2002–2014 Kawasaki KLX110 / KLX110L Service Manual
This comprehensive manual covers diagnostics, removal sequences, and maintenance for the KLX110/KLX110L. Includes engine top end, fuel system, clutch, and wheels/tires. Part No. 99969-1078-01.
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Models Covered & Key Technical Specifications
Kawasaki KLX110, KLX110L (99969-1078-01) – 2002–2014
This Service Manual provides detailed diagnostic and repair procedures for the KLX110 and KLX110L models.
- Engine Top End Specifications: Standard camshaft height measurements for exhaust and inlet valves are provided, ensuring precise valve adjustments.
- Fuel System Performance: Carburetor specifications, including main jet, pilot screw settings, and float height, are detailed for optimal fuel delivery.
- Clutch System Measurements: Friction and steel plate thickness, along with warp specifications, are outlined to ensure proper clutch operation.
- Wheels/Tires Data: Standard and service limit values for rim runout and axle runout are specified for safe wheel performance.
- Engine Lubrication System Details: Engine oil type, viscosity, and capacity are listed, alongside oil pressure specifications at operating temperatures.
- Crankshaft/Transmission Tolerances: Connecting rod radial and side clearances, along with crankshaft runout limits, are provided for accurate engine assembly.
Professional Workshop Service Manual & Technical Specifications
Kawasaki KLX110, KLX110L Service Manual: 2002–2014 - Comprehensive Maintenance & Repair for Owners and Technicians System-Standards
Year-Coverage: 2002-2014 // Maintenance-Category: Motorcycle / Off-Road Logic // Procedure-Type: Repair & Maintenance Data.
Engine Lubrication System
This manual details the engine lubrication system, including engine oil specifications, oil level inspection, and oil change procedures. It covers oil filter replacement and oil screen cleaning. Detailed instructions for oil pump removal, installation, and inspection are included, alongside oil pipe maintenance and oil pressure measurement.
Clutch System
The clutch sections provide comprehensive coverage for both KLX110C and KLX110D models. It includes exploded views, specifications, and detailed procedures for clutch lever and cable adjustments, clutch cover removal/installation, and clutch disassembly/assembly. Wear inspection for clutch components like friction plates and housing fingers is also covered.
Crankshaft/Transmission
This section covers the crankshaft and transmission systems, including specifications for connecting rod clearances and crankshaft runout. Procedures for crankcase splitting and assembly are detailed, along with transmission shaft disassembly and assembly. Inspection of shift forks and gear dog/hole damage is also included.
Wheels and Tires
Manual coverage extends to wheels and tires, detailing rim specifications, spoke tightness, and rim/axle runout inspections. Tire removal and installation procedures are outlined, along with air pressure adjustments. Hub bearing removal, installation, and inspection are also covered.
Engine Top End
Engine top-end procedures include camshaft inspection, valve clearance adjustments, and cylinder head warp inspection. It details piston ring inspection and clearance measurements, as well as connecting rod and crankshaft wear inspection. Muffler and spark arrester cleaning procedures are also provided.
Torque Statement: This manual documents torque specifications for various engine and chassis components to ensure proper assembly and dynamic load distribution.
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