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Motorcycle Service Manual: Downloaded From Manuals Search Engine
Motorcycle
Service Manual
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Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System 3 j
Engine Top End 4 j
Clutch 5 j
Engine Lubrication System 6 j
Engine Removal/Installation 7 j
Crankshaft / Transmission 8 j
Wheels/Tires 9 j
Final Drive 10 j
Brakes 11 j
Suspension 12 j
Steering 13 j
Electrical System 14 j
Troubleshooting 15 j
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 Division/Consumer Products & Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2001 Kawasaki Heavy Industries, Ltd. 8th Edition (1): May 16, 2008 (K)
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 eliminates the release of cranckcase vapors into the atmosphere. Instead, the
vapors are routed through an oil separator to the inlet side of the engine. While the engine is
operating, the vapors are drawn into combustion chamber, where they are burned along with the
fuel and air supplied by the carburetor.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel and ignition systems of this motorcycle have been carefully designed
and constructed to ensure an efficient engine with low exhaust pollutant levels.
California State 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 replace-
ment, of any device or element of design incorporated into any new motorcycle for the purposes
of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2)
the use of the motorcycle after such device or element of design has been removed or rendered
inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
Do not tamper with the original emission related parts:
• Carburetor and internal pars
• Spark plug
• Magneto ignition system
• Air cleaner element
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 for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below:
• Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
• Removal of the muffler(s) or any internal portion of the muffler(s).
• Removal of the air box or air box cover.
• Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such
modifications result in increased noise levels.
General Information 1
Table of Contents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-5
General Specifications............................................................................................................ 1-6
Torque and Locking Agent...................................................................................................... 1-8
Special Tools and Sealants .................................................................................................... 1-11
Cable, Wire and Hose Routing ............................................................................................... 1-17
Unit Conversion Table ............................................................................................................ 1-22
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 (628 N, 141 lb)
Curb Mass:
KLX110A9F ∼ 64 kg (628 N, 141 lb)
Front 31 kg (304 N, 68 lb)
Rear 37 kg (363 N, 82 lb)
Fuel Tank Capacity 3.8 L (1.0 US gal)
Performance
Minimum Turning Radius 1.6 m (5.2 ft)
Engine
Type 4-stroke, SOHC, single cylinder
Cooling System Air-cooled
Bore and Stroke 53.0 × 50.6 mm (2.09 × 1.99 in.)
Displacement 111 cm³ (6.77 cu in.)
Compression Ratio 9.5 : 1
Carburetion System Carburetor, KEIHIN PB18
Starting System Kick
Ignition System Magneto CDI
Ignition Timing From 10° BTDC @1 300 r/min (rpm) to 31°
BTDC @4 000 r/min (rpm)
Spark Plug NGK CR6HSA
Valve Timing:
Inlet:
Open 0° BTDC
Close 80° ABDC
Duration 260°
Exhaust:
Open 35° BBDC
Close 45° ATDC
Duration 260°
Lubrication System Forced lubrication (wet sump)
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 1.1 L (1.2 US gt): (when engine is completely dry)
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 Ratios:
1st 3.273 (36/11) (KLX110-A1)
3.000 (36/12) (KLX110-A2 ∼)
2nd 1.938 (31/16)
3rd 1.350 (27/20)
Final Drive System:
Type Chain drive
Reduction Ratio 2.642 (37/14) (KLX110-A1)
2.357 (33/14) (KLX110-A2 ∼)
Overall Drive Ratio 10.873 @Top gear (KLX110-A1)
10.848 @Top gear (KLX110-A2 ∼)
Frame
Type Backbone
Caster (Rake Angle) 25.5°
Trail 54 mm (2.1 in.)
Front Tire:
Type C803
Size 2.50 - 14 4PR
2.50 - 14 M/C 4PR (KLX110-A2 ∼)
Rear Tire:
Type C803
Size 3.00 - 12 4PR
3.00 - 12 M/C 4PR (KLX110-A2 ∼)
Rim Size:
Front 14 × 1.40
Rear 12 × 1.60
Front Suspension:
Type Telescopic fork
Wheel Travel 110 mm (4.3 in.)
Rear Suspension:
Type Swingarm
Wheel Travel 107 mm (4.2 in.)
Brake Type:
Front Drum
Rear Drum
Specifications are subject to change without notice, and may not apply to every country.
Torque
Fastener Remarks
N·m kgf·m ft·lb
Fuel System
Fuel Tap Bolts (KLX110-A3 ∼) 4.9 0.5 43 in·lb
Engine Top End
Rocker Arm Shaft Stopper Screws 5.2 0.53 46 in·lb
Valve Adjusting Screw Locknuts 8.8 0.9 78 in·lb
Camshaft Sprocket Bolt 12 1.2 104 in·lb L
Cylinder Head Nuts 22 2.2 16 S
Cylinder Head Bolts 12 1.2 104 in·lb L,S
Spark Plug 13 1.3 113 in·lb
Chain Tensioner Mounting Bolts 5.2 0.53 46 in·lb L
Tensioner Cap Bolt 5.2 0.53 46 in·lb
Camshaft Sprocket Cover Bolts 5.2 0.53 46 in·lb
Camshaft Chain Guide Bolt 5.2 0.53 46 in·lb
Camshaft Chain Holder Screws 5.2 0.53 46 in·lb
Valve Adjusting Cap Bolts 5.2 0.53 46 in·lb
Spark Arrester Mounting Bolts 8.8 0.9 78 in·lb
Clutch
Clutch Cover Screws (KLX110-A1 ∼ A7F) 5.2 0.53 46 in·lb S
Clutch Cover Bolts (KLX110A8F ∼) 8.8 0.9 78 in·lb S
Clutch Cover Plate Screws 2.9 0.3 26 in·lb
Clutch Hub Nut (Primary) 72 7.3 53
Clutch Hub Nut (Secondary) 72 7.3 53
Clutch Spring Bolts (KLX110-A1 ∼ A2) 3.4 0.35 30 in·lb
Clutch Spring Bolts (KLX110-A3 ∼) 5.0 0.51 44 in·lb
Clutch Adjusting Screw Locknut 19 1.9 14
Shift Drum Position Plate Screw 5.2 0.53 46 in·lb
Shift Drum Positioning Lever Pivot Bolt 5.2 0.53 46 in·lb L
Kick Guide Screw 5.2 0.53 46 in·lb
Return Spring Pin 22 2.2 16
Engine Lubrication System
Oil Pipe Banjo Bolts 15 1.5 11
Oil Pipe Clamp Screw 5.2 0.53 46 in·lb
Oil Pump Mounting Screw 5.2 0.53 46 in·lb
Oil Filter Cap Bolts 5.2 0.53 46 in·lb
Engine Oil Drain Plug 29 3.0 21
Engine Removal/Installation
Engine Mounting Nuts 54 5.5 40
Side Stand Mounting Nut 23 2.3 17
Torque
Fastener Remarks
N·m kgf·m ft·lb
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 Bolt 5.2 0.53 46 in·lb L
Magneto Flywheel Nut 10 mm (KLX110-A1) 42 4.3 31
Magneto Flywheel Nut 12 mm (KLX110-A2 ∼) 54 5.5 40
Clutch Hub Nut 72 7.3 53
Wheels/Tires
Spoke Nipples 1.2 0.12 10 in·lb
Front Axle Nut 44 4.5 32
Rear Axle Nut 64 6.5 47
Torque Link Nut 25 2.5 18
Final Drive
Swingarm Pivot Shaft Nut 78 8.0 58
Rear Sprocket Nuts 34 3.5 25
Rear Axle Nut 64 6.5 47
Torque Link Nut 25 2.5 18
Brakes
Front Axle Nut 44 4.5 32
Rear Axle Nut 64 6.5 47
Brake Pedal Bolt 8.8 0.9 78 in·lb
Rear Cam Lever Mounting Bolt 7.0 0.7 60 in·lb
Suspension
Front Fork Clamp Bolts:
Upper 20 2.0 15
Lower 29 3.0 22
Front Fork Bottom Allen Bolts 20 2.0 15
Torque Link Nuts:
Front 25 2.5 18
Rear 25 2.5 18
Swingarm Pivot Shaft Nut 78 8.0 58
Rear Shock Absorber Mounting Nuts:
Upper 39 4.0 29
Lower 39 4.0 29
Steering
Front Fork Clamp Bolts:
Upper 20 2.0 15
Lower 29 3.0 22
Steering Stem Head Nut 44 4.5 32
Handlebar Holder Bolts 25 2.5 18
Steering Stem Locknut 4.9 0.5 43 in·lb
Torque
Fastener Remarks
N·m kgf·m ft·lb
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 Mounting Screws 5.2 0.53 46 in·lb
Crankshaft Sensor Mounting Screw 2.9 0.3 26 in·lb
Magneto Cover Screws (KLX110-A1 ∼ A7F) 5.2 0.53 46 in·lb S
Magneto Cover Bolts (KLX110A8F ∼) 8.8 0.9 78 in·lb S
Exciter Coil Plate Screw 5.2 0.53 46 in·lb
Crankshaft Sensor Plate Screw 5.2 0.53 46 in·lb
Magneto Cover Damper 2.9 0.3 26 in·lb
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads dia. Torque
(mm) N·m kgf·m ft·lb
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb
8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23 ∼ 33 165 ∼ 240
Oil Seal & Bearing Remover: Valve Seat Cutter, 45° - 27.5:
57001-1058 57001-1114
Valve Spring Compressor Adapter, 20: Valve Seat Cutter, 32° - 22:
57001-1154 57001-1206
Oil Pressure Gauge Adapter, M10 × 1.25: Rotor Puller, M16/M18/M20/M22 × 1.5:
57001-1182 57001-1216
Spark Plug Wrench, Hex 16: Compression Gauge Adapter, M10 × 1.0:
57001-1262 57001-1317
Units of Volume:
L × 0.2642 =
Units of Pressure:
gal (US)
kPa × 0.01020 = kgf/cm²
L × 0.2200 = gal (imp)
kPa × 0.1450 = psi
L × 1.057 = qt (US)
kPa × 0.7501 = cmHg
L × 0.8799 = qt (imp)
kgf/cm² × 98.07 = kPa
L × 2.113 = pint (US)
kgf/cm² × 14.22 = psi
L × 1.816 = pint (imp)
cmHg × 1.333 = kPa
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (imp)
mL × 0.06102 = cu in
Units of Speed:
km/h × 0.6214 = mph
Units of Force:
N × 0.1020 = kg
Units of Power:
N × 0.2248 = lb
kW × 1.360 = PS
kg × 9.807 = N
kW × 1.341 = HP
kg × 2.205 = lb
PS × 0.7355 = kW
PS × 0.9863 = HP
Units of Temperature:
Periodic Maintenance
Table of Contents
2
• Clean
vent.
the fuel tap filter screen in a high-flash point sol-
• Turn in the air screw and count the number of turns until
it seats fully but not tightly.
○For United States model; The air screw adjuster (special
tool) may be used.
Special Tool - Pilot Screw Adjuster: 57001-1665
• Back out the same number of turns counted when turned
in. This is to set the screw to its original position.
NOTE
○A carburetor has different “turns out” of the pilot screw
for each individual unit. When setting the pilot screw,
use the “turns out” determined during disassembly. Use
the specifications in this manual only if the original num-
ber is unknown.
• Remove
chapter).
the air cleaner element [A] (see Fuel System
NOTE
○Valve clearance must be checked when the engine is
cold (at room temperature).
• Remove:
Left Shroud
Spark Plug (see Electrical System chapter)
Camshaft Sprocket Cover [A] (see Camshaft Sprocket
Removal in the Engine Top End chapter)
Valve Adjusting Covers [B] (see Rocker Arm Removal in
the Engine Top End chapter)
• Tighten
position.
the locknut without changing the adjusting screw
• After the oil has completely drained, install the drain plug
with its gasket.
Replace the drain plug gasket with a new one if it is dam-
aged.
• Tighten the drain plug.
Torque - Engine Oil Drain Plug: 29 N·m (3.0 kgf·m, 21 ft·lb)
• Pour in the specified type and amount of oil.
Recommended Engine Oil
Type: 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 10 W-40
Capacity: 1.1 L (1.2 us qt)
(When engine is completely dry)
1.0 L (1.1 us qt) (When filter is removed)
0.9 L (1.0 us qt)
(When filter is not removed)
Wheels/Tires
Wheels Inspection
• Place the jack under the frame so that the front/rear wheel
is raised off the ground.
Special Tool - Jack: 57001-1238
• Spin the wheel lightly, and check for roughness or binding.
• Visually inspect
If roughness or binding is found, replace the hub bearings.
• If axle damagedthe front and rear axles for damage.
• or bent, replace it.
Spoke Tightness Inspection
• Check that all the spokes [A] are tightened evenly.
Standard spoke tightening torque is shown below. Over-
or under-tightening may cause breakage.
Torque - Spokes nipples: 1.2 N·m (0.12 kgf·m, 10 in·lb)
• Check the rim runout.
WARNING
If any spoke breaks, it should be replaced immedi-
ately. A missing spoke places an additional load on
the other spokes, which will eventually cause other
spokes to break.
• Rotate the rear wheel to find the position where the chain
is tightest.
• Push up [A] the chain midway between the engine
sprocket and rear sprocket.
• The drive chain slack is that the drive chain [B] protrude
within 0 ∼ 5 mm (0 ∼ 0.2 in.) [C] from the hollow [D] of the
chain guard [E].
If the drive chain slack exceeds the standard, adjust it.
Chain Slack
Standard: 0 ∼ 5 mm (0 ∼ 0.2 in.)
• Ifadjusting
the chain is too tight, back out the left and right chain
nuts [A] evenly, and kick the wheel forward until
the chain is too loose.
• Turn both chain adjusting nuts evenly until the drive chain
has the correct amount of slack. To keep the chain and
wheel properly aligned, the notch [B] on the right chain
adjuster [C] should align with the same swingarm mark
[D] that the left chain adjuster notch aligns with.
Chain Lubrication
The chain should be lubricated with a lubricant which will
both prevent its exterior from rusting and also absorb shock
and reduce friction in the interior of the chain. An effective,
good quality lubricant specially formulated for chains is best
for regular chain lubrication. If a special lubricant is not
available, a heavy oil such as SAE 90 is preferred to a lighter
oil because it will stay on the chain longer and provide better
lubrication.
• If the chain appears especially dirty, it should be cleaned
before lubrication.
• Apply oil to the sides of the rollers and between the side
plates of the links so that oil will penetrate to the bushings
and pins where most wear takes place.
• Wipe off any excess oil.
Oil applied area [A]
Sprocket Wear Inspection
• Visually inspect the engine and rear sprocket teeth for
wear and damage.
If they are worn as illustrated or damaged, replace the
sprocket with new ones and inspect the drive chain wear.
Worn Tooth (Engine Sprocket) [A]
Worn Tooth (Rear Sprocket) [B]
Direction of Rotation [C]
NOTE
○If a sprocket requires replacement, the chain is proba-
bly worn also. When replacing a sprocket, inspect the
chain.
Brakes
Brake Lever, Brake Pedal Free Play Inspection
• Check the front brake lever free play [A] when the brake
is lightly applied.
Lever Free Play
Standard: 4 ∼ 5 mm (0.16 ∼ 0.20 in.)
If the lever has improper play, adjust it.
• Operate the lever a few times to see that it returns to its
rest position immediately upon release.
• Check the brake pedal free play [A] when the pedal is
pushed down lightly by hand.
Brake Pedal Free Play
Standard: 20 ∼ 30 mm (0.8 ∼ 1.2 in.)
• 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 lever angle greater than 90° reduces
braking effectiveness, cam lever angle adjustment
should not be neglected.
WARNING
When remounting the cam lever, be sure that the
position of the wear indicator on the serrated shaft
is not altered.
A change in cam lever angle is caused by wear of
internal brake parts. Whenever the cam lever angle
is adjusted, also check for drag and proper opera-
tion, taking particular note of the brake lining wear
indicator position.
In case of doubt as to braking effectiveness, disas-
semble and inspect all internal brake parts. Worn
parts shall result in the brake to lock or fail.
•○Use the oil level gauge to measure the fork oil level.
With the fork fully compressed, put the oil level gauge [A]
and the stopper [B], and adjust the distance from the top
of the inner tube to oil.
Special Tool - Fork Oil Level Gauge: 57001-1290
• Check both top plug O-ring [A] for damage and replace
them if necessary.
• Use the jack under the frame so that the rear wheel is
raised off the ground.
Special Tool - Jack: 57001-1238
• Move the swingarm [A] side to side to check for worn,
damaged or loose suspension pivot components.
If any play is detected, check for looseness of swingarm
pivot bolt or for damage to the swingarm rubber bushings.
• Turn the steering stem locknut [A] with the steering stem
nut wrench [B] to obtain the proper adjustment.
If the steering is too tight, loosen the stem locknut a frac-
tion of a turn; if the steering is too loose, tighten the lock-
nut a fraction of a turn.
Special Tool - Steering Stem Nut Wrench: 57001-1100
NOTE
○Turn the locknut 1/8 turn at a time maximum.
Side Stand
Side Stand Inspection
• See
[B].
if the side stand [A] moves smoothly and retracts fully
Electrical System
Spark Plug Gap
• Remove the spark plug (see Electrical System chapter).
• If the gaptheis incorrect,
Measure gap with a wire-type thickness gauge.
carefully bend the side electrode
with a suitable tool to obtain the correct gap.
Insulator [A]
Center Electrode [B]
Plug Gap [C]
Side Electrode [D]
Spark Plug Gap
0.6 ∼ 0.7 mm (0.024 ∼ 0.028 in.)
Fuel System
Table of Contents
3
Exploded View........................................................................................................................ 3-2
Specifications ......................................................................................................................... 3-6
Throttle Grip and Cable .......................................................................................................... 3-7
Free Play Inspection ......................................................................................................... 3-7
Free Play Adjustment........................................................................................................ 3-7
Throttle Cable and Choke Cable Installation .................................................................... 3-7
Cable Lubrication and Inspection...................................................................................... 3-7
Carburetor .............................................................................................................................. 3-8
Idle Speed Inspection ....................................................................................................... 3-8
Idle Speed Adjustment...................................................................................................... 3-8
Fuel Level Inspection ........................................................................................................ 3-8
Fuel Level Adjustment ...................................................................................................... 3-9
Float Removal................................................................................................................... 3-10
Fuel System Cleanliness Inspection ................................................................................. 3-10
Carburetor Removal.......................................................................................................... 3-10
Carburetor Installation....................................................................................................... 3-11
Carburetor Cleaning.......................................................................................................... 3-11
Carburetor Disassembly ................................................................................................... 3-12
Carburetor Assembly ........................................................................................................ 3-13
Carburetor Inspection ....................................................................................................... 3-14
Air Cleaner.............................................................................................................................. 3-16
Air Cleaner Housing Removal........................................................................................... 3-16
Air Cleaner Housing Installation........................................................................................ 3-16
Element Removal.............................................................................................................. 3-16
Element Installation........................................................................................................... 3-17
Element Cleaning and Inspection ..................................................................................... 3-17
Oil Draining ....................................................................................................................... 3-17
Fuel Tank ................................................................................................................................ 3-18
Fuel Tank Removal ........................................................................................................... 3-18
Fuel Tank Installation ........................................................................................................ 3-18
Fuel Tap Removal ............................................................................................................. 3-18
Fuel Tap Installation .......................................................................................................... 3-18
Fuel Tap Inspection........................................................................................................... 3-19
Fuel Tank and Tap Cleaning ............................................................................................. 3-19
Carburetor
Make/Type KEIHIN PB18 – – –
Main Jet #80 – – –
Main Air Jet #180 – – –
Jet Needle NCFA – – –
Throttle Valve Cutaway #3.0 – – –
Pilot Jet #38/38 – – –
Air Screw 1 1/4 turns out – – –
Idle Speed 1 250 ∼ 1 350 r/min (rpm) – – –
Service Fuel Level 3.0 ±1 mm (0.12 ±0.04 in.)
– – –
(below the bottom edge of carburetor body)
Float Height 10.7 ±2 mm (0.42 ±0.08 in.) – – –
Air Cleaner
Air Cleaner Element Oil High-quality foam-air filter oil – – –
Special Tool - Fuel Level Gauge: 57001-1017
• Put the fuel tank on a bench, and connect the fuel tap to
the carburetor using a suitable hose.
• Prepare a rubber hose [A].
• with the rubber
Connect the fuel gauge [B] to the carburetor float bowl
hose.
Special Tool - Fuel Level Gauge: 57001-1017
• Hold the gauge vertically against the side of the carburetor
body so that the "middle" line [C] is several millimeters
higher than the bottom edge of the carburetor body.
• Turn the fuel tap to the ON position to feed fuel to the
carburetor, then turn out the carburetor drain plug a few
turns.
• Wait until the fuel level [D] in the gauge settles.
• Keeping the gauge vertical, slowly lower the gauge until
the "middle" line is even with the bottom edge [E] of the
carburetor body.
NOTE
○Do not lower the "middle" line below the bottom edge of
the carburetor body. If the gauge is lowered and then
raised again, the fuel level measure shows somewhat
higher than the actual fuel level. If the gauge is lowered
too far, dump the fuel out of it into suitable container and
start the procedure over again.
If the fuel level is incorrect, the float level can not be ad-
justed on this model. Inspect the float, float valve needle,
and the contacting surface between the carburetor body
and its float valve needle. If they are damaged, replace
them.
• Install the carburetor.
Fuel Level Adjustment
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions. Always stop the en-
gine and do not smoke. Make sure the area is well
-ventilated and from any source of flame or sparks;
this includes any appliance with a pilot light.
• Remove
tainer.
the carburetor, drain the fuel into a suitable con-
• Remove the float bowl [A] taking out the screws [B] with
lockwashers.
• Check the float level.
[A] Float
[B] Float Valve Needle Rod (contacted but unloaded).
[C] Float bowl mating surface
[D] Float height
Float Height
10.7 ±2 mm (0.42 ±0.08 in.)
If the float height is incorrect, the float height can not be
adjusted on this model. Inspect the float, float valve nee-
dle.
NOTE
○Float height is the distance from the float bowl mat-
ing surface of the carburetor body (with the gasket re-
moved) to the top of the float.
○Do not push the needle rod in during the float height
measurement. Measure the height with the carburetor
upside down.
• Using a screwdriver, turn out the drain plug [A] a few turns
and drain the carburetor to a suitable container and check
to see if water or dirt come out.
If any water or dirt appears during the above inspection,
clean the fuel system.
• Tighten the drain plug securely.
Carburetor 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
light.
• 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 gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.
If the throttle valve is not removed from the cable,
wrap clean cloths around the throttle valve to avoid
damaging to it.
Carburetor Installation
• Installation is the reverse of removal.
•○Check fuel leakage
After installing the carburetor, perform the following.
from the carburetor.
WARNING
Fuel spilled from the carburetor is hazardous.
○Adjust the following.
Idle Speed
Throttle Grip Free Play
Carburetor Cleaning
WARNING
Clean the carburetor in a well-ventilated area, and
take care that there is no spark or flame anywhere
near the working area; this includes any appliance
with a pilot light. Because of the danger of high
flammable liquids, do not use gasoline or low flash
-point solvents to clean the carburetor.
• Pull out the retainer [A], and jet needle with circlip [B].
Carburetor Assembly
• Clean the disassembly parts before assembling.
• solventtheandfuelcompressed
Clean and air passages with a high-flash-point
air.
• smaller diameter end [B] ofintothethejet carburetor
Install the needle jet [A] so that the
goes in first.
• Turn in the air screw [A] fully but not tightly, and then back
it out 1 1/4 turns.
•○After installing the carburetor, do the following.
Check the fuel leakage.
○Adjust the following items if necessary.
Throttle grip free play.
Idle speed.
• Check that the throttle valve [A] moves smoothly and re-
turn back with the spring tension. The surface of the valve
must not be excessively worn.
If the throttle valve does not move smoothly, or if it is very
loose in carburetor body, replace the carburetor.
If the spring tension is weak, replace it.
• 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.
• Check the jet needle [A] and needle jet holder [B] for wear.
A worn needle jet holder or jet needle should be replaced.
• Check the tapered portion [A] of the pilot screw [B] for
wear or damage.
If the pilot screw is worn or damaged on the tapered por-
tion it will prevent the engine from idling smoothly. Re-
place it.
Element Removal
• Remove the left shroud.
• Unscrew the mounting screws [A] and remove the air
cleaner housing cover [B].
Element Installation
• When installing the element, coat the lip of the element
with a thick layer of all purpose grease [A] to assure a
complete seal against the air cleaner element base. Also,
coat the base and wire screen where the lip of the element
fits.
• Remove:
Shrouds
Seat
• Turn the fuel tap to the OFF position.
• Pull the fuel hose off the fuel tap.
• Remove the fuel tank mounting bolt [A] and band [B].
• Remove the fuel tank [C].
• Drain the fuel tank.
• Remove the fuel tank mounting bolt and band, and move
the fuel tank [A] backward.
• Remove the camshaft chain tensioner [B] while the push
rod [E] clockwise [D] and compressing [F] it with a suitable
screwdriver [C].
CAUTION
Do not pull the rod holder plate while the tensioner
is removed. This could detach the rod and the ten-
sioner cannot be installed easily.
• Pull the lower side of the chain taut and fit it onto the
sprocket so that the line [A] on the sprocket aligns with
the mark on the sprocket cover mating surface projection
[B].
• Remove
[B].
the camshaft chain holder [A] and chain guides
• While holding the rocker arm [A] with hand, pull out the
rocker arm shaft [B] and take off the rocker arms.
○Mark and record the rocker arm locations so that the
rocker arm can be reinstalled in their original positions.
Camshaft Installation
• Clean the camshaft with a high-flash-point solvent.
• Install the camshaft
Apply clean engine oil to all cam parts.
• Install the rocker arm.in the cylinder head.
• Install the other removed parts.
•○Check and adjust the valve clearance.
Camshaft Inspection
• Visually inspect the cam for wear or damage.
If there is any damage or wear, replace the camshaft.
• Measure the height [A] of each cam.
Cam Height
Standard:
Exhaust 29.021 ∼ 29.201 mm (1.1426 ∼ 1.1496 in.)
Inlet 28.984 ∼ 29.164 mm (1.1411 ∼ 1.1482 in.)
Service Limit:
Exhaust 28.92 mm (1.139 in.)
Inlet 28.88 mm (1.137 in.)
If any cam is worn down past service limit, replace the
camshaft.
Camshaft Bearing Inspection
• Visually inspect each camshaft bearing [A].
If there is any damage replace the camshaft.
• Turn the bearing back and forth while checking for rough-
ness or binding.
If roughness or binding is found, replace the camshaft.
If it is noisy, does not spin smoothly, or has any rough
spots, replace the camshaft.
The following table should be consulted if the obtainable compression reading is not within the us-
able range.
Problem Diagnosis Remedy (Action)
Cylinder compression is Carbon accumulation on piston and Remove the carbon deposits
higher than usable range in combustion chamber possibly and replace damaged parts if
due to damaged valve stem oil seal necessary.
and/or damaged position oil rings
(This may be indicated by white
exhaust smoke).
Incorrect cylinder head gasket, Replace the gasket with a
cylinder base gasket thickness. standard part.
Cylinder compression is Gas leakage around cylinder head. Replace damaged gasket and
lower than usable range check cylinder head warp.
Bad condition of valve seating. Repair if necessary.
Incorrect valve clearance. Adjust the valve clearance.
Incorrect piston/cylinder clearance. Replace the piston and/or
cylinder
Piston seizure. Inspect the cylinder (and liner)
and replace/repair the cylinder
and/or piston as necessary.
Bad condition of piston ring and/or Replace the piston and/or the
piston ring grooves. piston rings.
• Remove the compression gauge, adapter and install the
spark plug.
Torque - Spark Plug: 13 N·m (1.3 kgf·m, 113 in·lb)
• Remove the oil pipe banjo bolts [A], screws [B], and take
off the oil pipe [C].
• Remove the spark plug cap [D].
• Remove the cylinder head bolts [A], nuts [B], and take off
the cylinder head.
NOTE
○The valve stem and guide must be in good condition or
this check will not be valid.
If the valve seating pattern is not correct, repair the seat.
• Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a
vernier caliper.
Good [F]
If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat (see Seat Repair).
Valve Seat Width
Standard:
Exhaust 0.80 ∼ 1.15 mm (0.0315 ∼ 0.0453 in.)
Inlet 0.80 ∼ 1.15 mm (0.0315 ∼ 0.0453 in.)
○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 seat outside diameter frequently to pre-
vent overgrinding.
○After making the 32° grind, return to the seat O.D. mea-
surement step above.
• To measure the seat width, use a vernier calipers to mea-
sure the width of the 45° angle portion of the seat at sev-
eral places around the seat.
If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too width, and then return to the seat
O.D. measurement step above.
If the seat width is too wide, make the 60° or 67.5° [A]
grind described below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
•Grind the seat at a 60° or 67.5° angle until the seat width
is within the specified range.
○To make the 60° or 67.5° grind, fit 60° or 67.5° cutter to
the holder, and slide it into the valve guide.
○Turn the holder, while pressing down lightly.
○After making the 60° or 67.5° grind, return to the seat
width measurement step above.
Correct Width [B]
• Lap the valve to the seat using a lapper, once the seat
width and O.D. are within the ranges specified above.
○Put a little coarse grinding compound on the face of the
valve in a number of places around the valve head.
○Spin the valve against the seat until the grinding com-
pound produces a smooth, matched surface on both the
seat and the valve.
○Repeat the process with fine grinding compound.
Lapper [A]
Valve Seat [B]
Valve [C]
•The seating area should be marked about in the middle
of the valve face.
If the seat area is incorrect place on the valve, be sure
to check the valve is the correct part. If it is, it may have
been refaced too much replace the valve.
•Be sure to remove all grinding compound before assem-
bly.
•When the engine is assembled, be sure to adjust the valve
clearance (see Valve Clearance Adjustment in the Peri-
odic Maintenance chapter).
• Repeat
the first.
the measurement in a direction at a right angle to
Cylinder Installation
NOTE
○If the cylinder block is replaced with a new one, piston to
cylinder clearance must be checked against the speci-
fied value.
• Pull the camshaft chain taut top avoid kicking it and use
a wrench on the crankshaft to set the piston at BTDC.
• Position the piston ring opening as follows.
Top Ring - Front [A]
Second Ring - Rear [B]
Upper Steel Rail - About 30° ∼ 90° of angle to the right
[C]
Expander - Rear [D]
Lower Steel Rail - About 30° ∼ 90° of angle to the left [C]
Piston [E]
• Apply engine oil to the piston rings and the cylinder inside
surface.
• Pull the camshaft chain up through the cylinder and insert
a screwdriver to keep the chain from falling back into the
engine.
• Place the upper camshaft chain guide inside the cylinder
blocks.
• Fit the bottom of the cylinder over the piston rings, press-
ing in on opposite sides of the rings as necessary. Take
care that the rings do not slip out of their proper positions.
• Insert the lower camshaft chain guide [A] all the way
down.
• Install the cylinder head.
• 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: 57001-910
Piston Installation
NOTE
○The oil ring rails have no "top" or "bottom".
• Install the oil ring expander [A] in the bottom piston ring
groove so that the ends [B] but together, never overlap.
• Install the oil ring steel rails, one above the expander and
one below it.
○Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
○Release the rail into the bottom piston ring groove.
• With the marked side facing up, install the second ring [A]
and top ring [B] in that order.
• Fit a new piston snap ring into the side of the piston so
that the ring opening [A] does not coincide with the slit [B]
of the piston pin hole.
○When installing a piston pin snap ring, compress it only
enough to install it no more.
CAUTION
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.
NOTE
○Abnormal wear such as a marked diagonal pattern
across the piston skirt may mean a bent connecting
rod or crankshaft.
NOTE
○Whenever the piston or cylinder has been replaced with
a new one, the motorcycle must be broken in the same
as with a new machine.
Boring, Honing
When boring and honing a cylinder, note the following:
○There are two sizes of oversize pistons available. Over-
size pistons require oversize rings.
Oversize Pistons and Rings
0.5 mm (0.0197 in.) Oversize
1.0 mm (0.0394 in.) Oversize
○Before boring a cylinder, first measure the exact diame-
ter of the service data section, oversize piston, and then,
according to the standard clearance in the determine the
rebore diameter. However, if the amount of boring nec-
essary would make the inside diameter greater than 1.0
mm oversize, the cylinder block must be replaced.
○Cylinder inside diameter must not vary more than 0.01
mm at any point.
○Be wary of measurements taken immediately after boring
since the heat affects cylinder diameter.
○In the case of a rebored cylinder and oversize piston, the
service limit for the cylinder is the diameter that the cylin-
der was bored to plus 0.1 mm and the service limit for
the piston is the oversize piston original diameter minus
0.20 mm. If the exact figure for the rebored diameter is
unknown, it can be roughly determined by measuring the
diameter at the base of the cylinder.
• Pull out the muffler mounting bolt and remove the muffler
assembly.
Muffler Installation
• Check the gasket and replace it if damaged.
• oughly warm upthethemounting
After tightening bolt and nuts securely, thor-
engine, wait until the engine cools
down and tighten all mounting bolt and nuts.
Spark Arrester Cleaning
• Refer to the Spark Arrester Cleaning in the Periodic Main-
tenance chapter.
Clutch
Table of Contents
Exploded View (KLX110-A1) .................................................................................................. 5-2
Exploded View (KLX110-A2 ∼ ) .............................................................................................. 5-4
Specifications ......................................................................................................................... 5-6
Clutch Cover........................................................................................................................... 5-7
Clutch Cover and Oil Screen Removal ............................................................................. 5-7 5
Clutch Cover and Oil Screen Installation .......................................................................... 5-8
Clutches.................................................................................................................................. 5-9
Clutch Removal................................................................................................................. 5-9
Clutch Installation.............................................................................................................. 5-9
Secondary Clutch Disassembly ........................................................................................ 5-11
Secondary Clutch Assembly ............................................................................................. 5-12
Primary Clutch Housing Wear Inspection ......................................................................... 5-12
Primary Clutch Shoe Lining Wear Inspection ................................................................... 5-13
One-Way Clutch Inspection .............................................................................................. 5-13
Clutch Plate Wear and Damage Inspection ...................................................................... 5-14
Clutch Plate Warp Inspection............................................................................................ 5-14
Secondary Clutch Housing Finger Damage Inspection .................................................... 5-14
Secondary Clutch Hub Spline Damage Inspection ........................................................... 5-15
Secondary Clutch Spring Free Length Measurement....................................................... 5-15
Clutch Adjustment............................................................................................................. 5-15
Kickstarter............................................................................................................................... 5-16
Kickstarter Removal.......................................................................................................... 5-16
Kickstarter Installation....................................................................................................... 5-16
Kickstarter Assembly ........................................................................................................ 5-16
Kickstarter Inspection........................................................................................................ 5-17
External Shift Mechanism....................................................................................................... 5-18
External Shift Mechanism Removal .................................................................................. 5-18
External Shift Mechanism Installation ............................................................................... 5-18
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]
• Install the clutch cover. Be sure that the release cam [A],
and release ball assembly [B] are not falling down.
KLX110-A1 ∼ A7F
•Tighten the clutch cover screws following the tightening
sequence.
Torque - Clutch Cover Screws: 5.2 N·m (0.53 kgf·m, 46
in·lb)
KLX110A8F ∼
•Tighten the clutch cover bolts following the tightening se-
quence.
Torque - Clutch Cover Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb)
• Adjust the clutch.
• Install the kick pedal [A] to the kick shaft [B], as shown.
• Remove the primary clutch hub nut [A], while holding the
primary clutch steady with the primary clutch holder [B].
Special Tool - Primary Clutch Holder: 57001-1507
• Pull out the primary clutch hub [C].
• Remove
together.
the primary clutch [A] and secondary clutch [B]
Clutch Installation
• Apply engine oil to the clutch sleeves, drive shaft, and
crankshaft.
• Install the spacer [A] to the drive shaft.
•○Be sure to secondary
Insert the clutch.
install the spacer [B] between secondary clutch
housing and clutch wheel. (KLX110-A1)
○Hard to install the secondary clutch, turn the drive shaft
while pushing the clutch.
• Tighten the secondary clutch nut, while holding the sec-
ondary clutch holder.
Torque - Secondary Clutch Hub Nut: 72 N·m (7.3 kgf·m, 53
ft·lb)
Special Tool - Clutch Holder: 57001-1508
• 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 [D].
○Fit the tooth form of the gears, and press the holder to the
clutch housing.
○Before installing the clutch housing, mark [E] on the tip of
optional tooth (1 place).
○The gear shall be rotated clockwise [F] more than 1 tooth
and less than 2 teeth. (Confirm that making is rotated).
•Install the clutch housing.
KLX110-A2 ∼
• Install the plate with the line mark [A] facing out, noting
the proper position.
• Apply
bly.
grease to the release cam and release ball assem-
• Install the release cam [A] and release ball assembly [B].
• shaft line
Install the release lever [C] to the shift shaft, with shift
[D] aligning to release lever line [E].
• Adjust the clutch
Install the cover.
• clutch.
• Install the last friction plate [A] fitting the tangs in the
grooves on the housing as shown.
• Tighten the clutch spring bolts.
Torque - Secondary Clutch Spring Bolts:
3.4 N·m (0.35 kgf·m, 30 in·lb)
5.0 N·m (0.51 kgf·m, 44 in·lb) KLX110-A3 ∼
KL110-A2 ∼
Clutch Adjustment
• Refer to the Clutch Adjustment in the Periodic Mainte-
nance chapter.
Kickstarter Installation
• Apply molybdenum disulfide grease to the thrust washer.
• kick shaftthrust
Put the washer [A] on the kick shaft end, and fit the
assembly in the crankcase.
• Fit the return spring end into the kick shaft, turn the spring
clockwise and insert the other end of the spring into the
crankcase.
• Install the plastic spring guide.
• Install the clutch cover.
Kickstarter Assembly
• Apply a thin coat of molybdenum disulfide grease [A] to
the ratchet teeth and the kick gear inside.
Ratchet [B]
Kick Gear [C]
Kick Shaft [D]
Spring Guide [E]
Return Spring [F]
CAUTION
Misalignment of the ratchet changes the kick
spring preload. Light preload could cause mech-
anism noise and heavy preload could weaken or
break the spring.
• Measure
fits.
the kick shaft diameter [A] where the kick gear
• Install the shift pedal [A] to the shift shaft so that the pedal
upper surface [B] is level with the footpeg upper surface
[C].
WARNING
Clean the oil screen 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 the oil screen. A fire or explosion could re-
sult.
Replace the screen with a new one if it is damaged.
• Install:
Oil Screen
Clutch Cover
WARNING
Take care against burns form hot engine oil that
will drain through the oil passage when the gauge
adapter is removed.
• Install the oil filter cap (see Oil Filter Element Replace-
ment in the Periodic Maintenance chapter).
Engine Removal/Installation
Table of Contents
Exploded View........................................................................................................................ 7-2
Engine Removal/Installation ................................................................................................... 7-4
Engine Removal................................................................................................................ 7-4
Engine Installation............................................................................................................. 7-6
WARNING
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. It could
cause an accident and injury.
• Remove
Shift Pedal [A]
Engine Sprocket Cover [B]
• Remove the bolts [A] and take off the front footpeg bracket
[B] with side stand.
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 bolts from left side of the engine.
• Tighten the engine mounting nuts.
Torque - Engine Mounting Nuts: 54 N·m (5.5 kgf·m, 40 ft·lb).
• Install the removed parts.
• Adjust the drive chain (see Final Drive chapter).
Crankshaft / Transmission
Table of Contents
Exploded View........................................................................................................................ 8-2
Specifications ......................................................................................................................... 8-4
Crankcase Splitting................................................................................................................. 8-5
Crankcase Splitting ........................................................................................................... 8-5
Crankcase Assembly ........................................................................................................ 8-5
Crankshaft, Connecting Rod .................................................................................................. 8-8
Crankshaft Disassembly and Assembly............................................................................ 8-8
Disassembly...................................................................................................................... 8-8
Assembly .......................................................................................................................... 8-8
Connecting Rod Big End Seizure Inspection .................................................................... 8-9
Connecting Rod Big End Radial Clearance Inspection.....................................................
Connecting Rod Big End Side Clearance Inspection........................................................
8-9
8-9
8
Crankshaft Runout Inspection........................................................................................... 8-10
Crankshaft Alignment Inspection ...................................................................................... 8-10
Crankshaft Main Bearing Wear Inspection ....................................................................... 8-11
Transmission .......................................................................................................................... 8-12
Transmission and Shift Mechanism Removal ................................................................... 8-12
Transmission Disassembly ............................................................................................... 8-12
Transmission Assembly .................................................................................................... 8-12
Transmission and Shift Mechanism Installation ................................................................ 8-13
Shift Fork Bending Inspection ........................................................................................... 8-14
Shift Fork Ear/Gear Shift Fork Groove Wear Inspection................................................... 8-14
Shift Fork Guide Pin/Shift Drum Groove Wear Inspection ................................................ 8-14
Gear Dog/Gear Dog Hole Damage Inspection ................................................................. 8-15
Ball and Needle Bearing Wear Inspection ........................................................................ 8-15
Oil Seal Inspection ............................................................................................................ 8-15
CAUTION
Do not remove the ball, needle bearings and the oil
seals unless it is necessary. Removal may damage
them.
• Chip off the old gasket from the mating surfaces of the
crankcase halves.
• Using compressed air, blow out the oil passages [A] in the
crankcase halves and the crankshaft.
• With a high-flash-point solvent, clean off the mating sur-
faces of the crankcase halves and wipe dry.
• Using a press and the bearing driver set, install new bear-
ings until they bottoms out.
○Press the output shaft bearing [B] in the left crankcase
half [A].
Special Tool - Bearing Driver Set: 57001-1129
• Apply high-temperature grease to the lips of the oil seals.
• the sealin surface
Press the oil seals [C] of the left crankcase half so that
is flush with the end of the hole.
• Install:
Shift Drum [A]
Transmission Shaft Assemblies [B]
Shift Forks [C]
• Check that the shift drum is in neutral position.
• Check that two dowel pins [A], O-rings [B] and drive shaft
spacer [C] in place.
• Fit the crankcase halves together hitting with a plastic
hammer on the left crankcase side.
Disassembly
• IfRemove
it should be necessary to disassemble the crankshaft.
• using thethe camshaft chain drive sprocket and bearing,
bearing puller if the drive sprocket and bearing
remains on the crankshaft.
• Remove the camshaft chain drive sprocket, oil pump gear
and bearings, using the bearing puller. (KLX110-A2 ∼ )
• Use a press to remove the crankpin.
• Removal of the crankpin separates the flywheels, con-
necting rod, big end needle bearing, and crankpin.
Special Tool - Bearing Puller: 57001-158
Assembly
• Press the bearing until it bottoms out.
• wheel as shown.
Press the camshaft chain drive sprocket on to the left fly-
Sprocket [A]
Crank Pin [B]
28.4 ±0.3 mm (1.12 ±0.01 in.) [C]
KLX110-A2 ∼
•Press the bearings until it bottoms out.
•Press the camshaft chain sprocket [A] oil pump gear [B]
until it bottoms out on to the left and right flywheels as
shown.
•Align bottom of sprocket tooth with opposit direction [C]
of crank pin [D].
KLX110-A2 ∼
• Incorrect
the case of both horizontal and vertical misalignment,
the horizontal misalignment first.
• (see Connecting
Recheck big end side clearance after aligning crankshaft
Rod Big End Side Clearance).
NOTE
○Ifcrankshaft alignment cannot be corrected by the
above method, replace the crankpin or crank halves as
required. Recheck the runout and repeat the process
until the runout is within service limit.
CAUTION
Don’t hammer the flywheel at the point [A].
• Remove
pin [D].
the cam holder [B], shift drum cam [C] and dowel
Transmission Assembly
•○Assemble the transmission gears as shown.
Replace the old circlip with a new one if it is removed.
○The drive shaft gears can be identified by size; the small-
est diameter gear is 1st gear, and the largest is 4th (not
working). Be sure that all parts are put back in the correct
sequence, facing the proper direction, and that the circlip
and the washer are properly in place.
2nd Gear [A]
3rd Gear [B]
4th Gear (not working) [C]
1st Gear [D]
Circlip [E]
Shim [F]
Apply Engine Oil [G]
Bushing [H]: KLX110-A2 ∼
• Apply a clean engine oil to the shift fork fingers, and fit
each shift fork into its gear-groove so that the shift fork
guide pin is in the proper shift drum-groove.
NOTE
○Fingers of the 1st/3rd shift fork are longer than the fin-
gers of the 2nd/4th shift fork.
• Apply a clean engine oil to the shift rods [A], and insert
each rod running it through each shift fork [B].
• Set the shift drum in neutral position, that is, drive and
output shaft turn freely.
• Assemble the crankcase.
• Measure the width [A] of the gear shift fork grooves in the
transmission gears.
If a gear shift fork groove is worn over the service limit,
the gear must be replaced.
Gear Shift Fork Groove Width
Standard: 4.05 ∼ 4.15 mm (0.159 ∼ 0.163 in.)
Service Limit: 4.3 mm (0.17 in.)
If any shift drum groove is worn over the service limit, the
drum must be replaced.
Shift Drum Groove Width
Standard: 5.05 ∼ 5.20 mm (0.199 ∼ 0.205 in.)
Service Limit: 5.3 mm (0.21 in.)
Wheels/Tires
Table of Contents
Exploded View........................................................................................................................ 9-2
Specifications ......................................................................................................................... 9-4
Wheels (Rims) ........................................................................................................................ 9-5
Front Wheel Removal ....................................................................................................... 9-5
Front Wheel Installation .................................................................................................... 9-5
Rear Wheel Removal........................................................................................................ 9-5
Rear Wheel Installation..................................................................................................... 9-6
Axle Inspection.................................................................................................................. 9-7
Tires........................................................................................................................................ 9-8
Air Pressure Inspection/Adjustment.................................................................................. 9-8
Tires Inspection................................................................................................................. 9-8
Tire Removal..................................................................................................................... 9-9
Tire Installation.................................................................................................................. 9-10
Hub Bearing............................................................................................................................ 9-11
9
Hub Bearing Removal....................................................................................................... 9-11
Hub Bearing Installation.................................................................................................... 9-11
Bearing Inspection ............................................................................................................ 9-11
Bearing Lubrication ........................................................................................................... 9-12
• Fit the tongue [B] on the fork leg into the groove [A] on the
front brake panel.
• 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 its allowable
spring extension.
• To remove the brake rod end from the brake cam lever,
first turn the brake panel clockwise [A] as far as it will go,
then depress the brake pedal lightly, the brake rod [B] will
be separated from the brake cam lever joint [C].
• Pull out the rear axle and remove the rear wheel from the
rear wheel coupling and from the motorcycle.
• Insert the cotter pins [A] through the torque link bolts [B]
and spread its ends.
• Insert the cotter pin through the axle nut to rear axle and
spread its ends.
• Adjust:
Drive Chain Slack (see Final Drive chapter)
Brake Pedal Free Play (see Brakes chapter)
Axle Inspection
• Visually inspect the front and rear axle for damages.
If the axle is damaged or bent, replace it.
• Place the axle in V blocks that are 100 mm (Rear Axle:
110 mm) [A] apart, and set a dial gauge on the axle at a
point halfway between the blocks.
• Turn the axle to measure the runout. The difference be-
tween the highest and lowest dial readings is the amount
of runout.
If runout exceeds the service limit, replace the axle.
Axle Runout/100 mm (4.0 in.) Rear Axle: 110 mm (4.3 in.)
Standard: 0.1 mm (0.004 in.)
Service Limit: 0.2 mm (0.008 in.)
NOTE
○Check and balance the wheel when a tire is replaced
with a new one.
Standard Tire
Front:
Size: 2.50-14 4PR
2.50-14 M/C 4PR (KLX110-A2 ∼ )
Make: CHENG SHIN
Type: C803
Rear:
Size: 3.00-12 4PR
3.00-12 M/C 4PR (KLX110-A2 ∼ )
Make: CHENG SHIN
Type: C803
• Break the beads away from both sides of the rim with the
bead breaker [A].
Special Tool - Bead Breaker Assembly: 57001-1072
• Step on the side of the tire opposite valve stem, pry the
tire off the rim with the tire iron [A] of the bead breaker
protecting the rim with rim protectors [B].
Special Tools - Rim Protector: 57001-1063
Tire Iron Protection of the Bead Breaker As-
sembly: 57001-1072
CAUTION
Take care not to insert the tire irons so deeply that
the tube gets damaged.
• Remove the tube when one side of the tire is pried off.
• Pry the tire off the rim.
• Pry one side of the tire back onto the rim. Fit the bead
protector into the tire.
• Pry the other side of the tire onto the rim, starting at the
side opposite the valve.
○Take care not to insert the tire irons so deeply that the
tube is damaged.
• Install the other side of the tire bead onto the rim in the
same manner.
• Check that the tube is not pinched between the tire and
rim.
• Tighten the bead protector nut and valve stem nut.
• Check and adjust the air pressure after installing.
• Install the air valve cap.
NOTE
○For correct tire alignment, the right bearing must be in-
stalled first rather than left bearing in both front and rear
hubs.
Bearing Inspection
Since the hub bearings are made to extremely close tol-
erances, the clearance cannot normally be measured.
CAUTION
Do not remove any bearings for inspection. If any
bearings are removed, they will need to be replaced
with new ones.
• Turn each bearing in the hub back and forth [A] while
checking for plays, roughness, or binding. If bearing play,
roughness, or binding is found, replace the bearing.
• Examine the bearing seal [B] for damage or leakage.
If the seal is damaged or is leaking, replace the bearing.
Final Drive
Table of Contents
Exploded View........................................................................................................................ 10-2
Specifications ......................................................................................................................... 10-4
Drive Chain............................................................................................................................. 10-5
Chain Slack Inspection ..................................................................................................... 10-5
Chain Slack Adjustment.................................................................................................... 10-5
Drive Chain Removal ........................................................................................................ 10-5
Drive Chain Installation ..................................................................................................... 10-5
Chain Wear Inspection...................................................................................................... 10-5
Chain Lubrication .............................................................................................................. 10-5
Sprockets, Coupling ............................................................................................................... 10-6
Engine Sprocket Removal ................................................................................................ 10-6
Engine Sprocket Installation ............................................................................................. 10-6
Rear Sprocket Removal.................................................................................................... 10-7
Rear Sprocket Installation................................................................................................. 10-7
Sprocket Wear Inspection................................................................................................. 10-7
Rear Sprocket Warp Inspection ........................................................................................ 10-7 10
Coupling Bearing Removal ............................................................................................... 10-7
Coupling Bearing Installation ............................................................................................ 10-8
Coupling Bearing Inspection and Lubrication ................................................................... 10-8
Coupling Damper Inspection............................................................................................. 10-8
• 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
• If-flash-point
the bearing is to be used again, rewash it with a high
solvent, dry it, and pack it with good quality
bearing grease. Turn the bearing around by hand a few
times to make sure the grease [A] is distributed uniformly
inside the bearing, and wipe the old grease out of the
coupling before bearing installation.
Brakes
Table of Contents
Exploded View........................................................................................................................ 11-2
Specifications ......................................................................................................................... 11-6
Brake Lever, Brake Pedal....................................................................................................... 11-7
Brake Lever, Brake Pedal Free Play Inspection ............................................................... 11-7
Front Brake Free Play Adjustment.................................................................................... 11-7
Brake Pedal Free Play Adjustment ................................................................................... 11-7
Brake Cable Removal ....................................................................................................... 11-7
Brake Cable Installation .................................................................................................... 11-7
Brake Cable Lubrication.................................................................................................... 11-7
Brake Pedal and Rod Removal......................................................................................... 11-7
Brake Pedal and Rod Installation...................................................................................... 11-8
Brake Panel and Drum ........................................................................................................... 11-9
Brake Lining Wear Inspection ........................................................................................... 11-9
Cam Lever Angle Adjustment ........................................................................................... 11-9
Brake Panel Removal ....................................................................................................... 11-9
Brake Panel Installation .................................................................................................... 11-9
Brake Panel Disassembly ................................................................................................. 11-9
Brake Panel Assembly...................................................................................................... 11-10 11
Brake Drum Wear Inspection............................................................................................ 11-10
Brake Shoe Lining Wear Inspection.................................................................................. 11-11
Camshaft Wear Inspection................................................................................................ 11-11
Brake Shoe Springs Inspection......................................................................................... 11-12
Brake Panel Lubrication.................................................................................................... 11-12
• Apply
-rings.
a multi purpose grease to the pedal pivot and O
• Remove
wheel.
the wheel and separate the brake panel from the
Suspension
Table of Contents
Exploded View........................................................................................................................ 12-2
Specifications ......................................................................................................................... 12-6
Front Fork ............................................................................................................................... 12-7
Fork Oil Level Check (Simplify)......................................................................................... 12-7
Oil Change/Oil Level Adjustment (each fork leg) .............................................................. 12-7
Front Fork Removal .......................................................................................................... 12-8
Front Fork Installation ....................................................................................................... 12-8
Front Fork Disassembly (each fork )................................................................................. 12-8
Front Fork Assembly (each fork)....................................................................................... 12-10
Front Fork Inner Tube Inspection...................................................................................... 12-10
Dust Seal/Oil Seal Inspection ........................................................................................... 12-11
Spring Tension Inspection................................................................................................. 12-11
Rear Shock Absorber ............................................................................................................. 12-12
Removal ........................................................................................................................... 12-12
Installation......................................................................................................................... 12-12
Rear Shock Absorber Inspection ...................................................................................... 12-12
Rear Shock Absorber Scrapping ...................................................................................... 12-12
Swingarm................................................................................................................................ 12-13
Swingarm Removal........................................................................................................... 12-13
Swingarm Installation........................................................................................................ 12-13 12
Swingarm Rubber Bushing Inspection.............................................................................. 12-13
Fork Spring
WARNING
The top plugs are under extreme spring force. Use
care when removing the top plugs. Wear eye and
face protection.
• 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].
Oil Seal
Bottom Allen Bolt Washer
•Inspect the following and replace them with new ones if
damaged.
Inner Tube (see Inner Tube Insspection)
Top Plug O-ring
•Insert the cylinder unit and spring in the inner tube.
•Insert the cylinder base [A] in the cylinder unit [B].
○The cylinder base must be installed with the tapered side
facing upward.
•Insert the inner tube and cylinder unit as a set into the
outer tube.
Replace it if necessary.
• Replace the oil seal [A] with a new one whenever it has
been removed.
Installation
• Press in the rubber bushings [A] as shown.
• Install the shock absorber.
• Tighten the shock absorber mounting bolt and nut.
Torque - Rear Shock Absorber Mounting Nut
Upper: 39 N·m (4.0 kgf·m, 29 ft·lb)
Lower: 39 N·m (4.0 kgf·m, 29 ft·lb)
• Remove:
Torque Link [A]
Chain Guide [B]
Chain Slipper [C]
Chain Cover [D]
• To remove the rubber bushing [E] at the pivot, tap out the
bushing with a suitable tool.
Swingarm Installation
• Installation is the reverse of removal.
• Tighten the pivot
Press in the rubber bushings [A] as shown.
• absorber. shaft nut after installed the rear shock
Steering
Table of Contents
Exploded View........................................................................................................................ 13-2
Specifications ......................................................................................................................... 13-4
Steering .................................................................................................................................. 13-5
Steering Inspection ........................................................................................................... 13-5
Steering Adjustment.......................................................................................................... 13-5
Steering Stem Removal .................................................................................................... 13-5
Steering Stem Installation ................................................................................................. 13-5
Steering Stem Race Removal........................................................................................... 13-6
Steering Stem Race Installation Notes ............................................................................. 13-7
Steering Stem Bearing Lubrication ................................................................................... 13-7
Steering Stem Bearing Inspection .................................................................................... 13-7
Steering Stem Warp Inspection ........................................................................................ 13-7
Handlebar ............................................................................................................................... 13-8
Handlebar Removal .......................................................................................................... 13-8
Handlebar Installation ....................................................................................................... 13-8
13
• Remove:
Steering Stem Cap [A]
Upper Inner Race [B]
Upper Steel Balls [C]
○There are 23 steel balls installed in the upper outer race.
• 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 stem locknut,
and pull the wrench at the hole by 22.2 kg force [B] in the
direction shown).
Special Tool - Steering Stem Nut Wrench: 57001-1100
○Check that there is no play and the steering stem turns
smoothly without rattles. If not, the steering stem bearings
may be damaged.
○Again back out the stem locknut a fraction of a turn until
it turns lightly.
○Turn the stem locknut lightly clockwise until it just be-
comes hard to turn. Do not overtighten, or the steering
will be too tight.
Torque - Steering Stem Locknut: 4.9 N·m (0.5 kgf·m, 43
in·lb)
• Install the front fork (see the Suspension chapter).
NOTE
○Tighten the fork upper clamp bolts first, next the stem
head nut, last the fork lower clamp bolt.
Torque - Steering Stem Head Nut: 44 N·m (4.5 kgf·m, 32
ft·lb)
Front Fork Clamp Bolt:
Upper: 20 N·m (2.0 kgf·m, 15 ft·lb)
Lower: 29 N·m (3.0 kgf·m, 22 ft·lb)
• Install the parts removed (see the appropriate chapter).
WARNING
Do not impede the handlebar turning by routing the
cables, wires and hoses improperly (see the Gen-
eral Information chapter).
• Drive the lower inner race [A] onto the steering stem using
the stem bearing driver [B].
Special Tool - Steering Stem Bearing Driver: 57001-137
Handlebar Installation
• Apply adhesive cement to the inside of the left handlebar
grip [A].
Electrical System
Table of Contents
Exploded View........................................................................................................................ 14-2
Specifications ......................................................................................................................... 14-4
Wiring Diagram....................................................................................................................... 14-5
Precautions............................................................................................................................. 14-6
Electrical Wiring...................................................................................................................... 14-7
Wiring Inspection .............................................................................................................. 14-7
Magneto Flywheel .................................................................................................................. 14-8
Magneto Cover Removal .................................................................................................. 14-8
Magneto Cover Installation ............................................................................................... 14-8
Magneto Cover Disassembly ............................................................................................ 14-8
Magneto Cover Assembly................................................................................................. 14-9
Magneto Flywheel Removal.............................................................................................. 14-9
Magneto Flywheel Installation........................................................................................... 14-9
Magneto Flywheels Inspection.......................................................................................... 14-10
Regulator/Rectifier Inspection........................................................................................... 14-10
Ignition System ....................................................................................................................... 14-11
Igniter Removal................................................................................................................. 14-11
Exciter Coil Resistance Measurement .............................................................................. 14-11
Crankshaft Sensor Resistance Measurement .................................................................. 14-11
Ignition Coil Removal ........................................................................................................ 14-12
Ignition Coil Installation ..................................................................................................... 14-12
Ignition Coil Inspection...................................................................................................... 14-12
Spark Plug Removal/Installation ....................................................................................... 14-13
Spark Plug Gap................................................................................................................. 14-13 14
Spark Plug Cleaning and Inspection................................................................................. 14-13
Igniter Inspection............................................................................................................... 14-13
Switches ................................................................................................................................. 14-17
Switch Inspection .............................................................................................................. 14-17
Gear Position Switch Removal ......................................................................................... 14-17
Gear Position Switch Installation ...................................................................................... 14-17
Gear Position Switch Inspection: ...................................................................................... 14-18
• Remove:
Magneto Cover Screws [A] (KLX110-A1 ∼ A7F)
Magneto Cover Bolts [A] (KLX110A8F ∼)
Magneto Cover [B]
KLX110-A1 ∼ A7F
•Tighten the magneto cover screws following the tighten-
ing sequence as shown.
Torque - Magneto Cover Screws: 5.2 N·m (0.53 kgf·m, 46
in·lb)
KLX110A8F ∼
•Tighten the magneto cover bolts following the tightening
sequence as shown.
Torque - Magneto Cover Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb)
• Fill the engine with engine oil (see Engine Lubrication
System chapter).
Magneto Cover Disassembly
• Remove
moval).
the magneto cover (see Magneto Cover Re-
• Remove:
Screws [A]
Clamps [B]
Crankshaft Sensor Screws [C]
Exciter Coil Screws [D]
• Pull the wiring grommet.
• Remove the crankshaft sensor and stator as a set.
• Thread the flywheel puller [A] and rotor puller [B] onto the
flywheel [C].
• Holding the flywheel puller, turn the rotor puller until the
flywheel is forced off the end of the crankshaft.
• Using the flywheel and rotor pullers, remove the magneto
flywheel.
Special Tools - Rotor Puller, M16/M18/M20/M22 × 1.5: 57001
-1216
Flywheel Puller, M28 × 1.0: 57001-1471
CAUTION
If the rotor is difficult to remove, turn the puller shaft
using a wrench while tapping the head of the puller
shaft with a hammer. Do not attempt to strike the
grab bar or the alternator rotor itself. Striking the
bar or the rotor can cause the bar to bend or the
magnets to lose their magnetism.
CAUTION
Use only Hand Tester 57001-1394 for this test. An
ohmmeter other than the Hand Tester may show
different readings. If a megger or a meter with a
large-capacity battery is used, the regulator will be
damaged.
CAUTION
Do not disconnect the electrical connections while
the engine is running. This is to prevent igniter
damage.
The negative side is grounded. This is to prevent
damage to the diodes and Igniter.
Igniter Removal
• Remove:
Seat
Connector [A]
Igniter [B]
• Install the ignition coil mounting bolt [A] with the ground
terminal [B] as shown (see Cable, Wire and Hose Routing
section in the General Information chapter).
Connection:
Tester Positive→ Black Lead [C]
Tester Negative→ Black/Yellow Lead (Ground) [D]
• Shift the gear to the neutral position, then free the engine
stop switch.
• Crank the engine by kicking the pedal several times to
measure the peak voltage of the primary ignition coil.
Peak Voltage 100 V or above
WARNING
Do not touch the metal portion of the probe in case
of measuring the voltage, or you may receive a se-
rious electric shock.
If the voltage is less than the specified value, see the
troubleshooting.
Crankshaft Sensor Peak Voltage Check:
•To check the peak voltage, do the following procedures.
○Disconnect the magneto lead connector.
NOTE
○Measure the voltage with each lead connected cor-
rectly. The correct value may not be obtained if
disconnected.
○Maintain the correct value of compression pressure for
the cylinder (Be sure to measure the voltage with the
spark plug installed to the cylinder head).
○The correct value may not be obtained if disconnected.
○Connect the peak voltage adapter [A] of the tester to the
terminals of the magneto lead connector [B].
Special Tools - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Hand Tester: 57001-1394
Connection:
Adapter Positive → Blue/Yellow Lead [C]
Adapter Negative → Engine Ground [D]
○Crank the engine by kicking the pedal several times to
measure the peak voltage of the crankshaft sensor.
Peak Voltage 4.6 V or above
WARNING
Do not touch the metal portion of the probe in case
of measuring the voltage, or you may receive a se-
rious electric shock.
If the voltage is less than the specified, check the crank-
shaft sensor.
• Remove:
O-ring [A]
Gear Position Switch Finger [B]
Spring [C]
Troubleshooting
Table of Contents
Troubleshooting Guide ........................................................................................................... 15-2
15
□:This digit in the frame number changes from one machine to another.