTENANCE AND ADJUSTMENT the rubber boot. • Install If the free play cannot be set by adjusting the upper • cable adjuster, use the adjuster on the lower end the rubber boot off the top of the carburetor • Pull and make the necessary free play adjustment with the adjuster on the lower end of
  • 2011 Kawasaki KLX140 | Owners Manual - Page 51
    MAINTENANCE AND ADJUSTMENT 49 if the throttle grip moves smoothly from full • Check open to close, and the throttle closes quickly and completely in all steering positions by the return spring. If not, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle
  • 2011 Kawasaki KLX140 | Owners Manual - Page 52
    50 MAINTENANCE AND ADJUSTMENT the choke knob fully up and set it where the • Pull knob stops. the rubber boot off the adjuster, and adjust • Pull with the adjuster so that the knob can be pushed back with a finger. j A. Choke Knob A. Rubber boot B. Adjuster NOTE ż If you over-tighten the
  • 2011 Kawasaki KLX140 | Owners Manual - Page 53
    MAINTENANCE AND ADJUSTMENT 51 Idle Speed The following procedure covers the idling adjustment, which should be performed whenever the idle speed is disturbed. the idling speed 1 350 a 1 450 r/min (rpm) • Adjust by turning the idling adjusting screw. j Idling Adjustment • Thoroughly warm up the
  • 2011 Kawasaki KLX140 | Owners Manual - Page 54
    52 MAINTENANCE AND ADJUSTMENT Clutch Clutch Lever Adjustment Proper clutch lever play is 2 a 3 mm (0.08 a 0.12 in.). Lever play increases with cable stretch and friction plate wear, requiring periodic adjustment. When the clutch lever play is out of specification, first try adjusting it at the
  • 2011 Kawasaki KLX140 | Owners Manual - Page 55
    MAINTENANCE AND ADJUSTMENT 53 the locknut. • Tighten Start the check that the clutch does not • slip and itengine, releases properly. • Slide the dust cover back into place. Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. j WARNING Too much cable play
  • 2011 Kawasaki KLX140 | Owners Manual - Page 56
    54 MAINTENANCE AND ADJUSTMENT Spark Arrester This vehicle is equipped with a spark arrester. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester. • Remove the muffler end mounting bolts. j NOTICE The spark arrester
  • 2011 Kawasaki KLX140 | Owners Manual - Page 57
    MAINTENANCE AND ADJUSTMENT 55 • Take off the spark arrester mounting bolts. • Remove the spark arrester. j A. Spark Arrester Mounting Bolts A. Spark Arrester B. Gasket a wire brush, remove the carbon off the inside • With of the spark arrester and muffler. the gasket to the new one. • Replace
  • 2011 Kawasaki KLX140 | Owners Manual - Page 58
    56 MAINTENANCE AND ADJUSTMENT Drive Chain For safety and to prevent excessive wear, the drive chain must be checked, adjusted, and lubricated before riding. If the chain becomes badly worn or maladjusted - either too loose or too tight - it could jump off the sprockets or break. Chain Slack
  • 2011 Kawasaki KLX140 | Owners Manual - Page 59
    MAINTENANCE AND ADJUSTMENT 57 rollers, loose pins and links and the sprockets for unevenly or excessively worn and damaged teeth. If there are any such defects, replace the drive chain and/or the sprockets. • j Chain Slack Adjustment the cotter pin from the rear axle nut. • Remove Loosen the •
  • 2011 Kawasaki KLX140 | Owners Manual - Page 60
    on a straight part of the chain from the center of the 1st pin to the center of the 21st pin. If the length exceeds the service limit, the chain should be replaced. Since overworn sprockets will cause a new chain to wear faster, inspect both the engine and rear sprockets whenever the
  • 2011 Kawasaki KLX140 | Owners Manual - Page 61
    MAINTENANCE AND ADJUSTMENT 59 NOTE żThe drive system was designed for use with a DAIDO D.I.D 428H (KLX140A: 122-link, KLX140B: 126-link) chain. For maximum stretch resistance and safety, a genuine part must be used for replacement. żTo minimize any chance of the Master Link coming apart, the
  • 2011 Kawasaki KLX140 | Owners Manual - Page 62
    60 MAINTENANCE AND ADJUSTMENT Chain Guide Wear Inspection j • Chain Slipper Wear Inspection aged. Visually inspect the drive chain guide and replace it if excessively worn or damaged. inspect the front end of the chain slippers • Visually on the swingarm and replace them if worn
  • 2011 Kawasaki KLX140 | Owners Manual - Page 63
    MAINTENANCE AND ADJUSTMENT 61 Sprocket Wear Inspection • Chain Lubrication Lubrication of the drive chain is necessary after riding in the rain or mud, or any time the chain appears dry. A heavy oil such as SAE90 is preferred to a lighter oil because it will stay on the chain longer and provide
  • 2011 Kawasaki KLX140 | Owners Manual - Page 64
    62 MAINTENANCE AND ADJUSTMENT Handlebar To suit various riding positions, the handlebar can be adjusted by turning the handlebar holders around. Remove the handlebar clamp bolts, the clamps and the handlebar. Check the handlebar for bent or crack. the handlebar holder nuts, turn the han• Loosen
  • 2011 Kawasaki KLX140 | Owners Manual - Page 65
    MAINTENANCE AND ADJUSTMENT 63 the handlebar on the handlebar holders. • Put Mount the handlebar clamps. • Align the gap at the rear with the punch mark on • the handlebar. Handlebar Clamp Bolts Tightening Torque 25 N·m (2.5 kgf·m, 18 ft·lb) j NOTE żTighten the two clamp bolts alternately two times
  • 2011 Kawasaki KLX140 | Owners Manual - Page 66
    64 MAINTENANCE AND ADJUSTMENT Brakes Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action. There are no parts on the brakes that require adjustment except brake lever position. the braking power and check that there is no • Test brake drag.
  • 2011 Kawasaki KLX140 | Owners Manual - Page 67
    MAINTENANCE AND ADJUSTMENT 65 NOTICE Do not spill brake fluid onto any painted surface. Do not use fluid from a container that has been left open or that has been unsealed for a long time. Check for fluid leakage around the brake system fittings. Check for brake hose damage. j Brake Fluid Level
  • 2011 Kawasaki KLX140 | Owners Manual - Page 68
    66 MAINTENANCE AND ADJUSTMENT the brake fluid in the front or rear reservoir is be• If low the minimum level line, check for fluid leaks in the brake line and fill the reservoir to the maximum level line. (The step inside the front and rear reservoirs indicate the maximum level.) j A. Rear
  • 2011 Kawasaki KLX140 | Owners Manual - Page 69
    MAINTENANCE AND ADJUSTMENT 67 Brake Pad Wear Inspection Inspect the brake pads for wear in accordance with the Periodic Maintenance chart. If the thickness of any pad in any (front or rear) brake caliper is less than 1 mm (0.04 in.), have both pads in the caliper replaced as a set. Pad replacement
  • 2011 Kawasaki KLX140 | Owners Manual - Page 70
    68 MAINTENANCE AND ADJUSTMENT Steering Adjustment j Raise the front wheel off the ground using a jack (special tool). Remove the handlebar. Loosen the left and right front fork upper clamp bolts. Remove the steering stem head nut, and raise the front fork upper clamp. the steering stem
  • 2011 Kawasaki KLX140 | Owners Manual - Page 71
    two times to ensure even tightening torque. Front Suspension Front Fork Inspection the brake lever, pump the front fork back • Holding and forth manually to check for smooth operation. inspect the front fork for oil leakage, scor• Visually ing or scratches on the outer surface of the inner
  • 2011 Kawasaki KLX140 | Owners Manual - Page 72
    70 MAINTENANCE AND ADJUSTMENT NOTICE If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straitening, can weaken the inner tube. Rear Suspension Rear Shock Absorber Inspection the seat down and up by 4 or 5 times, and • Pump inspect the smooth stroke.
  • 2011 Kawasaki KLX140 | Owners Manual - Page 73
    MAINTENANCE AND ADJUSTMENT 71 Rebound ONLY) Damping Adjustment (KLX140B Rebound Damping Adjuster Settings To adjust the rear shock absorber rebound damping, turn the rebound damping adjuster at the bottom of the rear shock absorber with a flat-head screwdriver. j A. Seated Position (Adjuster
  • 2011 Kawasaki KLX140 | Owners Manual - Page 74
    72 MAINTENANCE AND ADJUSTMENT NOTICE Do not force the rebound and compression damping force adjusters beyond the fully seated position, or the adjusting mechanism may be damaged. j Compression Damping Adjuster Setting The compression damping adjuster is a 4-stage adjustable. Compression Damping
  • 2011 Kawasaki KLX140 | Owners Manual - Page 75
    MAINTENANCE AND ADJUSTMENT 73 Spring Preload Adjustment The rear shock absorber can be adjusted by changing the spring preload for various riding and loading conditions. If the spring action feels too soft or too stiff, have it adjusted by an authorized Kawasaki dealer. Wheels Tire Air Pressure
  • 2011 Kawasaki KLX140 | Owners Manual - Page 76
    74 MAINTENANCE AND ADJUSTMENT Spokes and Rims The spokes on both wheels must all be securely and evenly tightened and not be allowed to loosen. Unevenly tightened or loose spokes will cause the rim to warp, the nipples and spokes to fatigue more quickly, and the spokes to break. Bead Protector
  • 2011 Kawasaki KLX140 | Owners Manual - Page 77
    MAINTENANCE AND ADJUSTMENT 75 Rim Runout Set up a dial gauge on the side of the rim and rotate the wheel to measure its axial runout. The difference between the highest and lowest readings is the amount of runout. Set up the dial gauge on the inner circumference of the rim and rotate the wheel to
  • 2011 Kawasaki KLX140 | Owners Manual - Page 78
    76 MAINTENANCE AND ADJUSTMENT Hoses Inspection Check the brake and fuel hoses for cracks or deterioration, and the connections for looseness in accordance with the Periodic Maintenance Chart. Inspect the brake hose and fittings for deterioration, cracks and signs of leakage by bending or twisting
  • 2011 Kawasaki KLX140 | Owners Manual - Page 79
    MAINTENANCE AND ADJUSTMENT 77 Battery The battery installed in this motorcycle is a sealed type, so it is not necessary to check the battery electrolyte level or add distilled water. However, in order to maximize battery life and ensure that it will provide the power needed to start the motorcycle
  • 2011 Kawasaki KLX140 | Owners Manual - Page 80
    install a conventional battery in this motorcycle, or the electrical system cannot work properly. NOTE żIf you charge the sealed battery, never fail to observe the instructions shown in the label on the battery.
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    MAINTENANCE AND ADJUSTMENT 79 WARNING Lead is a toxic substance. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. • Remove the bolt and remove the seat. j Battery Removal • Remove the bolt and remove the side cover. A. Bolt B. Seat
  • 2011 Kawasaki KLX140 | Owners Manual - Page 82
    80 MAINTENANCE AND ADJUSTMENT the cables from the battery, first from • Disconnect the (-) terminal and then the (+) terminal. Battery Installation j the battery in the battery case. • Place Install the battery holder and tighten the bolts. • Connect the red cable to the (+) terminal, and then •
  • 2011 Kawasaki KLX140 | Owners Manual - Page 83
    MAINTENANCE AND ADJUSTMENT 81 Fuse The main fuse (10 A) is mounted on the starter relay under the seat. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage. WARNING Substituting fuses can cause wiring to
  • 2011 Kawasaki KLX140 | Owners Manual - Page 84
    82 MAINTENANCE AND ADJUSTMENT Tightening Torques of Nuts and Bolts Location of nuts and bolts Before the first ride of each day of operation, check the tightness of the nuts and bolts shown below. Check also that all cotter pins are in place and in good condition. j 1. 2. 3. 4. 5. 6. Front Fork
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    MAINTENANCE AND ADJUSTMENT 83 j 16. 17. 18. 19. Spark Plug Cylinder Head Bolts Muffler End Mounting Bolts Spark Arrester Mounting Bolts 20. Rear Master Cylinder Mounting Bolts 21. Steering Head Nut 22. Front Master Cylinder Mounting Bolts 23. Rear Brake Disk Mounting Bolts 24. Rear Axle Nut 25.
  • 2011 Kawasaki KLX140 | Owners Manual - Page 86
    84 MAINTENANCE AND ADJUSTMENT Torque table Tighten all nuts and bolts to the proper torque using an accurate torque wrench. An insufficiently tightened nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider. An overtightened nut or bolt may
  • 2011 Kawasaki KLX140 | Owners Manual - Page 87
    MAINTENANCE AND ADJUSTMENT 85 Part Name Brake Caliper Bolts Brake Disc Mounting Bolts Engine Bracket Nut/Bolt Engine Mounting Bolts Front Axle Nut Front Fork Clamp Bolts Handlebar Clamp Bolts Swingarm Pivot Shaft Nut Rear Axle Nut Rear Brake Pedal Pivot Bolt Rear Frame Bolts Rear Shock Absorber
  • 2011 Kawasaki KLX140 | Owners Manual - Page 88
    86 MAINTENANCE AND ADJUSTMENT Part Name Rear Shock Absorber Lower Nut Rear Shock Absorbor Lower Bolt Spokes Steering Stem Head Nut Steering Stem Locknut UNI-TRAK® Arm Bolt UNI-TRAK® Rod Bolts Rear Sprocket Nuts Front Brake Master Cylinder Clamp Bolts Rear Brake Master Cylinder Mounting Bolts N·m 29
  • 2011 Kawasaki KLX140 | Owners Manual - Page 89
    MAINTENANCE AND ADJUSTMENT 87 Cleaning Your Motorcycle General Precautions Frequent and proper care of your Kawasaki motorcycle will enhance its appearance, optimize overall performance, and extend its useful life. Covering your motorcycle with a high quality, breathable motorcycle cover will help
  • 2011 Kawasaki KLX140 | Owners Manual - Page 90
    88 MAINTENANCE AND ADJUSTMENT cleaning your motorcycle, check the rubber • After boot covering the shift pedal ball joint for correct installation. Be sure the sealing lip of the rubber boot fits into the groove of the ball joint. the boot is damaged, replace it with a new one. • If If the boot is
  • 2011 Kawasaki KLX140 | Owners Manual - Page 91
    or as conditions require. Avoid surfaces with "satin" or "flat" finishes. Always use nonabrasive products and apply them according to the instructions on the container. j Chrome and Aluminum Chrome and uncoated aluminum parts can be treated with a chrome/aluminum polish. Coated aluminum should
  • 2011 Kawasaki KLX140 | Owners Manual - Page 92
    90 MAINTENANCE AND ADJUSTMENT Leather, Vinyl, and Rubber If your motorcycle has leather accessories, special care must be taken. Use a leather cleaner/treatment to clean and care for leather accessories. Washing leather parts with detergent and water will damage them, shortening their life. Vinyl
  • 2011 Kawasaki KLX140 | Owners Manual - Page 93
    MAINTENANCE AND ADJUSTMENT 91 brake pedal • Rear Rear brake • Foot peg rod joints • Apply an aerosol cable lubricant with a pressure lubricator on all cables: Clutch cable Throttle cable Hot starter cable • • • j Cable Lubrication
  • 2011 Kawasaki KLX140 | Owners Manual - Page 94
    92 MAINTENANCE AND ADJUSTMENT j Apply grease to the following points: Upper end of clutch cable Upper end of throttle cable Upper end of hot starter cable Shift pedal Drive Chain Lubrication Lubricate the drive chain after riding through rain or on wet track, or any time that the chain
  • 2011 Kawasaki KLX140 | Owners Manual - Page 95
    TROUBLESHOOTING GUIDE 93 TROUBLESHOOTING GUIDE NOTE żThis troubleshooting guide is not exhaustive and does not give every possible cause for each problem listed. It is meant simply as a quick guide to assist you in troubleshooting for some of the more common difficulties. Fuel-air mixture
  • 2011 Kawasaki KLX140 | Owners Manual - Page 96
    94 TROUBLESHOOTING GUIDE Clutch not operating smoothly - Clutch slipping Friction plate worn Clutch springs weak Shock absorption too hard Tire air pressure too high j • • Clutch doesn't disengaging properly
  • 2011 Kawasaki KLX140 | Owners Manual - Page 97
    STORAGE 95 STORAGE Before Storage When the motorcycle is to be stored for any length of time, it should be prepared for storage as follows. Clean the entire vehicle thoroughly. Run the engine for about five minutes to warm the oil, then stop it and drain the engine oil. WARNING Gasoline is
  • 2011 Kawasaki KLX140 | Owners Manual - Page 98
    96 STORAGE the motorcycle to keep dust and dirt away • Cover from it. After Storage the plastic bag from the muffler. • Remove Make sure the spark plug is tight. • NOTE żFit the plug cap securely onto the spark plug, and pull the cap lightly to make sure that it is properly installed. the fuel
  • 2011 Kawasaki KLX140 | Owners Manual - Page 99
    ENVIRONMENTAL PROTECTION 97 ENVIRONMENTAL PROTECTION To protect our environment, properly discard used batteries, tires, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper
  • 2011 Kawasaki KLX140 | Owners Manual - Page 100
    98 WIRING DIAGRAM WIRING DIAGRAM
  • 2011 Kawasaki KLX140 | Owners Manual - Page 101
    Am I Responsible For? You are responsible for maintaining your vehicle according to the maintenance schedule shown in this owner's manual. You are responsible for notifying your dealer immediately if there is a problem, and you, as the owner, will need to authorize the dealer to inspect the unit.
  • 2011 Kawasaki KLX140 | Owners Manual - Page 102
    , be sure to record your service in the Maintenance Record section of this Owner's Manual. Keep all receipts for the service and/or items necessary to perform vehicle if there is a failure, investigating the cause of the problem, and getting any needed authorization from Kawasaki if the repair is
  • 2011 Kawasaki KLX140 | Owners Manual - Page 103
    by a Kawasaki dealer. What if I am not Satisfied With My Warranty Service? If you aren't satisfied with your dealership's repair work or operations, dealership and work with it in resolving your problem. Want to Contact Kawasaki? This owner's manual should answer most of your questions about your
  • 2011 Kawasaki KLX140 | Owners Manual - Page 104
    102 YOUR WARRANTY/OWNER SATISFACTION Please send your correspondence to: Consumer Services Kawasaki Motors Corp., U.S.A. P.O. Box 25252 Santa Ana, CA 92799-5252 (949) 460-5688
  • 2011 Kawasaki KLX140 | Owners Manual - Page 105
    it finds that a safety defect exists in a group of vehicles, if may order a recall and remedy campaign. However, the CPSC cannot become involved in individual problems between you, your dealer, or Kawasaki Motors Corporation, U.S.A.
  • 2011 Kawasaki KLX140 | Owners Manual - Page 106
    104 MAINTENANCE RECORD MAINTENANCE RECORD Owner Name...Address ...Phone Number ...Engine Number ...Vehicle Number...Selling Dealer Name ...Address ...Phone Number ...Warranty Start Date ...Note: Keep this information and a spare key in a secure location. Date Odometer Reading Maintenance Performed
  • 2011 Kawasaki KLX140 | Owners Manual - Page 107
    MAINTENANCE RECORD 105 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2011 Kawasaki KLX140 | Owners Manual - Page 108
    106 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2011 Kawasaki KLX140 | Owners Manual - Page 109
    MAINTENANCE RECORD 107 Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2011 Kawasaki KLX140 | Owners Manual - Page 110
    108 MAINTENANCE RECORD Date Odometer Reading Maintenance Performed Dealer Name Dealer Address
  • 2011 Kawasaki KLX140 | Owners Manual - Page 111
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