(TM) Kawasaki Manual de Propietario Kawasaki KLX 140 y KLX 140 L 2012 en Ingles PDF

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GENERAL INFORMATION j
Quick Reference Guide
This Quick Reference Guide will assist you in MAINTENANCE AND ADJUSTMENT j
finding the information you’re looking for.
TROUBLESHOOTING GUIDE j
STORAGE j
A Table of Contents is included after the

Foreword.

IMPORTANT INFORMATION
• This vehicle is designed for the operator only, no passengers.

• highways. is an off-road motorcycle only and was not manufactured for use on public streets, roads or
This vehicle
• Respect the environment and the rights of other people.

• Read owner’s manual.

Whenever you see the symbols shown below, IMPORTANT
heed their instructions! Always follow safe operat- Off-road motorcycling is a wonderful sport,
ing and maintenance practices. and we hope you will enjoy it to the fullest. How-
ever, if improperly conducted, this sport has the
DANGER potential to cause environmental problems as
DANGER indicates a hazardous situation well as conflicts with other people.
which, if not avoided, will result in death or Responsible use of your off-road motorcycle
serious injury. will ensure that these problems and conflicts do
not occur. TO PROTECT THE FUTURE OF YOUR
SPORT, MAKE SURE YOU USE YOUR MOTOR-
WARNING CYCLE LEGALLY, SHOW CONCERN FOR THE
ENVIRONMENT, AND RESPECT THE RIGHTS
WARNING indicates a hazardous situation OF OTHER PEOPLE.
which, if not avoided, could result in death
or serious injury. WARNING
NOTICE
• THIS VEHICLE IS AN OFF-ROAD VEHICLE
ONLY AND WAS NOT MANUFACTURED
FOR USE ON PUBLIC STREETS, ROADS,
NOTICE is used to address practices not re- OR HIGH-WAYS.
lated to personal injury.
• USE YOUR BIKE LEGALLY.
NOTE
• RESPECT THE ENVIRONMENT AND THE
RIGHTS OF OTHER PEOPLE.
This note symbol indicates points of particular in-
terest for more efficient and convenient operation.

IMPORTANT NOTE TO PARENTS ABOUT SAFE RIDING
Your youngster’s safety will depend on your commitment to always provide a safe riding environment and
a properly maintained vehicle. As with any moving vehicle there are possible safety risks; be sure to
heed these precautions.
1. Always equip your child with suitable protective gear and riding apparel. Be sure he or she always
wears a helmet, over-the-ankle footwear or sturdy boots, eye protection, groves, long pants, and a
long-sleeved shirt while riding.
2. Never allow your child to carry a passenger. This motorcycle is designed for an OPERATOR ONLY.
3. This motorcycle is designed for off-road riding and should never be operated on public roads or
paved surfaces.
4. This motorcycle was not designed for hard riding such as motocross.
5. Always obey local off-road riding laws and regulations. Obtain permission to ride on private property.
6. You, the parent (and most likely “riding instructor/mechanic” as well), must be familiar with motorcycle
controls and maintenance requirements plus riding techniques. Read and understand the owner’s
manual provided with the motorcycle. Review all instructions and warnings with your child.
7. You must determine your child’s readiness to ride this off-road motorcycle. Your child should already be
familiar with motorcycle controls (location and function) and basic riding techniques. Your child should
also be physically large enough, and strong enough to be able to straddle the motorcycle and hold it up,
plus be able to pick up it up if it is on its side.
8. Your child’s safety depends in part on the good mechanical condition of the motorcycle. Be sure to
follow the maintenance and adjustment requirements contained in the Periodic Maintenance Chart,
Daily Pre-ride Inspection, and After-Race Check Points. Be sure your child understands the importance
of checking all items thoroughly before riding the motorcycle. Also, familiarity with the motorcycle is
important should a problem occur far from help.
9. Do not allow your child to ride unsupervised. He or she should always ride in the company of an
experienced adult.

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 your child before you leave so he or she will know in advance what riding techniques
may be necessary to negotiate the terrain safely. If you are not familiar with the area, lead the way
and reduce your speed.
KLX140A only
NOTICE
KLX140A is designed for a rider weighting less than 70 kg (154 ponds). Exceeding this limit could
damage the motorcycle.

FOREWORD
We wish to thank you for choosing this Kawasaki Motorcycle. It is the end product of Kawasaki’s advanced
engineering, exhaustive testing, and continuous striving for superior reliability, and performance. By 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 all, how to operate it safety.
Due to improvements in design and performance made during production, in some cases there may be minor discrepancies between
the actual vehicle and the illustrations and text in this manual.
KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company
©2012 Kawasaki Heavy Industries, Ltd. Feb. 2012. (1)

TABLE OF CONTENTS
SPECIFICATIONS............................................ 9 Valve Clearance ............................................ 52
GENERAL INFORMATION.............................. 12 Spark Arrester ............................................... 53
Location of Parts ........................................... 12 Drive Chain.................................................... 55
Side Stand..................................................... 15 Handlebar...................................................... 60
Fuel Tap......................................................... 15 Brakes ........................................................... 62
Fuel ............................................................... 16 Steering ......................................................... 66
Engine Stop Switch ....................................... 19 Front Suspension .......................................... 68
Starter Button ................................................ 20 Rear Suspension........................................... 69
Starting the Engine ........................................ 20 Wheels .......................................................... 72
Moving Off ..................................................... 23 Hoses Inspection........................................... 75
Shifting Gears................................................ 23 Battery ........................................................... 76
Stopping the Motorcycle................................ 24 Fuse .............................................................. 80
Stopping the Engine ...................................... 25 Tightening Torques of Nuts and Bolts............ 81
Break-In......................................................... 25 Cleaning Your Motorcycle.............................. 86
Daily Pre-Ride Checks .................................. 26 Lubrication..................................................... 89
MAINTENANCE AND ADJUSTMENT............. 28 TROUBLESHOOTING GUIDE......................... 92
EMISSION CONTROL INFORMATION ........ 28 STORAGE........................................................ 94
Periodic Maintenance Chart .......................... 31 Before Storage .............................................. 94
Engine Oil...................................................... 35 After Storage ................................................. 95
Spark Plug..................................................... 39 ENVIRONMENTAL PROTECTION.................. 96
Air Cleaner .................................................... 41 WIRING DIAGRAM .......................................... 97
Throttle Cable ................................................ 46 YOUR WARRANTY/OWNER SATISFACTION
Choke Knob................................................... 48 ...................................................................... 98
Idle Speed ..................................................... 50 REPORTING SAFETY DEFECTS ................... 102
Clutch ............................................................ 51 MAINTENANCE RECORD .............................. 103

SPECIFICATIONS 9
SPECIFICATIONS
DIMENSIONS
Overall length 1 820 mm (71.7 in.) B: 1 895 mm (74.6 in.)
Overall width 790 mm (31.1 in.)
Overall height 1 050 mm (41.3 in.) B: 1 075 mm (42.3 in.)
Wheelbase 1 260 mm (49.6 in.) B: 1 285 mm (50.6 in.)
Road clearance 235 mm (9.3 in.) B: 255 mm (10.0 in.)
Curb Mass 93 kg (205 lb) B: 95 kg (209 lb.)
Fuel tank capacity 5.8 L (1.5 US gal)
ENGINE
Type SOHC, 2-valve, single-cylinder, 4-stroke, Air-cooled
Bore × stroke 58.0 × 54.4 mm (2.3 × 2.1 in.)
Displacement 144 cm³ (8.8 cu in.)
Compression ratio 9.5 : 1
Carburetor KEIHIN PB20
Starting system Electric Starter
Ignition system CDI
Ignition timing 10° BTDC @1 400 r/min (rpm) a 30° BTDC @4 000 r/min (rpm)
Lubrication system Forced lubrication (wet sump)
Spark plug NGK CR7HSA
Spark plug terminal Screw type

10 SPECIFICATIONS
TRANSMISSION
Transmission type 5-speed, return shift
Clutch type Wet, multi disc
Drive system Chain drive
Gear ratios:
1st gear 2.667 (40/15)
2nd gear 1.895 (36/19)
3rd gear 1.474 (28/19)
4th gear 1.182 (26/22)
5th gear 1.000 (24/24)
Primary reduction ratio 2.880 (72/25)
Final reduction ratio 3.571 (50/14)
Overall ratio (top gear) 10.286
Engine oil:
Capacity 1.1 L (1.2 US qt)
Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
FRAME
Type Tubular, semi-double cradle
Steering angle 41° to either side
Castor 27°
Trail 85 mm (3.3 in.) B: 96 mm (3.8 in.)

SPECIFICATIONS 11
Tire size, type:

70/100-17 40M, IRC., LTD. IX05H
Front
B: 70/100-19 42M, IRC., LTD. IX05H
90/100-14 49M, IRC., LTD. IX05H
Rear
B: 90/100-16 52M, IRC., LTD. IX05H
Rim size:
Front 17 × 1.40 B: 19 × 1.40
Rear 14 × 1.60 B: 16 × 1.85
Suspension:
Front Telescopic fork
Rear New Uni-trak® swingarm
Front suspension travel 180 mm (7.1 in.)
Rear wheel travel 180 mm (7.1 in.)
Front fork oil:
Type SHOWA SS-8 or equivalent
Capacity (per fork leg) 296 mL (10.0 US oz) B: 290 mL (9.8 US oz)
BRAKES
Type (Front & Rear) Disc
ELECTRICAL EQUIPMENT
Battery 12 V 6 Ah
B: KLX140B
Specifications are subject to change without notice.

12 GENERAL INFORMATION
j
GENERAL INFORMATION
Location of Parts
1. Clutch Lever 5. Front Brake Lever

2. Engine Stop Switch 6. Throttle Grip
3. Choke Knob 7. Starter Button
4. Front Brake Fluid Reservoir 8. Fuel Tank Cap

GENERAL INFORMATION 13
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9. Front Fork 16. Brake Caliper

10. Fuel Tank 17. Engine Oil Drain Plug
11. Fuel Tap 18. Side Stand
12. Carburetor 19. Drive Chain
13. Seat 20. Swingarm
14. Air Cleaner Element 21. Chain Guide
15. Brake Disc 22. Rear Shock Absorber

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23. Muffler 27. Chain Adjuster

24. Fuse 28. Rear Brake Fluid Reservoir
25. Battery 29. Oil Filler Cap/Dipstick
26. Rear Axle Nut 30. Rear Brake Pedal

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Side Stand Fuel Tap
The motorcycle is equipped with a side stand. 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 L
(0.29 US gal) of usable fuel remains can be used by
turning the tap lever to the RES position.
A. Side Stand
Do not sit on the motorcycle while it is on its side
stand. Always kick the stand fully up before sitting
on the motorcycle.
A. Fuel Tap
WARNING B. ON Position
Riding with the side stand down could cause C. OFF Position
an accident resulting in serious injury or D. RES Position
death. Always be sure the side stand is fully Turn the fuel tap lever to OFF position when the
raised before riding. fuel tank is removed for maintenance and adjust-
ments or the motorcycle is stored for a long time.

j
NOTE
Since riding distance is limited when on RES, re- Fuel
fuel at the earliest opportunity.
Make certain that the fuel tap lever is turned to ON The required of fuel is specified under “Fuel Re-
quirements”.
(not RES), after filling up the fuel tank.
The capacity of the fuel tank is 5.8 L (1.5 US gal).
To open the fuel tank cap, pull out the breather hose
WARNING from the hole in the steering shaft and turn the tank
Practice operating the fuel tap with the mo- cap counterclockwise.
torcycle stopped. To prevent an accident you Avoid filling the tank in the rain or where heavy dust
should be able to operate the fuel tap while is blowing so that the fuel does not get contaminated.
riding without taking your eyes off the road.
Be careful not to touch the hot engine while
operating the fuel tap.
A. Fuel Tank Cap

B. Breather Hose
Filling the Tank:

Avoid filling the tank in the rain or where heavy dust
is blowing so that the fuel does not get contaminated.

j
WARNING
Gasoline is extremely flammable and can be
explosive under certain conditions, creating
the potential for serious burns. Always stop
the engine and do not smoke. Make sure
the area is well-ventilated and free from any
source of flame or sparks; this includes any
appliance with a pilot light. Never fill the tank
completely to the top. As the fuel expands
in a warm tank, it may overflow through the
vents in the tank cap. After refueling, make
sure the fuel tank cap is closed securely. If
gasoline is spilled on the fuel tank, wipe it off
immediately.
A. Tank Cap
B. Fuel Tank
C. Top Level Fuel Requirements:
D. Filler Neck
Fuel Type
Use clean, fresh unleaded gasoline with a mini-
mum 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 measure of its re-
sistance to detonation or “knocking”. The Antiknock
Index is an average of the Research Octane Num-
ber (RON) and the Motor Octane Number (MON) as
shown in the table below.
Minimum
Octane Rating Method
Rating
(RON + MON)
Antiknock Index 87
2

j
NOTICE products such as corn), also known as “gasohol” is
approved for use.
If engine “knocking” or “pinging” occurs,
use a different brand of gasoline of a higher NOTICE
octane rating. If this condition is allowed to
continue it can lead to severe engine dam- Avoid using blends of unleaded gasoline and
age. methanol (wood alcohol) whenever possible,
Gasoline quality is important. Fuels of low and never use “gasohol” containing more
quality or not meeting standard industry than 5% methanol. Fuel system damage and
specifications may result in unsatisfac- performance problems may result.
tory performance. Operating problems
that result from the use of poor quality or Gasoline/Ether Blends - The most common ether
non-recommended fuel may not be covered is methyl tertiary butyl ether (MTBE). You may use
under your warranty. gasoline containing up to 15% MTBE.
NOTE
Fuels Containing Oxygenates Other oxygenates approved for use in unleaded
Gasoline frequently contains oxygenates (alco- gasoline include TAME (up to 16.7%) and ETBE
hols and ethers) especially in areas of the U.S. and (up to 17.2%). Fuel containing these oxygenates
Canada which are required to sell such reformu- can also be used in your Kawasaki.
lated fuels as part of a strategy to reduce exhaust
emissions.
The types and volume of fuel oxygenates ap-
proved for use in unleaded gasoline by the U.S.
Environmental Protection Agency include a broad
range of alcohols and ethers, but only two compo-
nents have seen any significant level of commercial
use.
Gasoline/Alcohol Blends - Gasoline containing up
to 10% ethanol (alcohol produced from agricultural

j
NOTICE
Never use gasoline with an octane rat-
Engine Stop Switch
ing lower than the minimum specified by
The engine stop switch is located on the left side of
Kawasaki.
the handlebar. The engine stop switch must be in the
Never use “gasohol” with more than 10%
ethanol, or more than 5% methanol. Gaso- position for the motorcycle to operate. Move
line containing methanol must also be the switch to the position to stop the engine.
blended with cosolvents and corrosion
NOTE
inhibitors.
Certain ingredients of gasoline may cause To avoid battery discharging, check that the en-
paint fading or damage. Be extra careful gine stop switch is in the position and the in-
not to spill gasoline or gasoline oxygenate dicator light (orange LED) goes off, when the mo-
blends during refueling. torcycle is not used.
When not operating your Kawasaki for 30
to 60 days, mix a fuel stabilizer (such as
STA-BIL) with the gasoline in the fuel tank.
Fuel stabilizer additives inhibit oxidation of
the fuel which minimizes gummy deposits.
Never store this product with “gasohol” in
the fuel system. Before storage it is rec-
ommended that you drain all fuel from the
fuel system. See the Storage section in this
manual.
A. Engine Stop Switch

B. Indicator Light (LED)

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Starter Button Starting the Engine
This motorcycle has the starter button. The starter
button operates the electric starter when the clutch
• Turn the fuel tap lever to the ON position.
lever pulled in.
A. ON Position
A. Starter Button • Shift the transmission into neutral.

NOTE
This motorcycle is equipped with a neutral switch
that prevents the engine from starting when the
transmission is not in neutral.

j
• position.
Check that the engine stop switch is in the 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 the choke knob.

B. Position
WARNING
Riding with the side stand in the down posi-
tion can cause a crash resulting in injury. Do
not start the engine or attempt to ride the mo-
torcycle when the side stand is down.
A. Choke Knob
• Leaving the throttle completely closed, push the

starter button until the engine starts.

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NOTE NOTICE
When the clutch lever is pulled, the motorcycle can Do not let the engine idle longer than five
be started with the transmission in any gear. minutes, or engine overheating and damage
may occur.
A. Starter Button
• Even after the engine has started, do not push

back immediately the choke knob until the engine
is thoroughly warmed up.
NOTE
When the engine is already warm or on a hot day,
open the throttle part way instead of using the
choke knob.

j
Moving Off Shifting Gears
• Check that the side stand is up. This motorcycle is equipped with a 5-speed “return
• Open the 1st
Shift into gear. shift” transmission. The neutral is located halfway
• throttle slowly. 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 selected.
• To engage first gear from the neutral position, pull
in the clutch lever and push down on the shift
pedal, gently release the clutch lever, then release
the shift pedal.
• To shift up to the next gear, pull in the clutch lever,
lift the shift pedal with your toes, gently release the
clutch lever, and then release the shift pedal.
• To shift down to the next gear, pull in the clutch
lever, push the shift pedal down as far as it will go,
gently release the clutch lever, then release the
shift pedal.
WARNING
Downshifting to a lower gear at high speed
causes engine rpm to increase excessively,
potentially damaging the engine and it may
also cause the rear wheel to skid and cause
an accident.

j
NOTICE
When changing gears, press firmly on the
Stopping the Motorcycle
shift pedal to ensure proper shifting. Care-
For maximum deceleration, close the throttle and
less, incomplete shifting can cause the
apply both front and rear brakes. Pull in the clutch
transmission to jump out of gear and lead to
lever as the motorcycle comes to a stop. Indepen-
engine damage.
dent use of the front or rear brake may be advanta-
geous in certain circumstances. Shift down progres-
sively to ensure good engine response at all speeds.
A. Shift Pedal

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Stopping the Engine Break-In
• Shift the transmission into the neutral position. The first one hour that the motorcycle is ridden is
• Close the throttle completely. designed as the break-in period. If the motorcycle is
• Push the engine stop switch to the position. not used carefully during this period, you may very
well end up with a “broken down” instead of a “bro-
ken in” motorcycle after the long use.
Do not start moving or race the engine immediately
after starting it, even if the engine is already warm.
Run the engine for two or three minutes at idle speed
to give the oil a chance to work up into all the engine
parts.
Avoid the quick acceleration or starting and drive
prudently for the first one hour of operation. Let the
motorcycle cool completely. The motorcycle is ready
for regular operation after this procedure is carried
out.

B. Position
• Turn the fuel tap lever to the OFF position.

NOTE
To avoid battery discharging, check that the en-
gine stop switch is in the position and the in-
dicator light (orange LED) goes off, when the mo-
torcycle is not used.

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 take the action required
to return the motorcycle to a safe operating condition.
WARNING
Failure to perform these checks before operation may result in serious damage or an accident. Al-
ways perform daily safety checks before operation.
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas.
Inhaling carbon monoxide can cause serious brain injury or death.
Do not run the engine in enclosed areas. Operate only in a well-ventilated area.
Engine
Engine Oil ........................................ No leakage
Level correct
Clutch .............................................. Functions properly
Spark Plug ....................................... Correctly torqued
Carburetor ....................................... Properly adjusted
Idle speed: 1 350 a 1 450 r/min (rpm)
Air Cleaner ....................................... Clean
Apply oil to air cleaner element if dry
Properly installed
Muffler .............................................. No damage
Properly installed
Engine sproket ................................. Not worn or damaged

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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 leakage
Throttle ............................................ Functions properly
Throttle grip returns smoothly
Steering ........................................... Smooth but not loose from lock to lock
No binding due to control cables
Front Fork ........................................ Functions properly
No leakage
Rear Shock Absorber ...................... Functions properly
No leakage
Fuel Tank ......................................... Mounted securely
No leakage
Rear Sproket ................................... No wear or damage
Electrical equipment ........................ Functions properly
Engine Stop Switch ......................... Functions properly
Nuts, Bolts, Fasteners ..................... Properly tightened

28 MAINTENANCE AND ADJUSTMENT
MAINTENANCE AND ADJUSTMENT

j 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 neglected.
With a basic knowledge of mechanics and the proper use of tools, you should be able to carry out many of the
maintenance items described in this chapter. If you lack proper experience or doubt your ability, all adjustments,
maintenance, and repair work should be completed by a qualified technician. Please note that Kawasaki cannot
assume any responsibility for damage resulting from incorrect or improper adjustment done by the owner.
EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and ex-
haust emission (2) control systems in compliance with applicable regulations of the United States Environmental
Protection Agency. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in com-
pliance with applicable regulations of the United States Environmental Protection Agency.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed
through an oil separator to the intake side of the engine. While the engine is operating, the vapors are drawn
into the 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 vehicle.
The fuel and ignition systems of this vehicle have been carefully designed and constructed to ensure an efficient
engine with low exhaust pollutant levels.
3. Evaporative Emission Control System
The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a fuel
tank.

MAINTENANCE AND ADJUSTMENT 29
MAINTENANCE
Proper maintenance is necessary to ensure that your vehicle will continue to have low emission levels. This
Owner’s Manual contains maintenance operations recommended for your vehicle. Maintenance operations
necessary to ensure compliance with the applicable emission standards are noted in the Periodic Maintenance
j
Chart. As the owner of this vehicle, you have the responsibility to make sure that the recommended mainte-
nance is carried out according to the instructions in this Owner’s Manual at your own expense.
You should keep a maintenance record for your vehicle. To assist you in keeping this record, we have provided
space at the end of this manual where an authorized Kawasaki dealer, or someone equally competent, can
record the maintenance. You should also retain copies of maintenance work orders, receipts, etc., as verifica-
tion of this maintenance.
Warranty
This vehicle is designed, built, and equipped in compliance with applicable regulation of the United States Envi-
ronmental Protection Agency (EPA) at the time of sale. The EPA requires that your vehicle comply with certain
emissions regulation during a portion of its useful life and is free from defects in material and workmanship
which could cause the vehicle to fail to conform with applicable regulation. Please read your Kawasaki Limited
Emission Control Systems Warranty delivered with this Owner’s Manual carefully and keep it valid by comply-
ing with the owner’s obligations it contains. To obtain warranty service, the Kawasaki Limited Emission Control
Systems Warranty requires that you return your vehicle to an authorized Kawasaki dealer for remedy under
warranty.
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 any
device or element of design incorporated into any new vehicle 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 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:
Do not tamper with the original emission related parts:
•Carburetor or internal parts •
Magneto ignition system
•Spark plug •
Air cleaner element

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any
person other than for purposes of maintenance, repair, or replacement, of any device or element of design
j 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 •
Removal of the air box or air box cover.
muffler with a component not in compliance with
Federal regulations.
•
Modifications to the muffler or air intake system
by cutting, drilling, or other means if such modifi-
•Removal of the muffler or any internal portion of
the muffler.
cations result in increased noise levels.

Periodic Maintenance Chart

The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accor-
j
dance with the Periodic Maintenance Chart to keep 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.
: Emission-related Item
1. Periodic Inspection (Engine Related Item)
FREQUENCY Initial Every
See
5 hours 50 hours 100 hours Page
OPERATION (1 month) (6 months) (12 months)
Spark plug - clean, gap † • • 39
(K) Clutch and friction plate - inspect † • • • –
Clutch cable - adjust † • • • 51
E
N
Valve clearance - inspect † • • 52
G Air cleaner element - clean † • • • 43

I
N
Throttle grip play - inspect † • • • 46
E (K) Fuel tap - clean • • –
Spark arrester - clean • 53
Engine sprocket - inspect † • • 59
(K) Fuel hose connections - inspect † • • 75

2. Periodic Inspection (Chassis Related Item)
j 100 See
5 hours 50 hours Page
hours (12
(1 month) (6 months)
OPERATION months)
Brake adjustment - inspect † • • • 62
Brake fluid level - check † • • • 63
Brake pad wear - check † • • • 65
Brake hoses connections - check † • • • 75
Spoke tightness and rim runout - check † • • • 72, 73
C
H
Drive chain wear - check † • • • 57
A
Drive chain - inspect and adjust † • • • 55, 56
S
S
Drive chain - lubricate • • • 60
I Drive chain guide and slipper - inspect † • • • 58, 59

S (K) Front fork - inspect and clean † • • 68
(K) Front fork oil - inspect † Every year –
Nuts, bolts, fasteners - inspect † • • • 81
Steering play - inspect † • • • 66
(K) Steering stem bearing - grease • –
Rear sprocket - inspect † • • 59


100 See
(1 month) (6 months)
hours (12 j
OPERATION months)
Battery - inspect † • • 76
Battery terminal - inspect † • • 78
Chassis parts - lubricate • • • 89
C
Side stand - inspect † • • –
H (K) Wheel bearing - check † • • –

A
S
(K) Swingarm and Uni-track linkage pivot - inspect • • –
S
I
(K) Swingarm and Uni-track linkage pivot - grease • • –
S
(K) Rear shock absorber - inspect † • • 69
Frame - inspect and clean • • • –
Wheels/tires - inspect † • • • 72
(K) Shift pedal ball joint - inspect • • 86
(K) Shift pedal pivot - grease • • –

3. Periodic Replacement (Engine and Chassis Related Item)
j 100 See
hours (12
OPERATION (1 month) (6 months)
months)
Engine oil - change • • • 36
Oil filter - replace • • • 36
(K) Brake hose - replace Every 4 years –
(K) Fuel hose - replace Every 5 years –
(K) Brake fluid - change Every 2 years 63
(K) Brake master cylinder cup and dust seal - replace Every 2 years –
(K) Brake caliper piston seal and dust seal - replace Every 2 years –
(K) Front fork oil - change • • –
(K) Rear shock oil - change • • –

NOTICE
Engine Oil Racing the engine before the oil reaches ev-
In order for the engine, transmission and clutch
ery part can cause engine seizure. j
to function properly, maintain the engine oil at the
proper level, and change the oil and oil filter period- • Ifminutes
the motorcycle has just been used, wait several
for all the oil to drain down.
ically.
Not only do dirt and metal particles collect in the • filler cap/dipstick,
With the motorcycle held level, unscrew the oil
wipe the dipstick on the cap dry,
oil, but the oil itself loses its lubricative quality if used
and reinsert it by screwing.
too long.
WARNING
Motorcycle operation with insufficient, de-
teriorated, or contaminated engine oil will
cause accelerated wear and may result in en-
gine or 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.
Oil Level Inspection

• Situate the motorcycle so that it is perpendicular
to the ground.
• Ifandtherunoil ithas just been changed, start the engine
for several minutes at idle speed. This
A. Oil Filler Cap/Dipstick
B. Screw in the oil filler plug fully to inspect the
fills the oil filter with oil. oil level.
• Stop the engine and wait several minutes for the
oil to settle.
C. High Level Line
D. Low Level Line

NOTICE NOTE
Be careful not to allow any dirt or foreign ma- Do not pinch the O-ring when installing the dipstick
j terials to enter the engine. on the oil filler neck.
When the O-ring comes off from the oil filler neck,
• Unscrew the cap and check the oil level by the dip-
stick on the cap. The oil level should be between
install the O-ring on the oil filler neck correctly first,
then install the dipstick.
the “H” (High) and “L” (Low) lines on the dipstick.
Oil and/or Oil Filter Change
The engine oil and/or oil filter should be changed
periodically to ensure long engine life.
• Warm up the engine thoroughly so that the oil will
pick up any sediment and drain easily.
• Stop the engine, and place a container beneath it.
• Remove the oil filler cap/dipstick.
• Remove the oil drain plugs and position the vehi-
cle by using the side stand to allow all the oil to
drain.
A. Dipstick
B. “H” (High) Line
C. “L” (Low) Line
D. O-ring
• Ifthrough
the oil level is too high, remove the excess oil
the oil filler opening using a syringe or
some other suitable device.
• If the oil level is too low, add the oil to reach the
correct level. Use the same type and brand of oil
that is already in the engine. A. Drain Plug

WARNING • Replace the oil filter element with a new one.

Engine oil is a toxic substance. Dispose of • Install the grease
Apply the oil to the grommet.
used oil properly. Contact your local author- • ward the engine. element with the grommet to-
oil filter
j
ities for approved disposal methods or pos-
sible recycling.
• When the oil filter is replaced, remove the oil filter

cover and take off the cover with O-ring.
A. Oil Filter Element

B. Grommet
NOTICE
A. Oil Filter Cover Inside-Out installation stop oil flow, the caus-
B. Bolts ing engine seizure.
C. Up Mark
• Install the oil filter cover facing the up mark to up

with the grease applied to a new O-ring and tighten
its bolts to the specified torque.
Oil Filter Cover Tightening Torque
8.8 N·m (0.9 kgf·m, 78 in·lb)

• After the oil has completely drained out, install the

drain plug with its new gasket. Proper torque for it
NOTE
is shown in the table.
Do not add any chemical additive to the oil. Oils
j fulfilling the above requirements are fully formu-
Engine Oil Drain Plug Tightening Torque lated and provide adequate lubrication for both the
18 N·m (1.8 kgf·m, 13 ft·lb) engine and the clutch.
• Start
Install the oil filler cap/dipstick.
NOTE • Checkthetheengine.
Replace the damaged gasket or O-ring with a new • oil level and oil leakage.
one. Engine Oil Capacity
0.93 L (0.98 US qt) [When filter is not removed]
• Fill the engine up to the upper level line with good
quality engine oil specified in the table. 0.95 L (1.00 US qt) [When filter is removed]
Recommended Engine Oil 1.10 L (1.16 US qt) [When engine is completely
Type: Kawasaki Performance 4-Stroke dry]
Motorcycle Oil*
Kawasaki Performance 4-Stroke Although 10W-40 engine oil is the recommended
Semi-Synthetic Oil* oil for most conditions, the oil viscosity may need
Kawasaki Performance 4-Stroke Full to be changed to accommodate atmospheric condi-
Synthetic Oil* tions in your riding area.
or other 4-stroke oils with API SG, SH,
SJ, SL, SM and JASO MA, MA1, MA2
rating
Viscosity: SAE 10W-40
*Kawasaki Performance Oils and Lubricants have

been specifically engineered for your vehicle. Con-
sistent use of these products meets or exceeds war-
ranty and service requirements and can help to ex-
tend the life of your Kawasaki.

Spark Plug
The spark plug should be taken out periodically for
j
inspection and regapping. Measure the gap with a
wire-type thickness gauge. If incorrect, adjust the
gap to the specified value by bending the outer elec-
trode.
Spark Plug Gap
0.6 ~ 0.7 mm
CR7HSA
(0.024 ~ 0.028 in.)
A. Gap
B. Outer Electrode

If the plug is oily or has carbon built up on it, clean
it (preferably with a sandblaster) and then clean
• Fit the plug cap securely onto the spark plug, and
pull the cap lightly to make sure that it is properly
off any abrasive particles. The plug may also be installed.
j cleaned using a high-flash-point solvent and a wire
brush or other suitable tool. If the spark plug elec-
• Check the spark plug lead is not damaged, or cor-
rectly routed.
trodes are corroded, or damaged, or if the insulator
is cracked, replace the plug. The standard spark
plug is shown in the table below.
Standard Spark Plug
NGK CR7HSA
NOTE
If the spark plug is replaced, use the genuine
Kawasaki spark plug.
Spark Plug Removal and Installation

• Clean the cylinder head around the spark plug cap
hole before removing the spark plug.
• Pull the spark plug cap off the plug before remov-
ing the spark plug.
A. Plug Cap
B. Spark Plug
• Apply a suitable wrench to the spark plug.
• When reinstalling
Loosen and remove the spark plug.
• ification. the spark plug, torque it to spec-
Spark Plug Tightening Torque

13 N·m (1.3 kgf·m, 9.6 ft·lb)

NOTE
Air Cleaner In dusty areas, the element should be cleaned
more frequently than recommended interval. j
A clogged air cleaner restricts the air intake, in- After riding through rain or on muddy roads, the
creases fuel consumption, reduces engine power, element should be cleaned immediately.
and can cause spark plug fouling. Inspect the air in-
take system, which includes the air filter and air duct Element Removal and Inspection
to the carburetor, and the duct clamps and carbure-
tor, before each race or practice session. • Remove the screw and remove the left side cover.
WARNING
Dirt in the engine can cause engine damage
or failure leading to an accident resulting in
serious injury. Regularly inspect the air in-
take system for dirt or dust. If any dirt or
dust is found in the system, the entire sys-
tem must be cleaned to help prevent engine
damage or failure.
NOTICE
A clogged air cleaner will affect fuel mixture
to the engine and reduce engine power and A. Left Side Cover
cause spark plug fouling. B. Bolt

• Remove
cover.
the bolts and remove the air cleaner • Remove
element.
the wing bolt, and take out the air cleaner
A. Air Cleaner Cover A. Air Cleaner Element

B. Bolts B. Wing Bolt
• Cover a clean, lint-free towel on the air cleaner

housing to keep dirt from entering the carburetor.
• Wipe out the inside of the air cleaner housing with
a clean, damp towel.
• Take the element off its frame.
NOTICE
Do not twist or wring the element, as it gets
easily torn or damaged.
• Inspect the element. If it is dirty, clean it. Also

check if the element is in good condition (no tears,
hardening or shrinkage). If damaged, replace the
element or it will allow dirt into the carburetor.

WARNING Element Cleaning and Installation

A clogged air cleaner may allow dirt and • Clean the element in a bath of a high flash point
solvent or hot soapy water. Rinse the element with
dust to enter the carburetor and the throttle
clear water to remove all traces of the cleaning
j
may stick resulting in a hazardous operating
solution.
condition. Clean the air filter according to
the periodic maintenance chart; more often • Squeeze the element dry in a clean towel.
if the vehicle is used in extremely dusty NOTICE
conditions.
Do not twist, wring or blow the element dry
to avoid damaging it.
NOTICE
A clogged air cleaner may allow dirt and dust
to enter the engine, causing it to wear exces-
sively or to become damaged.
A. Air Cleaner Element

B. Element Frame

cause tearing. In this case, too much oil is better
than too little. Finally pat the inside of the element
with a paper towel to remove any excess oil.
j
• Before installation, check the element for damage
such as tears, hardening, or shrinkage. If dam-
aged, replace the element.
• Apply grease to all mating surfaces and to the
screw hole in the air cleaner housing and intake
tract.
• Remove the towel from the carburetor.
• Install the element onto its frame, and coat the
element lip and lip seat with a thick layer of all
-purpose grease to assure a complete seal.
WARNING
Gasoline and low flash-point solvents can
be flammable and/or explosive and cause
severe burns. Clean the element in a
well-ventilated area, and take care that
there is no spark or flame anywhere near the
working areas. Do not use gasoline or low
flash-point solvents to clean the element.
• After cleaning, let the filter dry completely. Satu-

rate the element with a high-quality foam air fil-
ter oil and make sure that the oil is evenly ap-
plied throughout the element. Squeeze out the ex- A. Apply Grease.
cess oil, but do not wring the element as this could

• Install an air cleaner element with its pointing end Oil Draining
facing toward the rear of the motorcycle. • Inspect the hose or plug to see if any oil or water
has run down.
j
A. Pointing end
A. Oil Plugs
• Install the wing bolt.
• Ifoil.there are any oil, remove the plug and drain the
• Install the front
Install the air cleaner cover.
• left side cover.
WARNING
Oil on tires will make them slippery and can
cause an accident and injury. Be sure to in-
stall the plug in the drain hose after draining.

• IfPullthere is improper play, adjust it.

Throttle Cable • cable. rubber boot off the upper end of the throttle
the
j
Throttle Cable Adjustment • Loosen the locknut on the upper end of the throttle
cable and turn the adjuster to obtain the specified
Inspect the throttle grip for smooth operation in
play.
all steering positions. Check and adjust the throttle
cable in accordance with the Periodic Maintenance • Then, tighten the locknut toward the adjuster.
Chart.
• Check that the throttle grip has 2 a 3 mm (0.08 a
0.12 in.) of play and turns smoothly.
A. Adjuster
B. Locknut
A. Throttle Grip
B. 2 a 3 mm (0.08 a 0.12 in.)

• Install the rubber boot. • Pull the rubber boot off the top of the carburetor
• cable adjuster,
If the free play cannot be set by adjusting the upper
use the adjuster on the lower end
and make the necessary free play adjustment with
the adjuster on the lower end of the cable. Then,
of the cable. tighten the locknut and reinstall the rubber boot.
j
• Remove the side cover and the seat. (see Battery
Removal)
• Remove the bolts and screw, and pull the right side
of the fuel tank cover up temporarily.
A. Locknut
B. Adjuster
A. Bolts
B. Screw
C. Fuel Tank Side Cover

• Check if the throttle grip moves smoothly from full

open to close, and the throttle closes quickly and Choke Knob
completely in all steering positions by the return
j spring. If not, check the throttle cable routing, grip
free play, and cable damage. Then lubricate the
Choke Knob Adjustment
throttle cable. • Take out the number plate by removing the bolt.
• With the engine idling, turn the handlebar both
ways and check if handlebar movement changes
the idling speed. If so, the throttle cable may be
improperly adjusted or incorrectly routed, or dam-
aged. Be sure to correct any of these conditions
before riding.
• Reinstall the parts removed.
WARNING
Operation with an improperly adjusted, in-
correctly routed, or damaged cables could
result in an unsafe riding condition. Be sure
the control cables are adjusted and routed
correctly, and are free from damage.
A. Bolt
B. Number Plate

• Pull the choke knob fully up and set it where the

knob stops.
• Pull the rubber boot off the adjuster, and adjust
with the adjuster so that the knob can be pushed
back with a finger.
j
A. Choke Knob
A. Rubber Boot
B. Adjuster
NOTE
If you over-tighten the adjuster, it will become hard
to push back.
• Reinstall the parts removed.

Idle Speed
• Adjust the idling speed 1 350 a 1 450 r/min (rpm)
by turning the idling adjusting screw.
j The following procedure covers the idling adjust-
ment, which should be performed whenever the idle
speed is disturbed.
Idling Adjustment
• Thoroughly warm up the engine.
DANGER
Exhaust gas contains carbon monoxide, a
colorless, odorless poisonous gas. Inhal-
ing carbon monoxide can cause serious
brain injury or death. DO NOT run the en-
gine in enclosed areas. Operate only in a
well-ventilated area.
A. Idling Adjusting Screw
WARNING • Open and close the throttle a few times to make

sure the idling speed does not change, and read-
The engine and exhaust system get ex- just if necessary.
tremely hot during normal operation and
can cause serious burns. Never touch a hot
• With the engine idling, turn the handlebar both
ways and check if handlebar movement changes
engine or an exhaust pipe during idle speed the idling speed. If so, the throttle cable may be
adjustment. improperly adjusted, incorrectly routed, or dam-
aged. Be sure to correct any of these conditions
before riding.
WARNING
Operation with a damaged cable could re-
sult in an unsafe riding condition. Replace
a damaged control cable before operation.

If the clutch lever play cannot be adjusted at the

Clutch clutch lever, make the adjustment further down the
cable as follows.
j
Clutch Lever Adjustment • Loosen the locknut at the clutch lever.
Proper clutch lever play is 2 a 3 mm (0.08 a 0.12 • Turn the adjuster in all the way, then tighten the
locknut.
in.). Lever play increases with cable stretch and fric-
tion plate wear, requiring periodic adjustment. • Loosen the locknut at the lower end of the clutch
cable, and turn the adjusting nut so that the clutch
When the clutch lever play is out of specification,
lever play is 2 a 3 mm (0.08 a 0.12 in.).
first try adjusting it at the clutch lever as follows.
• Slide the clutch lever dust cover back.
• Loosen the locknut, turn the adjuster to obtain the
proper amount of clutch lever play, then tighten the
locknut.
A. Locknuts
B. Clutch Cable
A. Clutch Lever
B. Locknut
C. Adjuster
D. 2 a 3 mm (0.08 a 0.12 in.)
E. Dust Cover

• Tighten the locknut.

• slip and itengine,
Start the check that the clutch does not
releases properly.
Valve Clearance
j
• Slide the dust cover back into place. Valve and valve seat wear decreases valve clear-
ance, upsetting valve timing.
WARNING
Too much cable play can prevent clutch dis-
NOTICE
engagement and cause an accident resulting If valve clearance is left unadjusted, wear will
in serious injury or death. When adjusting eventually cause the valves to remain partly
the clutch or replacing the cable, be sure the open, which lowers performances, burns the
upper end of the clutch outer cable is fully valves and valve seats, and may cause seri-
seated in its fitting, or it could slip into place ous engine damage.
later, creating enough cable play to prevent
clutch disengagement. Valve clearance for each valve should be checked
and adjusted in accordance with the Periodic Main-
tenance Chart. Inspection and adjustment should be
done only by an authorized Kawasaki dealer.
NOTE
If the engine is hot, wait until the engine cools.
Valve clearance must be checked when the en-
gine is cold (room temperature).

Spark Arrester
• Remove the muffler end mounting bolts.
This vehicle is equipped with a spark arrester. It
j
must be properly maintained to ensure its efficiency.
In accordance with the Periodic Maintenance Chart,
clean the spark arrester.
NOTICE
The spark arrester must be installed cor-
rectly and functioning properly to provide
adequate fire protection.
Spark Arrester Cleaning

WARNING A. Muffler End Mounting Bolts
B. Muffler End
Hot exhaust system parts can cause serious
burns. The exhaust system becomes very
hot soon after the engine is started. To avoid
burns, be sure the exhaust system is cold
before cleaning the spark arrester.

• Take off the spark arrester mounting bolts. • Remove the spark arrester.
j
A. Spark Arrester Mounting Bolts A. Spark Arrester

B. Gasket
• With a wire brush, remove the carbon off the inside

of the spark arrester and muffler.
• Replace the gasket to the new one.
• muffler. spark arrester into the rear end of the
Install the
• Install the muffler end.

Chain Slack Inspection

Drive Chain • Raise the rear wheel off the ground, then rotate
the rear wheel to find the place where the chain is
For safety and to prevent excessive wear, the drive tightest (because it wears unevenly).
j
chain must be checked, adjusted, and lubricated be-
fore riding. If the chain becomes badly worn or mal-
• Push up the drive chain in the middle of the upper
chain run to measure the chain slack. The dis-
adjusted - either too loose or too tight - it could jump tance between the chain and the swingarm (at the
off the sprockets or break. end of the chain slipper) should be within the stan-
dard value.
WARNING Drive Chain Slack
A chain that breaks or jumps off the sprock- Standard 35 a 41 mm (1.4 a 1.6 in.)
ets could snag on the engine sprocket or lock
the rear wheel, severely damaging the motor-
cycle and causing it to go out of control. In-
• Adjust
cation.
the drive chain if its slack is out of specifi-
spect the chain for damage and proper ad-
justment before each ride.
A. Chain Slack

• Inwheel
addition to checking the slack, rotate the rear
to inspect the drive chain for damaged
rollers, loose pins and links and the sprockets
j for unevenly or excessively worn and damaged
teeth.
• If there are any such defects, replace the drive
chain and/or the sprockets.
Chain Slack Adjustment
• Remove the cotter pin from the rear axle nut.
• Loosen the rear axle nut and both chain adjuster
locknuts.
• Turn both chain adjusting bolts evenly until the
drive chain slack (measured between the chain
and the swingarm) is within the standard value.
A. Axle Nut
For the rear wheel to be properly aligned, the chain B. Adjusting Bolt
adjuster end of the left chain adjuster should align C. Locknut
with the same swingarm mark that the chain ad- D. Marks
juster end of the right chain adjuster aligns with. E. Chain Adjuster End
Drive Chain Slack F. Cotter pin
35 a 41 mm (1.4 a 1.6 in.) NOTE
Wheel alignment can also be checked using the
straightedge or string method.
WARNING
Misalignment of the wheel will result in ab-
normal wear, and may result in an unsafe
riding condition. Align the rear wheel using
the marks on the swingarm or measuring the
distance between the center of the axle and
swingarm pivot.

• Tighten both chain adjuster locknuts. • Measure the 20-link section on a straight part of
• Torque the axle nut to the specified torque. the chain from the center of the 1st pin to the cen-
ter of the 21st pin. If the length exceeds the ser-
Rear Axle Nut Tightening Torque
vice limit, the chain should be replaced. Since
j
79 N·m (8.1 kgf·m, 58 ft·lb) overworn sprockets will cause a new chain to wear
faster, inspect both the engine and rear sprockets
• Rotate the wheel, measure the chain slack again
at the tightest position, and readjust it if necessary.
whenever the chain is replaced, and replace them
if necessary.
• Install a new cotter pin through the axle, and
spread its ends.
WARNING
A loose axle nut can lead to an accident re-
sulting in serious injury or death. Tighten
the axle nut to the proper torque and install
a new cotter pin.
• Check the rear brake effect.

Chain Wear Inspection
When the chain has reached its wear limit (i.e.,
when it has stretched by 1.7% of its original length),
it is no longer safe for use and should be replaced.
Since it is impractical to measure the entire length of A. Weight
the chain, determine the degree of wear by measur- B. Tape Measure
ing a 20-link section of the chain.
• Tighten the chain either by using the chain ad-
justers or by hanging a 10 kg (22 lb) weight on the
Drive Chain 20-Link Section
254.0 a 254.6 mm
chain. Standard length
(10.00 a 10.02 in.)
Wear limit 259 mm (10.2 in.)

NOTE Chain Guide Wear Inspection
The drive system was designed for use with • Visually inspect the drive chain guide and replace
it if excessively worn or damaged.
j 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.
To minimize any chance of the Master Link coming
apart, the master link clip must be installed with
the closed end of the “U” pointing in the direction
of chain rotation.
A. Chain Guide
A. Master Link Clip

B. Direction of Rotation

Chain Slipper Wear Inspection Sprocket Wear Inspection

• Visually inspect the front end of the chain slippers
on the swingarm and replace them if worn or dam-
• Visually inspect the sprocket teeth and replace the
sprocket if its teeth are worn or damaged.
aged. Sprocket Tooth Wear
j
A. Chain Slippers A. Good Teeth

B. Swingarm B. Worn Teeth
C. Damaged Teeth
NOTE
Sprocket wear is exaggerated in the illustration.

Chain Lubrication
Lubrication of the drive chain is necessary after rid- Handlebar
ing in the rain or mud, or any time the chain appears
j dry. A heavy oil such as SAE90 is preferred to a To suit various riding positions, the handlebar
lighter oil because it will stay on the chain longer and can be adjusted by turning the handlebar holders
provide better lubrication. around.
• Apply oil to the side of the rollers so that it will
penetrate to the rollers and bushings.
• Remove the handlebar clamp bolts, the clamps
and the handlebar.
• Wipe off any excess oil. • Check the handlebar for bent or crack.
A. Handlebar Clamps
B. Bolts
C. Handlebar

• Loosen the handlebar holder nuts, turn the han-

dlebar holders 180°, and securely tighten the nuts.
• Align the gap at the rear with the punch mark on
the handlebar.
j
A. Handlebar Holders A. Front

B. Handlebar Holder Nuts B. Handlebar Clamps
C. Punch Mark
• Put the handlebar on the handlebar holders. D. Gap
• Mount the handlebar clamps.
• Tighten the front and rear bolts of the handlebar
clamps equally. If the handlebar clamps are cor-
rectly installed, there will be even gap on the front
and rear side of the clamp after the bolts torqued.
Handlebar Clamp Bolts Tightening Torque
25 N·m (2.5 kgf·m, 18 ft·lb)
NOTE
Tighten the two clamp bolts alternately two times
to ensure even tightening torque.

• Check the front brake for the proper brake effect,

or no brake drag. Brakes
j Disc and disc pad wear is automatically compen-
sated 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.
Brake Lever Position
The brake lever position can be adjusted to suit
the rider’s preference.
• To adjust the brake lever position, loosen the lock-
nut, and turn the adjuster to either side.
• After adjustment, tighten the locknut securely.
A. Brake Lever
B. Adjuster
C. Locknut

• Test the braking power and check that there is no

brake drag.
NOTICE
Do not spill brake fluid onto any painted sur-
WARNING face. j
Do not use fluid from a container that has
Air in the brake lines diminish braking perfor- been left open or that has been unsealed for
mance and can cause an accident resulting a long time.
in injury or death. If the brake lever or pedal Check for fluid leakage around the brake sys-
feels mushy when it is applied, there might tem fittings.
be air in the brake lines or the brake may be Check for brake hose damage.
defective. Have the brake checked immedi-
ately by an authorized Kawasaki dealer.
Brake Fluid Level Inspection (Front and Rear
Reservoirs)
Disc Brake Fluid With the front or rear reservoir positioned horizon-
Inspect the brake fluid level in the front and rear tally, the brake fluid must always be above the mini-
reservoirs and change the brake fluid in accordance mum level line.
with the Periodic Maintenance Chart. The brake fluid
should also be changed when contaminated with dirt
or water.
Use only heavy-duty brake fluid as follows.
Front brake fluid : DOT 3 or DOT 4

Rear brake fluid : DOT 4
NOTE
The motorcycle is shipped with brake fluid DOT4
in the brake system.
A. Front Reservoir
B. Minimum Level Line

• Iflowthethebrake fluid in the front or rear reservoir is be-

minimum level line, check for fluid leaks
in the brake line and fill the reservoir to the maxi-
j mum level line. (The step inside the front and rear
reservoirs indicate the maximum level.)
A. Rear Reservoir
B. Minimum Level Line
A. Front Reservoir
B. Maximum Level Line

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
j
than 1 mm (0.04 in.), have both pads in the caliper
replaced as a set. Pad replacement should be done
by an authorized Kawasaki dealer.
Usable Brake Pad Range
A. Rear Reservoir
B. Maximum Level Line
WARNING
Mixing brands and types of brake fluid can
reduce the brake system’s effectiveness
and cause an accident resulting in injury
or death. Do not mix two brands of brake
fluid. Change the brake fluid in the brake line
completely if the brake fluid must be refilled A. Lining Thickness
but the type and brand of the brake fluid that B. 1 mm (0.04 in.)
is already in the reservoir are unidentified.

Steering Adjustment
Steering • Raise the front wheel off the ground using a jack
(special tool).
j The steering should always be kept adjusted so • Remove the handlebar.
that the handlebar will turn freely but not have ex-
cessive play.
• bolts.
Loosen the left and right front fork upper clamp
Steering Inspection • Remove the steering stem head nut, and raise the
front fork upper clamp.
• To check the steering adjustment, raise the front
wheel off the ground using a jack (special tool).
• Push the handlebar lightly to either side. If the
handlebar continues moving under its own mo-
mentum, the steering is not too tight.
• Squatting in front of the motorcycle, grasp the
lower ends of the front fork at the axle, and push
and rock the front fork back and forth as shown.
If play is felt, the steering is too loose and needs
to be adjusted.
A. Front Fork Upper Clamp

B. Steering Stem Head Nut
C. Front Fork Upper Clamp Bolts

• Turn the steering stem locknut with a stem nut

wrench (special tool) to obtain the proper adjust-
• Install the handlebar.
ment.
NOTE
Tighten the two clamp bolts alternately two times j
• Install the handlebar and apply the specified

torque, check the steering again and readjust it if
necessary.
Handlebar Clamp Bolts Tightening Torque
25 N·m (2.5 kgf·m, 18 ft·lb)
NOTE
Tighten the two clamp bolts alternately two times
A. Steering Stem Locknut

• Check the front brake for the proper brake effect,
or no brake drag.
B. Stem Nut Wrench (P.N. 57001-1100)
• Install
position.
the front fork upper clamp to the original
• Apply the specified torques to the steering head

nut and front fork upper clamp bolts.
Steering Stem Head Nut Tightening Torque
64 N·m (6.5 kgf·m, 47 ft·lb)
Front Fork Upper Clamp Bolt Tightening Torque

20 N·m (2.0 kgf·m, 15 ft·lb)

NOTICE
Front Suspension If the inner tube is badly bent or creased,
j replace it. Excessive bending, followed by
Front Fork Inspection subsequent straitening, can weaken the in-
• Holding the brake lever, pump the front fork back
and forth manually to check for smooth operation.
ner tube.
• Visually inspect the front fork for oil leakage, scor-

ing or scratches on the outer surface of the inner
tube.
• IfKawasaki
necessary, repair or replace by an authorized
dealer.
A. Inner Tube

Rebound Damping Adjustment (KLX140B

Rear Suspension ONLY)
To adjust the rear shock absorber rebound damp-
ing, turn the rebound damping adjuster at the bottom
j
Rear Shock Absorber Inspection of the rear shock absorber with a standard tip screw-
• Pump the seat down and up by 4 or 5 times, and
inspect the smooth stroke.
driver.
• Iftheit oildoes not smoothly or noise is found, inspect

leak and rear shock absorber mounting.
• Visually
leakage.
inspect the rear shock absorber for oil
• IfKawasaki
necessary, repair or replace by an authorized
dealer.
Rear Shock Absorber Adjustment
The spring preload of the shock absorber can be
adjusted or the spring can be replaced with an op-
tional one to suit various riding conditions. In addi-
tion, the damping force can be adjusted easily, mak-
ing it unnecessary to change the oil viscosity.
A. Rebound Damping Adjuster

If the damping feels too soft or too stiff, adjust it in
accordance with the following table.

Rebound Damping Adjuster Settings NOTICE
Do not force the rebound and compression
j damping force adjusters beyond the fully
seated position, or the adjusting mechanism
may be damaged.
Compression Damping Adjustment (KLX140B

ONLY)
To adjust the rear shock absorber compression
damping, turn the compression damping adjuster on
the gas reservoir with a standard tip screwdriver.
A. Seated Position (Adjuster Turned Fully

Clockwise)
B. Softer (Counterclockwise)
C. Harder (Clockwise)
D. Standard Setting
* Number of turns counterclockwise usable
range-22 clicks or more
Standard Rebound Damping Adjuster Setting
10 th clicks*
* Counterclockwise from the fully seated position A. Compression Damping Adjuster

If the damping feels too soft or too stiff, adjust it in
accordance with the following.

Compression Damping Adjuster Setting Spring Preload Adjustment

The compression damping adjuster is a 4-stage The rear shock absorber can be adjusted by
adjustable. changing the spring preload for various riding and
loading conditions. If the spring action feels too
j
soft or too stiff, have it adjusted by an authorized
Kawasaki dealer.
NOTE
The installation and removal of the rear shock ab-
sorber should be done by an authorized Kawasaki
dealer.
A. 1st (Softest)
B. 2nd
C. 3rd
D. 4th (Hardest)
E. Adjusting Mark
Standard Compression Damping Adjuster

Setting
2nd position

Spokes and Rims
Wheels The spokes on both wheels must all be securely
and evenly tightened and not be allowed to loosen.
j Unevenly tightened or loose spokes will cause the
Tire Air Pressure rim to warp, the nipples and spokes to fatigue more
Tire air pressure affects traction, handling, and tire
quickly, and the spokes to break.
life. Adjust the tire air pressure to suit track condi-
tions and rider preference, but keep it close within
the recommended range.
• To check the tire air pressure, remove the air valve
cap, and make sure to tighten the cap securely
after checking the tire pressure.
• Reduce the tire air pressure to increase the tire
tread surface on the ground when riding on a wet,
muddy, sandy or slippery track.
• Increase the tire air pressure to prevent damage
or punctures (though the tires will skid more easily)
when riding on a pebbly or hard track.
Tire Air Pressure Adjustable Range
80 kPa (0.8 kgf/cm², 11 psi) a
100 kPa (1.0 kgf/cm², 14 psi) A. Spoke and Spark Plug Wrench
NOTE
Tire air pressure should be checked when the tires
are cold, before you ride the motorcycle.

Bead Protector Rim Runout

There is a bead protector on the both wheels. The Set up a dial gauge on the side of the rim and
bead protector prevents the tire and tube from slip- rotate the wheel to measure its axial runout. The
ping on the rim and damaging the valve stem. Valve difference between the highest and lowest readings
j
stem damage may cause the tube to leak, necessi- is the amount of runout.
tating tube replacement. In order to keep the tire and
tube in position on the rim, inspect the bead protec-
• Set up the dial gauge on the inner circumference
of the rim and rotate the wheel to measure its ra-
tor before riding and tighten it if necessary. Tighten dial runout. The difference between the highest
the valve stem nut finger tight only. and lowest readings is the amount of runout.
• A certain amount of rim warpage (runout) can be
corrected by recentering the rim, that is, by loos-
ening some spokes and tightening other to change
the position of certain portions of the rim. If the rim
is badly bent, however, it should be replaced.
NOTE
The welding spot of the rim may show exces-
sive runout. Disregard this when measuring rim
runout.
A. Bead Protector

Rim Runout
A. Axial Rim Runout Measurement

A. Rim
B. Radial Runout
C. Axial Runout
Rim Runout Maximum Limit

Axial
2.0 mm (0.08 in.)
Radial
A. Radial Rim Runout Measurement

Hoses Inspection
• Check the hose are securely
clamps are tightened correctly.
connected and
Check the brake and fuel hoses for cracks or de-

j
terioration, and the connections for looseness in ac-
cordance with the Periodic Maintenance Chart.
• Inspect the brake hose and fittings for deteriora-
tion, cracks and signs of leakage by bending or
twisting the hoses.
• If damaged, replace the hoses.
A. Leakage
B. Cracks
C. Bulges
D. Ozone Cracks

Self-discharge
Battery Approx. Number of Days from
j The battery installed in this motorcycle is a sealed
100% charged to 100% discharged
Temperature
type, so it is not necessary to check the battery elec- Lead-Antimony Lead-Calcium
trolyte level or add distilled water. Battery Battery
However, in order to maximize battery life and en-
sure that it will provide the power needed to start 40°C (104°F) 100 Days 300 Days
the motorcycle you must properly maintain the bat- 25°C (77°F) 200 Days 600 Days
tery’s charge. When used regularly, the charging
system in the motorcycle helps keep the battery fully 0°C (32°F) 550 Days 950 Days
charged. If your motorcycle is only used occasion-
ally or for short periods of time, the battery is more Current Drain
likely to discharge. Days from 100% Days from 100%
Due to their internal composition, batteries contin- Discharging
charged to 50% charged to 100%
ually self discharge. The discharge rate depends Ampere
discharged discharged
on the type of battery and ambient temperature. As
temperatures rise, so does the discharge rate. Ev- 7 mA 60 Days 119 Days
ery 15°C (59°F) doubles the rate. 10 mA 42 Days 83 Days
Electrical accessories, such as digital clocks and
computer memory, also draw current from the bat- 15 mA 28 Days 56 Days
tery even when the engine stops. Combine such 20 mA 21 Days 42 Days
“engine-stop” draws with hot temperature, and a bat- 30 mA 14 Days 28 Days
tery can go from fully charged to completely dis-
charged in a matter of days. In extremely cold weather the fluid in an inade-
quately charged battery can easily freeze, which
can crack the case and buckle the plates. A fully
charged battery can withstand sub-freezing temper-
atures with no damage.

Battery Sulfation Kawasaki-recommended chargers are:

A common cause of battery failure is sulfation. Battery Mate 150-9
Sulfation occurs when the battery is left in a dis- OptiMate 4
charged condition for an extended time. Sulfate is a Yuasa MB-2040/2060
j
normal by product of the chemical reactions within a Christie C10122S
battery. But when continuous discharge allows the If the above chargers are not available, use equiv-
sulfate to crystallize in the cells, the battery plates alent one.
become permanently damaged and will not hold a For more details, ask your Kawasaki dealer.
charge. Battery failure due to sulfation is not war-
Battery Charging
rantable.
Battery Maintenance
•Remove the battery from the motorcycle (see Bat-
tery Removal).
It is the owner’s responsibility to keep the battery
fully charged. Failure to do so can lead to battery
•Attach the leads from the charger and charge the
battery at a rate (amperage × hours) that is indi-
failure and leave you stranded. cated on the battery. If it is not possible to read
If you are riding your vehicle infrequently, inspect the rate, charge the battery at an amperage that
the battery voltage weekly using a voltmeter. If is about 1/10th of the battery capacity.
it drops below 12.8 volts, the battery should be
charged using an appropriate charger (check with
•The charger will keep the battery fully charged un-
til you are ready to reinstall the battery in the mo-
your Kawasaki dealer). If you will not be using the torcycle (see Battery Installation).
motorcycle for longer than two weeks, the battery
should be charged using an appropriate charger. NOTICE
Do not use an automotive-type quick charger that Do not install a conventional battery in this
may overcharge the battery and damage it. motorcycle, or the electrical system cannot
NOTE work properly.
Leaving the battery connected causes the electri-
cal components to make the battery discharged, NOTE
resulting the over discharge of the battery. In this If you charge the sealed battery, never fail to ob-
case, the repair or replacement of the battery is serve the instructions shown in the label on the
not included in the warranty. If you do not drive for battery.
four weeks or more, disconnect the battery from
the vehicle.

WARNING • Remove the bolt and remove the seat.

Lead is a toxic substance. Battery posts, ter-
j minals and related accessories contain lead
and lead compounds. Wash hands after han-
dling.
Battery Removal
• Remove the bolt and remove the side cover.
A. Bolt
B. Seat
A. Bolt
B. Side Cover

• Disconnect the cables from the battery, first from Battery Installation
the (–) terminal and then the (+) terminal. • Place the battery in the battery case.
• Connectthethebattery
Install holder and tighten the bolts.
j
• connect the black cableto tothethe(+)(–)terminal,
red cable and then
terminal.
NOTE
Install the battery in the reverse order of the Bat-
tery Removal.
NOTICE
Installing the (–) cable to the (+) terminal of
the battery or the (+) cable to the (–) termi-
nal of the battery can seriously damaged the
electrical system.
A.
B.
(+) Terminal
(–) Terminal
• Put a light coat of grease on the terminals to pre-
vent corrosion.
C.
D.
Battery Holder
Bolts • Reinstall the parts removed.
• Take out battery holder by removing the bolt.
• Cleanthethebattery
Take out of the case.
• and water. Be sureusing
battery a solution of baking soda
that the cable connections are
clean.

WARNING
Fuse Substituting fuses can cause wiring to over-
j The main fuse (10 A) is mounted on the starter
heat, catch fire and/or fail. Do not use any
substitute for the standard fuse. Replace the
relay under the seat. If a fuse fails during operation,
blown fuse with a new one of the correct ca-
inspect the electrical system to determine the cause,
pacity, as specified on the junction box and
and then replace it with a new fuse of proper amper-
main fuse.
age.
A. Main Fuse (10 A)

B. Spare Fuse

Tightening Torques of Nuts and Bolts

j
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.
1. Front Fork Clamp Bolts 10. Engine Mounting Bolts and Nuts
2. Handlebar Clamp Bolts 11. Camshaft Chain Tensioner Bolts
3. Clutch Lever Holder Bolt 12. Swingarm Pivot Shaft Nut
4. Valve Adjusting Cap Bolts 13. Rear Sprocket Nut
5. Camshaft Cap Bolts 14. Seat Bolt
6. Spokes 15. Engine Oil Drain Plug
7. Front Brake Disc Mounting Bolts 16. Side Stand Bolt
8. Front Axle Nut 17. Side Stand Nut
9. Front Brake Caliper Bolts

18. Spark Plug 26. Rear Axle Nut

19. Cylinder Head Bolts 27. Rear Brake Caliper Bolts
20. Muffler End Mounting Bolts 28. UNI-TRAK® Lever Rod Bolt
21. Spark Arrester Mounting Bolts 29. Rear Brake Pedal Pivot Bolt
22. Rear Master Cylinder Mounting Bolts 30. Rear Shock Absorber Bolt and Nut
23. Steering Head Nut 31. UNI-TRAK® Arm Bolt
24. Front Master Cylinder Mounting Bolts 32. Rear Frame Bolts
25. Rear Brake Disk Mounting Bolts 33. Oil Filter Cover Bolts

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 become damaged, broken, or fall out.
j
Part Name N·m kgf·m ft·lb
Cylinder Head Cover Bolts 8.8 0.9 (78 in·lb)
Cylinder Head Bolts (M8) 22 2.2 16
(M6) 15 1.5 11
Camshaft Chain Tensioner Bolts 5.2 0.53 (46 in·lb)
Camshaft Cap Bolts 8.8 0.9 (78 in·lb)
Engine Oil Drain Plug 18 1.8 13
Oil Filter Cover Bolts 8.8 0.9 (78 in·lb)
Spark Plug 13 1.3 9.6
Generator Cover Bolts 8.8 0.9 (78 in·lb)
Shift Pedal Tie Rod 9.8 1.0 (87 in·lb)
(Left hand threads) 9.8 1.0 (87 in·lb)


Brake Caliper Bolts (Front) 34 3.5 25
j (Rear) 25 2.5 18
Brake Disc Mounting Bolts (Front) 9.8 1.0 (87 in·lb)
(Rear) 9.8 1.0 (87 in·lb)
Engine Bracket Nut/Bolt M8 29 3.0 21
M10 49 5.0 36
Engine Mounting Bolts 49 5.0 36
Front Axle Nut 79 8.1 58
Front Fork Clamp Bolts 20 2.0 14
Handlebar Clamp Bolts 25 2.5 18
Side Stand Bolt 29 3.0 21
Side Stand Nut 44 4.5 32
Swingarm Pivot Shaft Nut 108 11.0 80
Rear Axle Nut 79 8.1 58
Rear Brake Pedal Pivot Bolt 25 2.5 18
Rear Frame Bolts 34 3.5 25
Rear Shock Absorber Upper Bolt 39 4.0 29


Rear Shock Absorber Lower Nut 29 3.0 21 (KLX140A)
Rear Shock Absorbor Lower Bolt 39 4.0 29 (KLX140B)
j
Spokes 2.0 0.2 (18 in·lb)
Steering Stem Head Nut 64 6.5 47
Steering Stem Locknut 4.9 0.5 (43 in·lb)
®
UNI-TRAK Arm Bolt 59 6.0 44
®
UNI-TRAK Rod Bolts 59 6.0 44
Rear Sprocket Nuts 32 3.3 24
Front Brake Master Cylinder Clamp Bolts 8.8 0.9 (78 in·lb)
Rear Brake Master Cylinder Mounting Bolts 10 1.0 (88 in·lb)

Cleaning Your Motorcycle

• Avoid applying degreaser to seals, brake pads,
and tires.
j • Always
isher.
use non-abrasive wax and cleaner/pol-
General Precautions
Frequent and proper care of your Kawasaki mo- • Avoid all harsh chemicals, solvents, detergents,
and household cleaning products such as ammo-
torcycle will enhance its appearance, optimize over-
nia-based window cleaners.
all performance, and extend its useful life. Covering
your motorcycle with a high quality, breathable mo- • Gasoline, brake fluid, and coolant will damage the
finish of painted and plastic surfaces: wash them
torcycle cover will help protect its finish from harmful
off immediately.
UV rays, pollutants, and reduce the amount of dust
reaching its surfaces. • Avoid wire brushes, steel wool, and all other abra-
sive pads or brushes.
WARNING • Use care when washing the plastic parts as they
can easily be scratched.
Build-up of debris or flammable material in
and around the vehicle chassis, engine, and
• Avoid using pressure washers; water can pene-
trate seals and electrical components and damage
exhaust can cause mechanical problems and your motorcycle.
increase the risk of fire.
When operating the vehicle in conditions
• Avoid spraying water in delicate areas such as in
air intakes, carburetors, brake components, elec-
that allow debris or flammable material to trical components, muffler outlets, and fuel tank
collect in and around the vehicle, inspect the openings.
engine, electrical component and exhaust
areas frequently. If debris or flammable Washing Your Motorcycle
materials have collected, park the vehicle • Rinse your bike with cold water from a garden
hose to remove any loose dirt.
outside and stop the engine. Allow the
engine to cool, then remove any collected • Mix a mild neutral detergent (designed for motor-
cycles or automobiles) and water in bucket. Use
debris. Do not park or store the vehicle in
an enclosed space prior to inspecting for a soft cloth or sponge to wash your motorcycle. If
build-up of debris or flammable materials. needed, use a mild degreaser to remove any oil or
grease build up.
• Be sure the engine and exhaust are cool before • After washing, rinse your motorcycle thoroughly
with clean water to remove any residue (residue
washing.

from the detergent can damage parts of your mo-

torcycle).
• IfIf the
the boot is damaged, replace it with a new one.
boot is not positioned in the groove correctly,
• Use a soft cloth to dry your motorcycle. As you dry,
inspect your motorcycle for chips and scratches.
replace it in the correct position.
j
Do not let the water air dry as this can damage
the painted surfaces.
• After cleaning your motorcycle, check the rubber
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.
A. Wrongly set lip not in the correct position

B. Lip set correctly in the groove
• Start the engine and let it idle for several minutes.

The heat from the engine will help dry moist areas.
• Carefully ride your motorcycle at a slow speed and
apply the brakes several times. This helps dry
the brakes and restores them to normal operating
A. Boots
performance.
• Lubricate the drive chain to prevent rusting.

NOTE Plastic Parts
The front fork may have a scrach by the spattered After washing use a soft cloth to gently dry plastic
stones, etc. but it is no effect for the performance parts. When dry, treat the non-painted plastic parts
j with an approved plastic cleaner/polisher product.
of the front fork. After riding in an area where the
roads are salted or near the ocean, immediately
wash your motorcycle with cold water. Do not use NOTICE
warm water as it accelerates the chemical reaction Plastic parts may deteriorate and break if
of the salt. After drying, apply a corrosion protec- they come in contact with chemical sub-
tion spray on all metal and chrome surfaces to pre- stances or household cleaning products
vent corrosion. such as gasoline, brake fluid, window clean-
ers, thread-locking agents, or other harsh
Semi-gloss Finish chemicals. If a plastic part comes in contact
To clean the semi-gloss finish; with any harsh chemical substance, wash it
• When washing the motorcycle, always use a mild
neutral detergent and water.
off immediately with water and a mild neu-
tral detergent, and then inspect for damage.
• The semi-gloss finish effect may be lost when the
finish is excessively rubbed.
Avoid using abrasive pads or brushes to
clean plastic parts, as they will damage the
• If any doubt, consult an authorized Kawasaki
dealer.
part’s finish.
Painted Surfaces Chrome and Aluminum

After washing your motorcycle, coat painted sur- Chrome and uncoated aluminum parts can be
faces, both metal and plastic, with a commercially treated with a chrome/aluminum polish. Coated
available motorcycle/automotive wax. Wax should aluminum should be washed with a mild neutral de-
be applied once every three months or as conditions tergent and finished with a spray polish. Aluminum
require. Avoid surfaces with “satin” or “flat” finishes. wheels, both painted and unpainted can be cleaned
Always use nonabrasive products and apply them with special non-acid based wheel spray cleaners.
according to the instructions on the container.

Leather, Vinyl, and Rubber

If your motorcycle has leather accessories, special Lubrication
care must be taken. Use a leather cleaner/treatment
to clean and care for leather accessories. Washing Lubricate the areas shown in the illustrations of
j
leather parts with detergent and water will damage this section with either motor oil or regular grease,
them, shortening their life. after each race and whenever the vehicle has been
operated under wet or rainy conditions, especially
Vinyl parts should be washed with the rest of the after using a high-pressure spray washer. Before
motorcycle, then treated with a vinyl treatment. lubricating a part, clean off any rust with rust remover
and wipe off any grease, oil, dirt, or grime.
The sidewalls of tires and other rubber compo-
nents should be treated with a rubber protectant to
General Lubrication
Apply motor oil or grease to the following pivots:
help prolong their useful life.
• Clutch lever
WARNING • Front brake lever
Rubber protectants can be slippery and, if

used on the tread area, cause loss of traction
resulting in accident causing injury or death.
Do not apply rubber protectant to any tread
area.

• Rear brake pedal Apply an aerosol cable lubricant with a pressure

• Foot peg rod joints
Rear brake lubricator on all cables:
j • • Clutch cable
• Throttle cable
• Hot starter cable
Cable Lubrication

Apply grease to the following points: Drive Chain Lubrication

• Upper end of clutch cable Lubricate the drive chain after riding through rain
• Upper end of throttle cable or on wet track, or any time that the chain appears
j
• Upper end of hot starter cable dry. A heavy oil such as SAE90 is preferred to a
• Shift pedal lighter oil because it will stay on the chain longer and
provide better lubrication.
• Apply oil to the sides of the rollers so that it will
penetrate to the rollers and bushings.
• Wipe off any excess oil.
A. Grease.

92 TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
NOTE Fuel-air mixture incorrect
This troubleshooting guide is not exhaustive and • Idle adjusting screw improperly adjusted
j does not give every possible cause for each prob- • Air cleaner element clogged
lem listed. It is meant simply as a quick guide to Compression low
assist you in troubleshooting for some of the more
common difficulties. • Spark plug loose
Poor or no high-speed performance –
Starting failure or difficulties – Fuel-air mixture incorrect
Engine does not turn over • Air cleaner element clogged
•Transmission not in neutral • Air cleaner duct loose
•Engine stop switch set to OFF Misfiring
Compression low • Spark plug worn
• Spark plug loose • Spark plug cap poorly connected or shorted
Spark missing or weak Knocking
• Spark plug faulty • Fuel poor quality
• Spark plug cap poorly connected or shorted Other
Fuel does not flow • Brake dragging
• No fuel in tank • Engine overheating
Engine
• Fuel hose clogged • Throttleoverheating
• tap clogged
Fuel • Engine oilvalve does not fully open
• Engine oil quality excessive
Engine flooded
• Starting technique faulty • viscosity too high
Engine overheating –
Poor low-speed performance –
• Brake dragging
Spark weak • Clutch slipping
•Spark plug faulty
•Spark plug gap excessive

TROUBLESHOOTING GUIDE 93
Clutch not operating smoothly – Shock absorption too hard

Clutch slipping •Tire air pressure too high
• Friction plate worn Shock absorption too soft

• Clutch springs weak • Tire air pressure too high
Clutch doesn’t disengaging properly • Suspension
Front fork spring worn
• Engine oil deteriorated • leaks oil j

• Engine oil viscosity too high Poor braking performance –
Poor handling and/or stability – • Air in the brake line
• Brake pad
Brake or disc worn
Handlebar hard to turn • Brake disc warped
fluid leaking
•Steering stem locknut too tight • Brake pads contaminated
•Tire air pressure too low • Brake fluid deteriorated
•Steering stem lubrication insufficient • Primary and/or secondary master cylinder cup(s)
Handlebar vibrates or shakes • damaged
• Swingarm bent
• Master cylinder scratched
• Front fork bent
• Brake maladjusted (lever or pedal play excessive)
• Frame bent
• Pivot shaft warpedincorrect
Wheel alignment
• Right/left front fork oil level uneven
•

94 STORAGE
STORAGE
WARNING
Before Storage Gasoline is extremely flammable and can be
explosive under certain conditions, creating
When the motorcycle is to be stored for any length the potential for serious burns. Always stop
of time, it should be prepared for storage as follows. the engine and never smoke while handling
• Clean the entire vehicle thoroughly. fuel. Make sure the area is well-ventilated
j • Run the engine for about five minutes to warm the
oil, then stop it and drain the engine oil.
and free from any source of flame or sparks;
this includes any appliance with a pilot light.
Make sure the engine is cold before working.
WARNING Wipe any fuel off the engine before starting
Engine oil is a toxic substance. Dispose of it. Gasoline is a toxic substance. Dispose of
used oil properly. Contact your local author- gasoline properly. Contact your local author-
ities for approved disposal methods or pos- ities for approved disposal methods.
sible recycling.
• Remove the spark plug and spray fogging oil,
• Install the oil drain plugs and fill in fresh engine oil. such as Kawasaki K-Kare Fogging oil (part num-
• Empty the fuel tank and the carburetor float bowl.
(Fuel will deteriorate if left for a long time.)
ber K61030-002), directly into the cylinder. Kick
the engine over slowly a few times to coat the
cylinder wall. Install the spark plug.
• Lubricate the drive chain and all the cables.
• Spray oil on all unpainted metal surfaces to pre-
vent rusting. Avoid getting oil on rubber parts and
on the brakes.
• Lift the motorcycle on a box or stand so that both
wheels are raised off the ground. (If this cannot be
done, put boards under the front and rear wheels
to keep dampness away from the tire rubber.)
• Tie a plastic bag over the muffler to prevent mois-
ture from entering.

STORAGE 95
• Cover
from it.
the motorcycle to keep dust and dirt away
After Storage
• Remove the plastic bag from the muffler.

• Make sure the spark plug is tight.
NOTE
Fit the plug cap securely onto the spark plug, and
pull the cap lightly to make sure that it is properly
installed. j
• Fill the fuel tank with fuel.
• Check all the points listed in the Daily pre-ride
checks section.
• Perform a General Lubrication Procedure.

96 ENVIRONMENTAL PROTECTION
ENVIRONMENTAL PROTECTION
Kawasaki subscribes to the guidelines of Tread Lightly! a program dedicated to protecting the great outdoors
through education and fostering responsible enjoyment of public lands. When using your Kawasaki motorcycle,
please follow these Tread Lightly! guidelines:
Tread Lightly!
Travel responsibly on designated roads and trails or in permitted areas.
Respect the rights of others including private property owners and all recreational trail users, campers and
others to allow them to enjoy their recreational activities undisturbed.
Educate yourself by obtaining travel maps and regulations from public agencies, planning for your trip, taking
recreation skills classes, and knowing how to use and operate your equipment safely.
A void sensitive areas such as meadows, lakeshores, wetlands and streams, unless on designated routes.
This protects wildlife habitat and sensitive soils from damage.
D o your part by leaving the area better than you found it, properly disposing of waste, minimizing the use of
fire, avoiding the spread of invasive species, restoring degraded areas, and joining a local enthusiast organi-
zation.
Properly discard used batteries, tires, engine oil, other vehicle components, or the entire vehicle that you
might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency
for their proper disposal procedure.

WIRING DIAGRAM 97
WIRING DIAGRAM

98 YOUR WARRANTY/OWNER SATISFACTION
YOUR WARRANTY/OWNER SATISFACTION

Welcome to the Kawasaki family!
Congratulations on buying your Kawasaki vehicle. You’ve chosen a great, high-quality product with state-of-the
-art features and built to Kawasaki’s high standards. Your satisfaction is important to your authorized Kawasaki
dealer and to Kawasaki Motors Corp., U.S.A. Here is some important information regarding your vehicle’s lim-
ited warranty.
Frequently Asked Questions
What is a Limited Warranty?
The most important thing to know about your warranty is that it protects you from manufacturing defects in
material or workmanship during the warranty period. You can find the warranty period in the Kawasaki Limited
Warranty Certificate your Kawasaki dealer provided to you at the time of sale. The warranty does not cover the
cost of regularly-scheduled maintenance. The warranty also does not apply to the normal wear of items such
as tires, brake pads, transmission drive belts, chains, sprockets, etc.
What is the Good Times Protection Plan?
Much of the warranty coverage offered by the limited warranty can be extended by purchasing Kawasaki’s
Good Time™ Protection Plan (GTPP). See your Kawasaki dealer or go to Kawasaki.com for more information
if you don’t already have the GTPP.
What 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.

YOUR WARRANTY/OWNER SATISFACTION 99
You will be responsible for paying for routine maintenance, including the first scheduled service. You can have
the required servicing done by your Kawasaki dealer (recommended) or an equally-qualified service facility.
You can also do your own maintenance work if you have the proper tools, service references, and mechanical
skills. However, if a failure is found to be caused by improper servicing, it would not be covered by the limited
warranty.
You may purchase a Kawasaki Service Manual and any necessary special tools directly from your Kawasaki
dealer.
You will be responsible for paying for repairs needed because of an accident, to replace worn parts such as
tires, chains, brakes, and for repairs needed because of a lack of maintenance, misuse or racing.
Whether you do it yourself or take your vehicle to a Kawasaki dealer, 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 the maintenance so that in the event of a failure you can document the service history.
What Are The Dealership’s Responsibilities?
Your Kawasaki dealer offers a wide range of services, parts, accessories, and information on your product and
on Kawasaki.
Each dealer is independently owned and operated and is responsible for the dealership’s operations, its repair,
warranty, and service work, and its personnel.
Your dealer is responsible for completing the set up and pre-delivery service of your new Kawasaki vehicle. The
dealership should also explain its operation, maintenance, and warranty provisions so you understand them at
the time of purchase or at any other time you have questions.
The dealership is responsible for inspecting your Kawasaki vehicle if there is a failure, investigating the cause
of the problem, and getting any needed authorization from Kawasaki if the repair is one that will be covered by
the limited warranty. The dealership will also file all necessary paperwork. The dealership is responsible for
correctly completing any necessary repairs, whether they are covered by the limited warranty or not.

100 YOUR WARRANTY/OWNER SATISFACTION
How Do I Get Warranty Service?
If there is a problem with your vehicle within the limited warranty period, you will need to schedule a service
appointment and provide any maintenance records to an authorized Kawasaki dealer for inspection and diag-
nosis. You can go to any Kawasaki dealer for warranty repairs. Your Kawasaki dealer will inspect your vehicle
and give you the results of the inspection. The dealer will perform the repairs at no cost to you if it is determined
that the problem is covered by the warranty.
Kawasaki will work with your dealer to resolve any warranty issues. No authorization for warranty work can be
given until your vehicle has been inspected 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, it is best to discuss the situation with the
appropriate dealership manager. If you have already done this, then contact the dealership’s owner or general
manager to request a review of the issue.
If you are unable to resolve a problem after consulting with the dealership management and need further as-
sistance, contact Kawasaki Motors Corp., U.S.A. at the address below. Please be certain to provide the model,
vehicle identification number (VIN), mileage or hours of use, accessories, dates that events occurred and what
action has been taken by both you and your dealer. Include the name and address of the dealership. To
assist us in resolving your inquiry, please include copies of related receipts and any other pertinent informa-
tion including the name of the dealership personnel with whom you have been working. Upon receipt of your
correspondence, Kawasaki Motors Corp., U.S.A. will contact the 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 Kawasaki. Your Kawasaki dealer should
either be able to answer any other questions you might have immediately or be able to find the answer for you.

YOUR WARRANTY/OWNER SATISFACTION 101
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

102 REPORTING SAFETY DEFECTS
REPORTING SAFETY DEFECTS

(For Products Sold in the Continental United States of America Only)
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you
should immediately inform the Consumer Product Safety Commission (CPSC) in addition to notifying Kawasaki
Motors Corporation, U.S.A.
If the CPSC receives similar complaints, it may open an investigation and if 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.

MAINTENANCE RECORD 103
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 Dealer Name Dealer Address

104 MAINTENANCE RECORD






(TM) Kawasaki Manual de Propietario Kawasaki KLX 140 y KLX 140 L 2012 en Ingles PDF

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com manuals search engine

A Table of Contents is included after the

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• This vehicle is designed for the operator only, no passengers.

• Respect the environment and the rights of other people.

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KAWASAKI HEAVY INDUSTRIES, LTD.

©2012 Kawasaki Heavy Industries, Ltd. Feb. 2012. (1)

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Tire size, type:

Specifications are subject to change without notice.

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1. Clutch Lever 5. Front Brake Lever

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9. Front Fork 16. Brake Caliper

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23. Muffler 27. Chain Adjuster

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A. Fuel Tank Cap

Filling the Tank:

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A. Engine Stop Switch

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A. Starter Button • Shift the transmission into neutral.

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When engine is cold:

A. Engine Stop Switch

• Leaving the throttle completely closed, push the

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• Even after the engine has started, do not push

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A. Engine Stop Switch

• Turn the fuel tap lever to the OFF position.

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MAINTENANCE AND ADJUSTMENT

EMISSION CONTROL INFORMATION

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Periodic Maintenance Chart

G Air cleaner element - clean † • • • 43

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I Drive chain guide and slipper - inspect † • • • 58, 59

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FREQUENCY Initial Every

H (K) Wheel bearing - check † • • –

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Oil Level Inspection