2002–2014 Kawasaki KLX110 / KLX110L Service Manual

2002–2014 Kawasaki KLX110 and KLX110L Service Documentation

• Covers 2002–2014 Kawasaki KLX110 and KLX110L models, including the KLX110C and KLX110D variants
• Official Kawasaki publication P/N 99969-1078-01
• Contains 41 exploded-view diagrams and 322 pages of technical data
• Stored against your account so you can retrieve it after a hard-drive loss
• Full-text search finds any part number in seconds
• This reference document is used for the KLX110/KLX110L model range, including detailed specifications for early and late build cycle engine components

What the Manual Documents:

This 2002–2014 Kawasaki KLX110 service manual provides structured technical data for maintaining and repairing the KLX110C and KLX110D model series. The documentation segment defines procedures for engine top end maintenance, clutch assembly, fuel system diagnostics, and electrical system checks. It outlines periodic service intervals for air filter cleaning, valve clearances, and chain tension adjustments for the KLX110 or KLX110L, alongside comprehensive chapters for frame inspection, steering, suspension, and braking system components.

Specification Highlights:

Technical data includes a complete table for fastener torque values, such as the 22 N·m (16 ft·lb) cylinder head nut torque and the 64 N·m (47 ft·lb) rear axle nut torque requirement. Fluid capacities are documented for the 1.1 L (1.2 US qt) engine oil volume when the engine is completely dry. The manual lists valve clearance at 0.04–0.08 mm for the inlet and 0.08–0.12 mm for the exhaust, ensuring accurate engine timing setups. Ignition timing is specified as 10° BTDC at 1,300 rpm to 31° BTDC at 4,000 rpm for these models. Reference values for rim runout and brake shoe lining thicknesses are also provided for chassis assessment.

Note: This page is a contents overview for the manual. It does not provide repair or diagnostic instructions.

An official 322-page Kawasaki OEM service manual covering the 2002–2014 KLX110 and KLX110L, documenting engine, chassis, electrical, and carburetor specifications for the KLX110C and KLX110D builds.