Service Manual Kawasaki KLX140 / KLX140L — Isi Lengkap 332 Halaman
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Halaman 1
# KAWASAKI
KLX140
KLX140L
(Image of a Kawasaki dirt bike)
## Motorcycle Service Manual
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Halaman 2
Quick Reference Guide
General Information
1
j
Periodic Maintenance
2
j
Fuel System
3
j
Engine Top End
4
j
Clutch
5
j
Engine Lubrication System
6
j
Engine Removal/Installation
7
j
Crankshaft/Transmission
8
j
Wheels/Tires
9
j
Final Drive
10
j
Brakes
11
j
Suspension
12
j
Steering
13
j
Frame
14
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Electrical System
15
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Appendix
16
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This quick reference guide will assist
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
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Halaman 3
Kawasaki
KLX140
KLX140L
Motorcycle
Service Manual
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Halaman 4
LIST OF ABBREVIATIONS
A
ampere(s)
lb
pound(s)
ABDC
after bottom dead center
m
meter(s)
AC
alternating current
min
minute(s)
ATDC
after top dead center
N
newton(s)
BBDC
before bottom dead center
Pa
pascal(s)
BDC
bottom dead center
PS
horsepower
BTDC
before top dead center
psi
pound(s) per square inch
°C
degree(s) Celsius
r
revolution
DC
direct current
rpm
revolution(s) per minute
F
farad(s)
TDC
top dead center
°F
degree(s) Fahrenheit
TIR
total indicator reading
ft
foot, feet
V
volt(s)
g
gram(s)
W
watt(s)
h
hour(s)
Ω
ohm(s)
L
liter(s)
COUNTRY AND AREA CODES
AU
Australia
US
United States
CA
Canada
KLX140A model is designed for a rider weighting less than 154 pounds (70 kg). Exceeding this
limit could damage the motorcycle.
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Halaman 5
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emis-
sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Addi-
tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
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 fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this vehicle. The fuel, ignition and exhaust systems of this vehicle have been carefully de-
signed 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.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s “tampering provisions”.
“Sec. 203(a) The following acts and the causing thereof are prohibited.
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know-
ingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title follow-
ing its sale and delivery to the ultimate purchaser...”
NOTE
○The phrase “remove or render inoperative any device or element of design” has been generally
interpreted as follows.
1. Tampering does not include the temporary removal or rendering inoperative of de-
vices or elements of design in order to perform maintenance.
2. Tampering could include.
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL
LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING
$10 000 PER VIOLATION.
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Halaman 6
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 incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below.
• Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
• Removal of the muffler or any internal portion of the muffler.
• Removal of the air box or air box cover.
• Modifications to the muffler or air intake system by cutting, drilling, or other means if such
modifications result in increased noise levels.
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Halaman 7
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in-
formation to make it useful to the owner who de-
sires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce-
dures must be understood in order to carry out
maintenance and repair satisfactorily.
When-
ever the owner has insufficient experience or
doubts his ability to do the work, all adjust-
ments, maintenance, and repair should be car-
ried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
before starting work, and then do the work care-
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may ad-
versely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
• Follow the Periodic Maintenance Chart in the
Service Manual.
• Be alert for problems and non-scheduled
maintenance.
• Use proper tools and genuine Kawasaki Mo-
torcycle parts.
Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.
• Follow the procedures in this manual care-
fully. Don’t take shortcuts.
• Remember to keep complete records of main-
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists in locating their chapters.
Each
chapter in turn has its own comprehensive Ta-
ble of Contents.
For example, if you want ignition coil informa-
tion, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chap-
ter to find the Ignition Coil section.
Whenever you see symbols, heed their in-
structions!
Always follow safe operating and
maintenance practices.
DANGER
DANGER indicates a hazardous situa-
tion which, if not avoided, will result in
death or serious injury.
WARNING
WARNING indicates a hazardous situa-
tion which, if not avoided, could result
in death or serious injury.
CAUTION
CAUTION indicates a hazardous situa-
tion which, if not avoided, could result
in minor or moderate injury.
NOTICE
NOTICE is used to address practices not
related to personal injury.
This manual contains four more symbols
which will help you distinguish different types
of information.
NOTE
○This note symbol indicates points of par-
ticular interest for more efficient and con-
venient operation.
• Indicates a procedural step or work to be
done.
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
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Halaman 8
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require spec-
ified tightening torque, oil, grease or a locking
agent during assembly.
General Information
Halaman 9
GENERAL INFORMATION 1-1
___
# General Information
### Table of Contents
Before Servicing ........................................................................................ 1-2
Model Identification ................................................................................... 1-7
General Specifications .............................................................................. 1-9
Unit Conversion Table .............................................................................. 1-12
[1]
Before Servicing
Halaman 10
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera-
tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
Battery Ground
Before completing any service on the motorcycle, discon-
nect the battery cables from the battery to prevent the en-
gine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) ca-
ble to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high-flash point solvent when cleaning parts. High
-flash point solvent should be used according to directions
of the solvent manufacturer.
Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during ve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
Before Servicing
Halaman 11
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse.
Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, Oil seals,
Grease seals, circlips, cotter pins or self-locking nuts must
be replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
GENERAL INFORMATION 1-3
Before Servicing
Halaman 12
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se-
quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar-
ter turn and them remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
Often, the tightening sequence is followed twice-initial
tightening and final tightening with torque wrench.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam-
age.
When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening,
shrinkage,
or damage of both gaskets
and O-rings after disassembly can reduce sealing per-
formance.
Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains.
Install new gaskets and replace used
O-rings when re-assembling
Liquid Gasket, Non-permanent Locking Agent
For
applications
that
require
Liquid
Gasket
or
a
Non-permanent Locking agent, clean the surfaces so
that no oil residue remains before applying liquid gasket
or Non-permanent locking agent. Do not apply them ex-
cessively. Excessive application can clog oil passages and
cause serious damage.
Before Servicing
Halaman 13
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing
the seal.
Circlips, Cotter Pins
Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when in-
stalling to prevent deformation.
GENERAL INFORMATION 1-5
Before Servicing
Halaman 14
1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri-
cation points are called out throughout this manual, apply
the specific oil or grease as specified.
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Ro-
tate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Leads
A two-color lead is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
leads must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.
Model Identification
Halaman 15
GENERAL INFORMATION 1-7
### Model Identification
#### KLX140A8F Left Side View
GB038364 P
#### KLX140A8F Right Side View
GB038365 P
| Frame Number | Engine Number |
| :----------------------------------------------- | :----------------------------------------------- |
|  |  |
| GB038363 P | GB038362 P |
Model Identification
Halaman 16
1-8 GENERAL INFORMATION
Model Identification
KLX140B8F Left Side View
KLX140B8F Right Side View
General Specifications
Halaman 17
General Specifications
Items
KLX140A8F ∼ABF
KLX140B8F ∼BBF
Dimensions
Overall Length
1 820 mm (71.65 in.)
1 895 mm (74.61 in.)
Overall Width
790 mm (31.1 in.)
←
Overall Height
1 050 mm (41.34 in.)
1 075 mm (42.32 in.)
Wheelbase
1 260 mm (49.61 in.)
1 285 mm (50.59 in.)
Road Clearance
235 mm (9.25 in.)
255 mm (10.0 in.)
Seat Height
780 mm (30.7 in.)
800 mm (31.5 in.)
Dry Mass:
KLX140A8F/B8F
88 kg (194 lb)
90 kg (198 lb)
Curb Mass:
KLX140A9F ∼/B9F ∼
93 kg (205 lb)
95 kg (209 lb)
Front
45 kg (99 lb)
46 kg (101 lb)
Rear
48 kg (105 lb)
49 kg (108 lb)
Fuel Tank Capacity
5.8 L (1.5 US gal)
←
Performance
Minimum Turning Radius
–
←
Engine
Type
4-stroke, single cylinder, SOHC ←
Cooling System
Air-cooled
←
Bore and Stroke
58.0 × 54.4 mm (2.28 × 2.14 in.) ←
Displacement
144 cm³ (8.79 cu in.)
←
Compression Ratio
9.5 : 1
←
Carburetion System
Carburetor, KEIHIN PB20
←
Starting System
Electric starter
←
Ignition System
DC-CDI
←
Timing Advance
Ignition Timing
BTDC 10° @1 400 r/min (rpm) ∼
BTDC 30° @4 000 r/min (rpm)
←
Spark Plug
NGK CR7HSA
←
Valve Timing:
Intake:
Open
BTDC 30°
←
Close
ABDC 44°
←
Duration
254°
←
Exhaust:
Open
BBDC 45°
←
Close
ATDC 35°
←
Duration
260°
←
Lubrication System
Forced lubrication (wet sump)
←
Engine Oil:
Type
API SG, SH, SJ, SL or SM with
JASO MA, MA1 or MA2
←
Viscosity
SAE 10W-40
←
Capacity
1.1 L (1.2 US qt)
←
GENERAL INFORMATION 1-9
General Specifications
Halaman 18
1-10 GENERAL INFORMATION
General Specifications
Items
KLX140A8F ∼ABF
KLX140B8F ∼BBF
Drive Train
Primary Reduction System:
Type
Gear
←
Reduction Ratio
2.880 (72/25)
←
Clutch Type
Wet, multi disc
←
Transmission:
Type
5-speed
←
Gear Ratios:
1st
2.667 (40/15)
←
2nd
1.895 (36/19)
←
3rd
1.474 (28/19)
←
4th
1.182 (26/22)
←
5th
1.000 (24/24)
←
Final Drive System:
Type
Chain drive
←
Reduction Ratio
3.571 (50/14)
3.923 (51/13)
Overall Drive Ratio
10.286 @Top gear
11.298 @Top gear
Frame
Type
Tube double cradle
←
Steering Angle
41° to either side
←
Caster (rake angle)
27°
←
Trail
85 mm (3.3 in.)
96 mm (3.8 in.)
Front Tire:
Size
70/100-17 40M
70/100-19 42M
Make/Type
IRC, IX05H, Tube
←
Rear Tire:
Size
90/100-14 49M
90/100-16 52M
Make/Type
IRC, IX05H, Tube
←
Rim Size:
Front
17 × 1.40
19 × 1.40
Rear
14 × 1.60
16 × 1.85
Front Suspension:
Type
Telescopic fork
←
Wheel Travel
180 mm (7.09 in.)
←
Rear Suspension:
Type
Swingarm (Uni-trak)
←
Wheel travel
180 mm (7.09 in.)
←
Brake Type:
Front and Rear
Single disc
←
Effective Disc Diameter:
Front (effect. dia.)
192 mm (7.56 in.)
←
Rear (effect. dia.)
150 mm (5.91 in.)
←
General Specifications
Halaman 19
General Specifications
Items
KLX140A8F ∼ABF
KLX140B8F ∼BBF
Electrical Equipment
Battery
12 V 6 Ah
←
Alternator:
Rated Output
4.8 A/14 V @9 000 r/min (rpm)
←
Specifications subject to change without notice, and may not apply to every country.
GENERAL INFORMATION 1-11
Unit Conversion Table
Halaman 20
1-12 GENERAL INFORMATION
Unit Conversion Table
Prefixes for Units:
Prefix
Symbol
Power
mega
M
× 1 000 000
kilo
k
× 1 000
centi
c
× 0.01
milli
m
× 0.001
micro
µ
× 0.000001
Units of Mass:
kg
×
2.205
=
lb
g
×
0.03527
=
oz
Units of Volume:
L
×
0.2642
=
gal (US)
L
×
0.2200
=
gal (imp)
L
×
1.057
=
qt (US)
L
×
0.8799
=
qt (imp)
L
×
2.113
=
pint (US)
L
×
1.816
=
pint (imp)
mL
×
0.03381
=
oz (US)
mL
×
0.02816
=
oz (imp)
mL
×
0.06102
=
cu in
Units of Force:
N
×
0.1020
=
kgf
N
×
0.2248
=
lb
kgf
×
9.807
=
N
kgf
×
2.205
=
lb
Units of Temperature:
Units of Length:
km
×
0.6214
=
mile
m
×
3.281
=
ft
mm
×
0.03937
=
in
Units of Torque:
N·m
×
0.1020
=
kgf·m
N·m
×
0.7376
=
ft·lb
N·m
×
8.851
=
in·lb
kgf·m
×
9.807
=
N·m
kgf·m
×
7.233
=
ft·lb
kgf·m
×
86.80
=
in·lb
Units of Pressure:
kPa
×
0.01020
=
kgf/cm²
kPa
×
0.1450
=
psi
kPa
×
0.7501
=
cm Hg
kgf/cm²
×
98.07
=
kPa
kgf/cm²
×
14.22
=
psi
cm Hg
×
1.333
=
kPa
Units of Speed:
km/h
×
0.6214
=
mph
Units of Power:
kW
×
1.360
=
PS
kW
×
1.341
=
HP
PS
×
0.7355
=
kW
PS
×
0.9863
=
HP
Periodic Maintenance
Halaman 21
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ..............
2-2
Torque and Locking Agent.................
2-4
Specifications ....................................
2-8
Special Tools .....................................
2-10
Periodic Maintenance Procedures.....
2-11
Fuel System....................................
2-11
Fuel Hose and Connection
Inspection..................................
2-11
Throttle Grip Free Play Inspection
2-11
Throttle Grip Free Play
Adjustment ................................
2-11
Idle Speed Inspection ..................
2-12
Idle Speed Adjustment.................
2-12
Air Cleaner Element Cleaning and
Inspection..................................
2-12
Fuel Inspection.............................
2-14
Fuel Tank, Filter and Tap
Cleaning....................................
2-14
Fuel Tap and Filter Inspection......
2-15
Engine Top End ..............................
2-15
Valve Clearance Inspection .........
2-15
Valve Clearance Adjustment........
2-15
Exhaust System Inspection..........
2-16
Spark Arrester Cleaning...............
2-16
Clutch..............................................
2-17
Clutch Lever Free Play Inspection
2-17
Clutch Lever Free Play
Adjustment ................................
2-17
Friction and Steel Plates
Inspection..................................
2-18
Engine Lubrication System.............
2-18
Engine Oil Change.......................
2-18
Oil Filter Change..........................
2-19
Wheel/Tires.....................................
2-20
Air Pressure Inspection/Adjust-
ment ..........................................
2-20
Tires Inspection............................
2-20
Spoke Tightness Inspection.........
2-21
Rim Runout Inspection.................
2-21
Wheel Bearing Inspection............
2-22
Final Drive.......................................
2-22
Drive Chain Slack Inspection.......
2-22
Drive Chain Slack Adjustment .....
2-23
PERIODIC MAINTENANCE 2-1
Drive Chain Wear Inspection .......
2-23
Drive Chain Lubrication................
2-24
Sprocket Wear Inspection............
2-24
Rear Sprocket Warp Inspection ...
2-25
Brakes.............................................
2-25
Brake Lever and Pedal Position
Adjustment ................................
2-25
Brake Fluid Level Inspection........
2-26
Brake Fluid Change .....................
2-27
Brake Pad Wear Inspection .........
2-29
Brake Master Cylinder Cup and
Dust Seal Replacement ............
2-29
Caliper Piston Seal and Dust Seal
Replacement.............................
2-31
Brake Hose and Connection
Check........................................
2-32
Brake Hose Replacement............
2-32
Suspension.....................................
2-33
Front Fork Inspection...................
2-33
Front Fork Oil Change (each fork
leg) ............................................
2-34
Rear Shock Absorber Inspection .
2-36
Swingarm and Uni-Trak Linkage
Inspection..................................
2-36
Swingarm and Uni-Track Linkage
Pivot Lubricate ..........................
2-36
Drive Chain Guide, Guide Roller,
Chain Slipper Wear...................
2-36
Steering ..........................................
2-37
Steering Inspection ......................
2-37
Steering Adjustment ....................
2-37
Stem Bearing Lubrication.............
2-39
Frame .............................................
2-39
Frame Inspection .........................
2-39
Side Stand Inspection..................
2-39
Electrical System ............................
2-40
Spark Plug Cleaning and
Inspection..................................
2-40
Cable Inspection.............................
2-40
Lubrication ...................................
2-40
Nut, Bolt, and Fastener Tightness
Inspection.....................................
2-41
Tightness Inspection ....................
2-41
2
Periodic Maintenance Chart
Halaman 22
2-2 PERIODIC MAINTENANCE
Periodic Maintenance Chart
The maintenance must be done in accordance with this chart to keep the motorcycle in good running
condition.
Periodic Inspection
FREQUENCY
Initial
Every
hours (month (s))
5
50
100
OPERATION
(1)
(6)
(12)
Spark plug - clean, gap †
•
•
2-40
Clutch and friction plate - inspect †
•
•
•
2-18
Clutch cable - adjust †
•
•
•
2-17
E
N
G
I
N
E
Valve clearance - inspect †
•
•
2-15
Air cleaner element - clean †
•
•
•
2-12
Throttle grip play - inspect †
•
•
•
2-11
Fuel tap - clean
•
•
2-14
Spark arrester - clean
•
2-16
Engine sprocket - inspect †
•
•
2-24
Fuel hose connections - inspect †
•
•
2-11
Brake adjustment - inspect †
•
•
•
2-25
Brake fluid level - check †
•
•
2-26
Brake pad wear - check †
•
•
2-29
Brake hoses connection - check †
•
•
2-32
Spoke tightness and rim runout - check †
•
•
•
2-21
Drive chain wear - check †
•
•
•
2-23
Drive chain - inspect and adjust
•
•
•
2-22
Drive chain - lubricate
•
•
•
2-24
Drive chain guide and slipper - inspect
•
•
2-36
C
H
A
S
S
I
S
Front fork - inspect and clean †
•
•
2-33
Front fork oil - inspect †
Every year
2-34
Nuts, bolts, fasteners - inspect †
•
•
•
2-41
Steering play - inspect †
•
•
•
2-37
Steering stem bearing - grease
•
2-39
Rear sprocket - inspect †
•
•
2-25
Chassis parts - lubricate
•
•
•
–
Side stand - inspect †
•
•
2-39
Wheel bearing - inspect †
•
•
2-22
Swingarm and Uni-trak linkage pivot - inspect †
•
•
2-36
Swingarm and Uni-trak linkage pivot - grease †
•
•
2-36
Rear shock absorber - inspect †
•
•
2-36
Frame - inspect and clean
•
•
•
2-39
Wheel/tires - inspect
•
•
•
2-20
†: Replace, add, adjust, clean or torque if necessary.
See
Page
Periodic Maintenance Chart
Halaman 23
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY
Initial
Every
hours (month (s))
5
50
100
OPERATION
(1)
(6)
(12)
Engine oil
•
•
•
2-18
Oil filter
•
•
•
2-19
Brake hose
Every 4 years
2-32
Fuel hose
Every 4 years
2-11
Brake fluid
Every 2 years
2-27
Brake master cylinder cup and dust seal
Every 2 years
2-29
Brake caliper piston seal and dust seal
Every 2 years
2-31
Front fork oil
•
•
2-34
PERIODIC MAINTENANCE 2-3
See
Page
Torque and Locking Agent
Halaman 24
2-4 PERIODIC MAINTENANCE
Torque and Locking Agent
Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently
tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The
following table lists the tightening toque for the major bolts and nuts, and the parts requiring use of a
non-permanent locking agent or liquid gasket.
When checking the tightening toque of the bolts and nuts, first loosen the bolt or nut by half a turn
and then tighten to specified torque.
Letters used in the "Remarks" column mean:
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
L: Apply a non-permanent locking agent to the threads.
Lh: Left-hand Threads
MO: Apply molybdenum disulfide oil.
S: Tighten the fasteners following the specified sequence.
Si: Apply Silicone grease.
R: Replacement Parts
T: First, tighten the stem locknut with 39 N·m (4.0 kgf·m, 29 ft·lb) of torque, then loosen it and
retighten it with 4.9 N·m (0.50 kgf·m, 43 in·lb) of torque.
Torque
Fastener
N·m
kgf·m
ft·lb
Remarks
Fuel System
Air Cleaner Housing Mounting Bolt
5.2
0.53
46 in·lb
Carburetor Holder Adapter Bolts
8.8
0.90
78 in·lb
Fuel Tank Cover Screws
5.0
0.51
44 in·lb
Engine Top End
Alternator Cover Center Cap
2.5
0.25
22 in·lb
Alternator Cover Plug
2.5
0.25
22 in·lb
Breather Plate Mounting Bolts
8.8
0.90
78 in·lb
L
Camshaft Chain Cap Bolts
8.8
0.90
78 in·lb
Camshaft Chain Guide Bolt
12
1.2
106 in·lb
L
Camshaft Chain Plate Screw
5.2
0.53
46 in·lb
Camshaft Sprocket Bolt
24
2.4
18
Lh
Carburetor Holder Bolts
8.8
0.90
78 in·lb
L
Chain Tensioner Cap Bolt
5.2
0.53
46 in·lb
Chain Tensioner Mounting Bolts
5.2
0.53
46 in·lb
Cylinder Head Bolt (M6)
15
1.5
11
S
Cylinder Head Bolt (M8)
22
2.2
16
S, M
Exhaust Pipe Cover Bolts
8.8
0.90
78 in·lb
L
Exhaust Pipe Holder Nuts
14.7
1.5
11
Muffler Cover Bolts
8.8
0.90
78 in·lb
L
Muffler Joint Clamp Bolt
17
1.7
13
Muffler Mounting Bolts
26
2.7
19
Rocker Shaft Holder Plate Bolts
5.2
0.53
46 in·lb
L
Valve Adjusting Cap Bolts
8.8
0.90
78 in·lb
Valve Adjusting Screw Locknuts
8.8
0.90
78 in·lb
Clutch
Clutch Cover Bolts
8.8
0.90
78 in·lb
Clutch Hub Bolt
65
6.6
48
L
Clutch Spring Bolts
8.8
0.90
in·lb
Oil Seal Retaining Plate Bolts
9.8
1.0
in·lb
L
Torque and Locking Agent
Halaman 25
Torque and Locking Agent
Torque
Fastener
N·m
kgf·m
ft·lb
Remarks
Engine Lubrication System
Clutch Cover Bolts
8.8
0.90
78 in·lb
Engine Oil Drain Plug
18
1.8
13
Oil Filter Cover Bolts
8.8
0.90
78 in·lb
Oil Pump Mounting Screw (L = 30)
5.2
0.53
46 in·lb
Oil Pump Mounting Screws (L = 18)
5.2
0.53
46 in·lb
Engine Removal/Installation
Engine Bracket Bolts
29
3.0
21
Engine Bracket Nuts
29
3.0
21
R
Engine Mounting Nuts
49
5.0
36
R
Crankshaft/Transmission
Bearing Retaining Screws
5.2
0.53
46 in·lb
L
Crankcase Bolts (L = 50)
8.8
0.90
78 in·lb
Crankcase Bolts (L = 60)
8.8
0.90
78 in·lb
Gear Set Lever Nut
9.8
1.0
87 in·lb
Neutral Switch
15
1.5
11
Primary Gear Nut
98
10
72
Lh, MO
Shift Adjuster Locknut
9.8
1.0
87 in·lb
Shift Drum Cam Bolt
12
1.2
106 in·lb
L
Shift Linkage Rod Clamp Bolt
12
1.2
106 in·lb
Shift Return Spring Pin
29
3.0
21
L
Wheels/Tires
Front Axle Nut
79
8.1
58
Rear Axle Nut
79
8.1
58
Final Drive
Drive Chain Cover Bolts
8.8
0.90
78 in·lb
AL
Rear Sprocket Nuts
32
3.3
24
Brakes
Brake Hose Banjo Bolts
25
2.5
18
Brake Lever Adjuster Locknut
5.9
0.60
52 in·lb
Brake Lever Pivot Bolt
5.9
0.60
52 in·lb
Si
Brake Lever Pivot Locknut
5.9
0.60
52 in·lb
Brake Pad Bolts
17
1.7
13
Brake Pedal Pivot Bolt
25
2.5
18
L
Front Brake Disc Mounting Bolts
9.8
1.0
87 in·lb
L
Front Caliper Bleed Valve
7.8
0.80
69 in·lb
Front Caliper Mounting Bolts
34
3.5
25
Front Master Cylinder Clamp Bolts
8.8
0.90
78 in·lb
Front Reserver Cap Screws
1.5
0.15
13 in·lb
Rear Brake Disc Mounting Bolts
9.8
1.0
87 in·lb
L
Rear Caliper Bleed Valve
7.8
0.80
69 in·lb
L
Rear Caliper Mounting Bolts
25
2.5
18
Rear Master Cylinder Mounting Bolts
in·lb
PERIODIC MAINTENANCE 2-5
Torque and Locking Agent
Halaman 26
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener
N·m
kgf·m
ft·lb
Remarks
Rear Master Cylinder Push Rod Locknut
17
1.7
13
Rear Reserver Cap Screws
1.5
0.15
13 in·lb
Suspension
Fork Bottom Bolt
20
2.0
15
Fork Top Bolt
22.5
2.3
17
Front Fork Clamp Bolts (Lower)
25
2.5
18
Front Fork Clamp Bolts (Upper)
20
2.0
15
Rear Shock Absorber Mounting Bolt (Lower)
39
4.0
29
Rear Shock Absorber Mounting Bolt (Upper)
39
4.0
29
Rear Shock Absorber Mounting Nut (Lower)
29
3.0
21
R
Rocker Arm Pivot Nut
59
6.0
44
R
Steering Stem Head Nut
64
6.5
47
Swingarm Pivot Shaft Nut
108
11
80
Tie-rod Mounting Nuts
59
6.0
44
R
Steering
Front Fork Clamp Bolts (Lower)
25
2.5
18
Front Fork Clamp Bolts (Upper)
20
2.0
15
Handlebar Clamp Bolts
25
2.5
18
AL
Steering Stem Head Nut
64
6.5
47
Steering Stem Nut
4.9
0.50
43 in·lb
Frame
Rear Frame Mounting Bolts
34
3.5
25
Electrical System
Alternator Cover Bolts (L30)
8.8
0.90
78 in·lb
Alternator Cover Bolts (L45)
8.8
0.90
78 in·lb
Alternator Cover Center Cap
2.5
0.25
22 in·lb
Alternator Cover Plug
2.5
0.25
22 in·lb
Alternator Rotor Bolt
38
3.9
28
MO
Crankshaft Sensor Lead Clamp Screws
5.2
0.53
46 in·lb
Crankshaft Sensor Mounting Screws
4.2
0.43
37 in·lb
Ignition Coil Mounting Bolt
2.9
0.30
26 in·lb
Regulator Mounting Bolt
8.8
0.90
78 in·lb
Spark Plug
13
1.3
115 in·lb
Starter Motor Clutch Bolts
12
1.2
106 in·lb
L
Starter Motor Mounting Bolts
6.9
0.70
61 in·lb
Starter Motor Terminal Locknut
6.9
0.70
61 in·lb
Starter Motor Terminal Nut
5.2
0.53
46 in·lb
Starter Motor Through Bolts
4.9
0.50
43 in·lb
Starter Relay Terminal Screws
2.9
0.30
26 in·lb
Stator Mounting Bolts
8.8
0.90
78 in·lb
Torque Limiter Cover Bolts
8.8
0.90
78 in·lb
Torque and Locking Agent
Halaman 27
Torque and Locking Agent
Basic Torque for General Fasteners
Threads dia.
Torque
(mm)
N·m
kgf·m
ft·lb
5
3.4 ∼4.9
0.35 ∼0.50
30 ∼43 in·lb
6
5.9 ∼7.8
0.60 ∼0.80
52 ∼69 in·lb
8
14 ∼19
1.4 ∼1.9
10.0 ∼13.5
10
25 ∼34
2.6 ∼3.5
19.0 ∼25
12
44 ∼61
4.5 ∼6.2
33 ∼45
14
73 ∼98
7.4 ∼10.0
54 ∼72
16
115 ∼155
11.5 ∼16.0
83 ∼115
18
165 ∼225
17.0 ∼23.0
125 ∼165
20
225 ∼325
23 ∼33
165 ∼240
PERIODIC MAINTENANCE 2-7
Specifications
Halaman 28
2-8 PERIODIC MAINTENANCE
Specifications
Item
Standard
Service Limit
Fuel System
Throttle Grip Free Play
2 ∼3 mm (0.08 ∼0.12 in.)
– – –
Air Cleaner Element Oil
High quality foam air filter oil
– – –
Engine Top End
Valve Clearance:
Exhaust
0.11 ∼0.15 mm (0.0043 ∼0.0059 in.)
– – –
Intake
0.04 ∼0.08 mm (0.0016 ∼0.0031 in.)
– – –
Clutch
Clutch Lever Free Play
2 ∼3 mm (0.08 ∼0.12 in.)
– – –
Friction Plate Thickness:
Small Inside Diameter
2.92 ∼3.08 mm (0.115 ∼0.121 in.)
2.6 mm (0.10 in.)
Large Inside Diameter
3.50 ∼3.60 mm (0.138 ∼0.142 in.)
3.2 mm (0.13 in.)
Friction Plate Warp
0.15 mm (0.0059 in.) or less
0.3 mm (0.01 in.)
Steel Plate Warp
0.15 mm (0.0059 in.) or less
0.3 mm (0.01 in.)
Engine Lubrication System
Engine oil:
Type
API SG, SH, SJ, SL or SM with JASO MA,
MA1 or MA2
– – –
Viscosity
SAE 10W-40
– – –
Capacity:
Oil Change-When filter is
not removed
0.93 L (0.98 US qt)
– – –
Oil Change-When filter is
removed
0.95 L (1.00 US qt)
– – –
when engine is completely
dry
1.10 L (1.16 US qt)
– – –
Wheels/Tires
Rim Runout:
Axial
TIR 0.8 mm (0.031 in.) or less
TIR 2.0 mm (0.08 in.)
Radial
TIR 1.2 mm (0.047 in.) or less
TIR 2.0 mm (0.08 in.)
Front and Rear Tires Air
Pressure
100 kPa (1.0 kgf/cm², 14 psi)
– – –
Standard Tire:
Front:
Size
– – –
KLX140A
70/100-17 40M
KLX140B
70/100-19 42M
Make
IRC
– – –
Type
IX05H, Tube
– – –
Rear:
Size
– – –
KLX140A
90/100-14 49M
KLX140B
90/100-16 52M
Make
IRC
– – –
Type
IX05H, Tube
– – –
Specifications
Halaman 29
PERIODIC MAINTENANCE 2-9
# Specifications
| Item | Standard | Service Limit |
| :-------------------------------------- | :-------------------------------------------------- | :------------------------- |
| **Final Drive** | | |
| Drive Chain Slack | 35 ~ 41 mm (1.4 ~ 1.6 in.) | --- |
| Drive Chain 20 Link Length | 254.0 ~ 254.6 mm (10.00 ~ 10.02 in.) | 260 mm (10.2 in.) |
| Rear Sprocket Warp | 0.4 mm (0.016 in.) or less | 0.5 mm (0.020 in.) |
| **Brakes** | | |
| Brake Lever Free Play | (to suit rider) | --- |
| Brake Fluid: | | |
| Type: | DOT3 or DOT4 | --- |
| Front/Rear | | |
| Brake pad lining thickness: | | |
| Front | 4.5 mm (0.18 in.) | 1 mm (0.04 in.) |
| Rear | 3.7 mm (0.15 in.) | 1 mm (0.04 in.) |
| **Suspension** | | |
| Fork Oil: | | |
| Oil Viscosity | SHOWA SS-8 or equivalent | --- |
| Oil Quantity: | | |
| KLX140A | 296 ±2.5 mL (10.01 ±0.085 US oz) | --- |
| KLX140B | 290 ±2.5 mL (9.80 ±0.085 US oz) | --- |
| **Electrical System** | | |
| Spark Plug Gap | 0.6 ~ 0.7 mm (0.02 ~ 0.03 in.) | --- |
TIR: Total Indicator Readings
Special Tools
Halaman 30
# 2-10 PERIODIC MAINTENANCE
## Special Tools
* **Inside Circlip Pliers:**
57001-143
(Image of circlip pliers)
* **Jack:**
57001-1238
(Image of a scissor jack)
* **Steering Stem Nut Wrench:**
57001-1100
(Image of a steering stem nut wrench)
* **Spark Plug Wrench, Hex 16:**
57001-1262
(Image of a T-handle spark plug wrench)
* **Valve Adjusting Screw Holder:**
57001-1217
(Image of a valve adjusting screw holder)
* **Fork Oil Level Gauge:**
57001-1290
(Image of a fork oil level gauge)
Throttle Grip Free Play Adjustment
Halaman 31
Periodic Maintenance Procedures
Fuel System
Fuel Hose and Connection Inspection
○The fuel hoses are designed to be used throughout the
motorcycle’s life without any maintenance, however, if the
motorcycle is not properly handled, the inside the fuel line
can cause fuel to leak [A] or the hose to burst.
• Check the fuel hose.
Replace the fuel hose if any fraying, cracks [B], bulges [C]
or ozonic cranks [D] are noticed.
• Check that the hose [A] is securely connected and clamps
[B] are tightened correctly.
• When installing the fuel hose, avoid sharp bending, kink-
ing, flattening or twisting, and route the fuel hose with a
minimum of bending so that the fuel flow will not be ob-
structed.
Replace the hose if it has been sharply bent or kinked.
Throttle Grip Free Play Inspection
• Check throttle grip free play [A] by lightly turning the throt-
tle grip [B] back and forth.
If the free play is improper, adjust the throttle cable.
Throttle Grip Free Play
Standard:
2 ∼3 mm (0.08 ∼0.12 in.)
• Check that the throttle grip moves smoothly from full open
to close, and the throttle closes quickly and completely in
all steering positions by the return spring.
If the throttle grip does not return properly, check the throt-
tle cable routing, grip free play and cable damage. Then
lubricate the throttle cable.
• Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed
does not change.
If the idle speed increase, check the throttle cable free
play and the cable routing.
Throttle Grip Free Play Adjustment
• Loosen the locknut [A] at the upper end of the throttle
cable.
• Screw throttle cable adjuster [B] to give the throttle grip
plenty of play.
• Tighten the locknut.
WARNING
Operation with an improperly adjusted, incorrectly
routed or damaged cables could result in an un-
safe riding Condition. Follow the service manual to
make sure to correct any of these conditions.
PERIODIC MAINTENANCE 2-11
Air Cleaner Element Cleaning and Inspection
Halaman 32
2-12 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Idle Speed Inspection
• Start the engine and warm it up thoroughly.
• With the engine idling, turn the handlebar to both sides
[A].
If handlebar movement changes the idle speed, the throt-
tle cable may be improperly adjusted or incorrectly routed,
or it may be damaged. Be sure to correct any of these
conditions before riding (see Cable, Wire and Hose Rout-
ing section in the Appendix chapter).
WARNING
Operation with an improperly adjusted, incorrectly
routed or damaged cables could result in an un-
safe riding Condition. Follow the service manual to
make sure to correct any of these conditions.
• Check the idle speed, using the engine revolution tester
for high accuracy.
If the idle speed is out of specified range, adjust it.
Idle Speed:
Standard:
1 400 ±100 r/min (rpm)
Idle Speed Adjustment
• Start the engine and warm it up thoroughly.
• Turn the idle adjusting screw [A] until the idle speed is
correct.
To increase idle speed [B]
To decrease idle speed [C]
• Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.
Air Cleaner Element Cleaning and Inspection
NOTE
○In dusty areas, the element should be cleaned more
frequently than recommended interval.
○After riding through rain or on muddy roads, the element
should be cleaned immediately.
○Since repeated cleaning opens the pores of the ele-
ment, replace it with a new one in accordance with the
Periodic Maintenance Chart. Also, if there is a break in
the element material or any other damage to the ele-
ment, replace the element with a new one.
Air Cleaner Element Cleaning and Inspection
Halaman 33
Periodic Maintenance Procedures
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 any-
where near the working areas. Do not use gasoline
or low-flash point solvents to clean the element.
• Remove:
Air Cleaner Element (see Element Removal in the Fuel
System chapter)
• Stuff a clean, lint-free towel into the carburetor so no dirt
is allowed to enter the carburetor.
• Wipe out the inside of the air cleaner housing with a clean
damp towel.
NOTICE
Check inside of the intake tract and carburetor for
dirt. If dirt is present, clean the intake tract and car-
buretor thoroughly. You may also need to replace
the element and seal the housing and intake tract.
• Separate the element [A] from the frame [B].
• Clean the element [A] in a bath of high-flash point solvent
using a soft bristle brush.
• Squeeze it dry in a clean towel [A]. Do not wring the ele-
ment or blow it dry; the element can be damaged.
• Check all the parts of the element for visible damage.
If any of the parts of the element are damaged, replace
them.
PERIODIC MAINTENANCE 2-13
Fuel Tank, Filter and Tap Cleaning
Halaman 34
2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• After cleaning, saturate the element with high-quality
foam-air-filter oil, squeeze out the excess, then wrap it in
a clean towel and squeeze it as dry as possible.
○Be careful not to tear the sponge filter.
• Assemble the element.
• Remove the towel from the carburetor.
• Apply grease to all connections and screw holes in the air
cleaner housing and intake tract.
• 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.
• Install the air cleaner element (see Element Installation in
the Fuel System chapter).
Fuel Inspection
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Always stop the
engine and do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Turn the fuel tap to the OFF position.
• Place a suitable container beneath the carburetor drain
hose [A].
• Loosen the drain plug [B] from the bottom of the float bowl
and check for water or dirt in the fuel.
If any water or dirt comes out, clean the carburetor, fuel
filter, fuel tap and fuel tank.
• Tighten the drain plug securely.
Fuel Tank, Filter and Tap Cleaning
WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause severe
burns. Clean the fuel tank in a well-ventilated area,
and take care that there are no sparks or flame any-
where near the working area. Do not use gasoline
or low-flash point solvents to clean the fuel tank.
• Remove the fuel tank and drain the fuel (see Fuel Tank
Removal in the Fuel System chapter).
• Pour some high-flash point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.
• Pour the solvent out of the tank.
• Remove the fuel tap (see Fuel Tamp Removal in the Fuel
System chapter).
• Clean the fuel tap and the fuel filter screens [A] in high
-flash point solvent. After cleaning, install the fuel tap.
○Pour the tap in all lever positions.
• Dry the tank, filter and tap with compressed air.
• Install the tap and fuel tank.
Valve Clearance Adjustment
Halaman 35
Periodic Maintenance Procedures
Fuel Tap and Filter Inspection
• Remove the fuel tap from the fuel tank.
• Check the fuel filter screens [A] for any breaks or deteri-
oration.
If the fuel filter screen have any breaks or is deteriorated,
it may allow dirt to reach the carburetor, causing poor run-
ning. Replace the fuel tap.
• Check the fuel tap for fuel leaks.
• If the fuel tap leaks, or allows fuel to flow when it is at OFF
position, replace the fuel tap.
Engine Top End
Valve Clearance Inspection
NOTE
○Valve clearance must be checked and adjusted when
the engine is cold (at room temperature).
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Valve Adjusting Caps [A]
Camshaft Chain Cover [B]
• Turn the crankshaft bolt clockwise with a wrench.
○Making sure that the intake valve opens and then closes,
start to turn the bolt in the same direction until the mark
[A] on the camshaft sprocket aligns with the projection [B]
on the cylinder head. This shows that the piston TDC is
at the end of the compression stroke.
• Using a thickness gauge [A], measure the valve clearance
between the adjusting screw [B] and valve stem. Measure
the clearance for both valves at a time.
Valve Clearance (when cold)
Standard:
Intake
0.04 ∼0.08 mm (0.002 ∼0.003 in.)
Exhaust
0.11 ∼0.15 mm (0.004 ∼0.006 in.)
Valve Clearance Adjustment
If the valve clearance is not within the specified range,
adjust the clearance by loosening the locknut and turning
the adjusting screw.
Special Tool - Valve Adjusting Screw Holder: 57001-1217
Torque - Valve Adjusting Screw Locknut:
8.8 N·m (0.90
kgf·m, 78 in·lb)
• Install the valve adjusting caps.
Torque - Valve Adjusting Cap Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
PERIODIC MAINTENANCE 2-15
Spark Arrester Cleaning
Halaman 36
2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Exhaust System Inspection
• The exhaust system, in particular the silencer, is designed
to reduce exhaust noise and conduct the exhaust gases
away from the rider while minimizing power loss. If car-
bon has built up inside the silencer, exhaust efficiency is
reduced, causing engine performance to drop.
If the silencer is badly damaged, dented, cracked or
rusted, replace it. Clean the spark arrester if the exhaust
noise becomes too loud or engine performance drops.
Spark Arrester Cleaning
This vehicle is equipped with a spark arrester. It must be
properly maintained to ensure its efficiency.
NOTICE
The spark arrester must be installed correctly and
functioning properly to provide adequate fire pro-
tection.
WARNING
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.
• Remove;
Muffler Cover Bolts [A]
Muffler Cover [B]
• Remove:
Spark Arrester Mounting Bolts [A]
Spark Arrester [B]
Clutch Lever Free Play Adjustment
Halaman 37
Periodic Maintenance Procedures
• With a wire brush, remove the carbon off the inside of the
spark arrester [A] and muffler.
• Replace the spark arrester gasket with a new one.
• Install the spark arrester into the rear end of the muffler.
• Apply a non-permanent locking agent to the muffler cover
bolts.
• Install the muffler cover.
Torque - Muffler Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
Clutch
WARNING
The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns. Never touch the engine or exhaust chamber
during clutch adjustment.
Clutch Lever Free Play Inspection
• Slide the clutch lever dust cover [A] out of place.
• Check that the clutch cable upper end is fully seated in
the adjusting bolt [B].
• Check that the clutch lever [C] of free play [D].
Clutch Lever Free Play
Standard:
2 ∼3 mm (0.08 ∼0.12 in.)
If it does not, adjust the lever play.
Clutch Lever Free Play Adjustment
• Slide the clutch lever dust cover [A] out of place.
• Loosen the locknut [B] and turn the adjuster [C] so that
the clutch lever will have 2 ∼3 mm (0.08 ∼0.12 in.) of
play.
NOTE
○Be sure that the outer cable end at the clutch lever is
fully seated in the adjusting bolt at the clutch lever, or
it could slip into the place later, creating enough cable
play to prevent clutch disengagement.
• If it cannot be done, loosen the rear locknut [A] at the
lower of the clutch cable, and turn the front locknut [B] so
that clutch lever has 2 ∼3 mm (0.08 ∼0.12 in.) of play.
• After the adjustment is made, tighten the locknut, and
start the engine and check that the clutch does not slip
and that it release properly.
PERIODIC MAINTENANCE 2-17
Engine Oil Change
Halaman 38
2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Friction and Steel Plates Inspection
• Remove the clutch plates (see Clutch Removal in the En-
gine Right Side chapter).
• Visually inspect the friction and steel plates to see if they
show any signs of seizure, or uneven wear.
If any plates show signs of damage, replace the friction
plates and steel plates as a set.
• Measure the thickness of the friction plates [A] with vernier
calipers.
If they have worn past the service limit, replace them with
new ones.
Friction Plate Thickness
Standard:
Small Inside Diameter
2.92 ∼3.08 mm
(0.115 ∼0.121 in.)
Large Inside Diameter
3.50 ∼3.60 mm
(0.138 ∼0.142 in.)
Service Limit:
Small Inside Diameter
2.6 mm (0.10 in.)
Large Inside Diameter
3.2 mm (0.13 in.)
• Place each friction plate or steel plate on a surface plate,
and measure the gap between the surface plate [A] and
each friction plate or steel plate [B] with a thickness gauge
[C]. The gap is the amount of friction or steel plate warp.
If any plate is warped over the service limit, replace it with
a new one.
Friction and Steel Plates Warp
Standard:
0.15 mm (0.0059 in.) or less
Service Limit:
0.3 mm (0.01 in.)
Engine Lubrication System
Engine Oil Change
• Warm up the engine thoroughly so that the oil will pick up
any sediment and drain easily. Then stop the engine.
WARNING
The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns.
Never touch the engine or exhaust pipe
during oil change.
• Remove the oil filler cap with level gauge.
• Remove the engine oil drain plug [A], and let the oil drain
completely.
• Replace the oil drain gasket with a new one.
• After draining, install the drain plug.
Torque - Engine Oil Drain Plug: 18 N·m (1.8 kgf·m, 13 ft·lb)
• Fill the engine with a good quality motor oil specified be-
low.
Oil Filter Change
Halaman 39
Periodic Maintenance Procedures
Recommended Engine
Type:
API SG, SH, SJ, SL or SM with JASO MA,
MA1 or MA2
Viscosity:
SAE 10W-40
Capacity:
0.93 L (0.98 US qt) (when filter is not
removed)
0.95 L (1.00 US qt) (when filter is removed)
1.10 L (1.16 US qt) (when engine is
completely dry)
NOTE
○Do not add any chemical additive to the oil. Oils fulfilling
the above requirements are fully formulated and provide
adequate lubrication for both the engine and the clutch.
• Check the oil level (see Engine Oil Level Inspection in the
Engine Lubrication System chapter).
Oil Filter Change
• Drain the engine oil (see Engine Oil Change).
• Remove:
Oil Filter Cover Bolts [A]
Oil Filter Cover [B]
• Replace the oil filter [A] with a new one.
• Apply engine oil to the grommet [B].
• Be sure to install the filter with the grommet facing inside.
NOTICE
Inside out installation stops oil flow, causing engine
seizure.
• Replace the oil filter cover O-ring [A] with a new one.
• Apply grease to the O-ring.
• Install the spring [B] securely.
• Install the oil filter cover.
Torque - Oil Filter Cover Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
• Pour in the specified type and amount of oil (see Engine
Oil Change).
PERIODIC MAINTENANCE 2-19
Tires Inspection
Halaman 40
2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Wheel/Tires
Air Pressure Inspection/Adjustment
• Using tire air pressure gauge [A], measure the tire pres-
sure when the tires are cold.
Adjust the tire air pressure to suit track conditions and
rider preference, but do not stray too far from the recom-
mended pressure.
Track Condition
Tire Pressure
When the track is wet, muddy, sandy
or slippery, reduce the tire pressure
to increase the tire tread surface on
the ground.
80 kPa (0.8 kgf/cm²,
11 psi)
↑
When the track is pebbly or hard,
increase the tire pressure to prevent
damage or punctures, through the
tires will skid more easily.
↓
100 kPa (1.0 kgf/cm²,
14 psi)
Tires Inspection
As the tire tread wears down, the tire becomes more sus-
ceptible the puncture and failure.
• Remove any imbedded stones or other foreign particles
from the tread.
• Visually inspect the tire for cracks and cuts, replacing the
tire in case of bad damage. Swelling or high spots indi-
cate internal damage, requiring tire replacement.
WARNING
Some replacement tires may adversely affect han-
dling and cause an accident resulting in serious in-
jury or death. To ensure proper handling and sta-
bility, use only the recommended standard tires for
replacement, inflated to the standard pressure.
NOTE
○Check and balance the wheel when a tire is replaced
with a new one.
Standard Tire
Front:
Size:
(KLX140A)
70/100-17 40M
(KLX140B)
70/100-19 42M
Make:
IRC
Type:
IX05H, Tube
Rear:
Size:
(KLX140A)
90/100-14 49M
(KLX140B)
90/100-16 52M
Make:
IRC
Type:
IX05H, Tube
Rim Runout Inspection
Halaman 41
Periodic Maintenance Procedures
Spoke Tightness Inspection
• Check that all the spokes are tightened evenly.
If spoke tightness is uneven or loose, tighten the spoke
nipples evenly.
• Check the rim runout (see Rim Runout Inspection).
WARNING
A missing spoke places an additional load on
the other spokes, which will eventually cause
other spokes to break, creating the potential for
an accident resulting in serious injury or death.
Immediately replace any broken spoke(s).
Rim Runout Inspection
• Place the jack under the frame so that the front/rear wheel
off the ground.
Special Tool - Jack: 57001-1238
• Inspect the rim for small cracks, dents, bending, or warp-
ing.
If there is any damage to the rim, it must be replaced.
• Set a dial gauge against the side of the rim, and rotate
the rim to measure the axial runout [A]. The difference be-
tween the highest and lowest dial readings is the amount
of runout.
• Set a dial gauge against the outer circumference of the
rim, and rotate the rim to measure radial runout [B]. The
difference between the highest and lowest dial readings
is the amount of runout.
If rim runout exceeds the service limit, check the wheel
bearings first. Replace them if they are damaged. If the
problem is not due to the bearings, correct the rim warp
(runout). A certain amount of rim warp can be corrected
by recentering the rim. Loosen some spokes and tighten
others within the standard torque to change the position of
different parts of the rim. If the rim is badly bent, however,
it must be replaced.
Rim Runout (with tire installed)
Standard:
Axial
TIR 0.8 mm (0.031 in.) or less
Radial
TIR 1.2 mm (0.047 in.) or less
Service Limit:
Axial
2.0 mm (0.08 in.)
Radial
2.0 mm (0.08 in.)
PERIODIC MAINTENANCE 2-21
Drive Chain Slack Inspection
Halaman 42
2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Wheel Bearing Inspection
• Raise the front/rear wheel off the ground.
Special Tool - Jack: 57001-1238
• Spin the wheel lightly, and check for roughness, binding
or noise.
If roughness, binding, abnormal noise is found, replace
the hub bearing.
• Turn the handlebar until the handlebar doesn’t move to
either side.
• The wheel edge is moved to one direction gripping the
edge of the wheel by both hands and the play of the wheel
bearing is checked.
If the play is found, replace the bearing.
Final Drive
Drive Chain Slack Inspection
• Raise the rear wheel off the ground, rotate the rear wheel
to find the place where the chain is tightest (because it
wears unevenly).
• Check the wheel alignment (see Wheel Alignment Inspec-
tion in the Final Drive chapter), and adjust it if necessary
(see Drive Chain Slack Adjustment).
NOTE
○Clean the drive chain if it is dirty, and lubricate it if it
appears dry.
• Rotate the rear wheel to find the position where the chain
is tightest.
• Measure the space (chain slack) [A] between the chain
and the swingarm at the rear of the chain slipper as
shown.
If the drive chain slack exceeds the standard, adjust it.
Chain Slack
Standard:
35 ∼41 mm (1.4 ∼1.6 in.)
Drive Chain Wear Inspection
Halaman 43
Periodic Maintenance Procedures
Drive Chain Slack Adjustment
• Loosen the left and right chain adjuster locknuts [A].
• Remove the cotter pin [B] and loosen the axle nut [C].
If the chain is too tight, back out the left and right chain
adjusting bolts [D] evenly, and push the wheel forward
until the chain is too loose.
If the chain is too loose, turn both chain adjusting bolts
evenly until the drive chain has the correct amount of
slack. To keep the chain and wheel properly aligned, the
notch on the left chain adjuster should align with the same
swingarm mark [E] as the right chain adjuster end [F].
Check the wheel alignment.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.
• Tighten both chain adjuster locknuts securely.
• Tighten the axle nut.
Torque - Rear Axle Nut: 79 N·m (8.1 kgf·m, 58 ft·lb)
• Rotate the wheel, measure the chain slack again at the
tightest position, and readjust if necessary.
• Install a new cotter pin into the axle, and bend it along
both sides.
WARNING
A loose axle nut can lead to an accident resulting in
serious injury or death. Tighten the axle nut to the
proper torque and install a new cotter pin.
• Check the rear brake.
Drive Chain Wear Inspection
• Rotate the rear wheel to inspect the drive chain for dam-
aged rollers, and loose pins and links.
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
• Stretch the chain taut by hanging a 98 N (10 kgf, 20 lb)
weight [A] on the chain.
• Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
of the 21st pin. Since the chain may wear unevenly, take
measurements at several places.
Chain 20-link Length
Standard:
254.0 ∼254.6 mm (10.00 ∼10.02 in.)
Service Limit:
260 mm (10.2 in.)
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
PERIODIC MAINTENANCE 2-23
Sprocket Wear Inspection
Halaman 44
2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
WARNING
A chain that breaks or jumps off the sprockets
could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control. Inspect the chain for
damage and proper adjustment before each ride.
If chain wear exceeds the service limit, replace it
with the standard chain.
Standard Chain
Make:
DAIDO
Type:
DID 428H
Link:
(KLX140A)
122 Links
(KLX140B)
126 Links
Drive Chain Lubrication
○The chain should be lubricated with a lubricant which will
both prevent the exterior from rusting and also absorb
shock and reduce friction in the interior of the chain.
If the chain is especially dirty, it should be washed in diesel
oil or kerosene, and afterward soaked in heavy oil. Shake
the chain while it is in the oil so that oil will penetrate to
the inside of each roller.
• An effective, good quality lubricant specially formulated
for chains is best for regular chain lubrication.
• If a special lubricant is not available, a heavy oil such as
SAE90 is preferred to a lighter oil because it will stay on
the chain longer and provide better lubrication.
• Apply oil to the sides of the rollers so that oil will penetrate
to the rollers and bushings.
• Wipe off any excess oil.
Oil applied area [A]
Sprocket Wear Inspection
• Visually inspect the front and rear sprocket teeth for wear
and damage.
If they are worn as illustrated or damaged, replace the
sprocket.
[A] Worn Tooth (Engine Sprocket)
[B] Worn Tooth (Rear Sprocket)
[C] Direction of Rotation
NOTE
○If a sprocket requires replacement, the chain is proba-
bly worn also. When replacing a sprocket, inspect the
chain.
Brake Lever and Pedal Position Adjustment
Halaman 45
Periodic Maintenance Procedures
Rear Sprocket Warp Inspection
• Using the jack, raise the rear wheel off the ground.
Special Tool - Jack: 57001-1238
• Set a dial gauge [A] against the rear sprocket [B] near the
teeth as shown and rotate [C] the rear wheel to measure
the sprocket runout (warp). The difference between the
highest and lowest dial gauge readings is the amount of
runout (warp).
If the runout exceeds the service limit, replace the rear
sprocket.
Rear Sprocket Warp
Standard:
0.4 mm (0.016 in.) or less
Service Limit:
0.5 mm (0.02 in.)
Brakes
Brake Lever and Pedal Position Adjustment
WARNING
An improperly adjusted brake could drag and cause
the brake to overheat, damaging the brake assem-
bly and possbily locking the rear wheel, resulting in
loss of control. Always maintain the proper brake
adjustment.
• Adjust the front brake lever [A] to suit you.
• Loosen the adjuster locknut [B] and turn the adjuster [C]
to either side.
• After adjustment, tighten the locknut.
NOTE
○Usually it is not necessary to adjust the pedal position,
but always adjust it when the master cylinder is disas-
sembled or pedal position is incorrect.
• If the length [A] is 67.8 ±1 mm (2.67 ±0.04 in.), the pedal
position will be within the standard range.
If it is not standard length, the brake pedal may be de-
formed or incorrectly installed.
If it is not within the standard length, adjust the push rod
in the master cylinder as follows.
PERIODIC MAINTENANCE 2-25
Brake Fluid Level Inspection
Halaman 46
2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
○Loosen the push rod locknut [A].
○Remove:
Cotter Pin [B]
Washer
Joint Pin [C]
○Turn the bracket [D] to obtain the specified length.
○Tighten the locknut.
Torque - Rear Master Cylinder Push Rod Locknut: 17 N·m
(1.7 kgf·m, 13 ft·lb)
○Replace the cotter pin with a new one.
Brake Fluid Level Inspection
• Check the brake fluid level in the front or rear brake reser-
voir [A].
NOTE
○Hold the reservoir horizontal when checking brake fluid
level.
• The front or rear reservoir must be kept above the lower
level line [B].
○If the fluid level in front or rear reservoir is lower than the
lower level line, fill the reservoir to the upper level line. In-
side the reservoir is stopped end showing the upper level
line [C].
Torque - Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13
in·lb)
WARNING
Mixing brands and types of brake fluid can reduce
the brake system’s effectiveness and cause an ac-
cident 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 re-
filled but the type and brand of the brake fluid that
is already in the reservoir are unidentified.
Brake Fluid Change
Halaman 47
Periodic Maintenance Procedures
Brake Fluid Change
In accordance with the Periodic Maintenance Chart,
change the brake fluid.
The brake fluid should also be
changed if it becomes contaminated with dirt or water.
Furthermore, the brake fluid should be changed to bleed
the air quickly and completely whenever the brake line
parts are removed.
WARNING
When working with the disc brake, observe the pre-
cautions listed below.
1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been left
unsealed or that has been open for a long time.
3. Do not mix two types and brands of fluid for use in
the brake. This lowers the brake fluid boiling point
and could cause the brake to be ineffective. It may
also cause the rubber brake parts to deteriorate.
4. Don’t leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
5. Don’t change the fluid in the rain or when a strong
wind is blowing.
6. Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid for cleaning these parts. Gasoline, engine oil,
or any other petroleum distillate will cause deterio-
ration of the rubber parts. Oil spilled on any part will
be difficult to wash off completely and will eventually
deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful that
no disc brake fluid or any oil gets on them. Clean off
any fluid or oil that inadvertently gets on the pads or
disc with a high-flash point solvent. Do not use one
which will leave an oily residue. Replace the pads
with new ones if they cannot be cleaned satisfacto-
rily.
8. Brake fluid quickly ruins painted surfaces;
any
spilled fluid should be completely wiped up imme-
diately.
9. If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.
Recommended Brake Fluid
Type:
DOT3 or DOT4
PERIODIC MAINTENANCE 2-27
Brake Fluid Change
Halaman 48
2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
NOTE
○The procedure to change the front brake fluid. Chang-
ing the rear brake fluid is the same as for the front brake.
• Level the brake fluid reservoir.
• Remove the screws [A] and reservoir cap [B] with di-
aphragm.
• Remove the rubber cap [A].
• Attach a clear plastic hose to the caliper bleed valve [B],
and run the other end of the hose into a suitable container.
• Change the brake fluid as follows:
○Repeat this operation until fresh brake fluid comes out
from the plastic hose or the color of the fluid changes.
1. Open the bleed valve [A]
2. Apply the brake and hold it [B]
3. Close the bleed valve [C]
4. Release the brake [D]
○Fill the reservoir with fresh specified brake fluid.
NOTE
○The fluid level must be checked often during the chang-
ing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.
Brake Master Cylinder Cup and Dust Seal Replacement
Halaman 49
Periodic Maintenance Procedures
• Remove the clear plastic hose.
• Tighten the bleed valve, and install the rubber cap.
Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m,
13 in·lb)
• After changing the fluid, check the brake for good braking
power, no brake drag and no fluid leakage.
If necessary, bleed the air from the lines (see Bleeding
the Brake Line in the Brakes chapter).
WARNING
Mixing brands and types of brake fluid can reduce
the brake system’s effectiveness and cause an ac-
cident 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 re-
filled but the type and brand of the brake fluid that
is already in the reservoir are unidentified.
Brake Pad Wear Inspection
• Remove the brake pads (see Caliper Piston Seal and
Dust Seal Replacement).
• Check the lining thickness [A] and condition of the pads
in each caliper.
If either pad is damaged, replace both pads in the caliper
as a set.
If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.
Pad Lining Thickness
Standard:
Front
4.5 mm (0.18 in.)
Rear
3.7 mm (0.15 in.)
Service Limit:
1 mm (0.04 in.)
Brake Master Cylinder Cup and Dust Seal
Replacement
Front Master Cylinder Disassembly
• Remove the front master cylinder (see Front Master Cylin-
der Removal in the Brakes chapter).
• Remove the reservoir cap and diaphragm, and pour the
brake fluid into a container.
• Unscrew the locknut and pivot bolt, and remove the brake
lever.
• Pull the dust cover [A] out of place, and remove the circlip
[B].
Special Tool - Inside Circlip Pliers: 57001-143
• Remove the washer [C].
• Pull out the piston [D], secondary cup [E], primary cup [F],
and return spring [G].
PERIODIC MAINTENANCE 2-29
Brake Master Cylinder Cup and Dust Seal Replacement
Halaman 50
2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
NOTICE
Do not remove the secondary cup from the piston
since removal will damage it.
Rear Master Cylinder Disassembly
• Remove the rear master cylinder (see Rear Master Cylin-
der Removal in the Brakes chapter).
NOTE
○Do not remove the push rod clevis for master cylinder
disassembly since removal requires brake pedal posi-
tion adjustment.
• Remove the reservoir cap and diaphragm, and pour the
brake fluid into a container.
• Slide the dust cover [A] on the push rod [B] out of place,
and remove the circlip [C].
Special Tool - Inside Circlip Pliers: 57001-143
• Pull out the push rod with the piston stop [D].
• Take off the piston [E], secondary cup [F], primary cup [G],
and return spring [H].
NOTICE
Do not remove the secondary cup from the piston
since removal will damage it.
Assembly
• Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.
NOTICE
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid for cleaning of these parts. Gasoline, engine
oil, or any other petroleum distillate will cause de-
terioration of the rubber parts. Oil spilled on any
part will be difficult to wash off completely, and will
eventually deteriorate the rubber used in the disc
brake.
• Apply brake fluid to the removed parts and the inner wall
of the cylinder.
• Take care not to scratch the piston or the inner wall of the
cylinder.
• Apply silicone grease (ex. PBC grease to the following).
Brake Lever Pivot Bolt
Brake Lever Pivot Contact
Push Rod Contact (Rear)
Dust Covers
Caliper Piston Seal and Dust Seal Replacement
Halaman 51
Periodic Maintenance Procedures
Caliper Piston Seal and Dust Seal Replacement
NOTE
○The procedure to replace the front caliper seals. Re-
placing the rear caliper seals is the same as for the front
caliper.
• Loosen the brake pad pin [A] and banjo bolt [B], and
tighten them loosely.
• Remove:
Front Caliper Mounting Bolts [C]
Banjo Bolt
Brake Hose [D]
Front Caliper
• Separate the caliper front holder [A] from the caliper [B]
and remove the anti-rattle spring [C].
○The rear caliper holder cannot be removed.
• Using compressed air, remove the pistons. One way to
remove the pistons is as follows.
○Cover the caliper opening with a clean, heavy cloth [A].
○Remove the pistons by lightly applying compressed air to
the hose joint opening [B].
WARNING
The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.
○Pull out the pistons [A] by hand.
• Remove the dust seals [B] and fluid seals [C].
NOTE
○If compressed air is not available, do as follows for both
calipers coincidentally, with the brake hose connected
to the caliper.
○Prepare a container for brake fluid, and perform the
work above it.
○Remove the spring and pads.
○Pump the brake lever until the pistons come out of the
cylinders, and then disassembly the caliper.
• Clean the caliper parts except for the pads.
NOTICE
For cleaning of the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
• The bleed valve was removed, install the bleed valve and
rubber cap.
Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
PERIODIC MAINTENANCE 2-31
Brake Hose Replacement
Halaman 52
2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Replace the fluid seal(s) [A] with new ones.
○Apply brake fluid to the fluid seal(s), and install them into
the cylinders by hand.
• Replace the dust seal(s) [B] with new ones.
○Apply brake fluid to the dust seal(s), and install them into
the cylinder by hand.
• Apply brake fluid to the outside of the pistons [C], and
push them into each cylinder by hand.
• Install the anti-rattle spring [A].
• Replace the shaft rubber friction boot [B] and dust boot
[C] if they are damaged.
• Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to
the caliper holder shafts [D] and holder holes (PBC is a
special high temperature, water-resistance grease).
• Install the brake pads and the caliper holder.
• Install the caliper (see Caliper Installation in the Brakes
chapter).
• Wipe up any spilled brake fluid on the caliper with wet
cloth.
Brake Hose and Connection Check
• Inspect the brake hose and fittings for deterioration,
cracks and signs of leakage.
○The high pressure inside the brake line can cause fluid to
leak [A] or the hose to burst if the line is not properly main-
tained. Bend and twist the rubber hose while examining
it.
Replace the hose if any cracks [B] or bulges [C] are no-
ticed.
Tighten any loose fittings.
Brake Hose Replacement
NOTICE
Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely washed away
immediately.
• When removing the brake hose, take care not to spill the
brake fluid on the painted or plastic parts.
• When removing the brake hose temporarily secure the
end of the brake hose to some high place to keep fluid
loss to a minimum.
• Immediately wash away any brake fluid that spills.
Front Fork Inspection
Halaman 53
Periodic Maintenance Procedures
• Remove each banjo bolts [A] and washers [B].
• Replace the washers with new ones.
(Front Brake)
• Remove:
Bolts [A]
Brake Hose Clamps [B]
(Rear Brake)
• Remove:
Master Cylinder [A]
Hose Clamps [B]
• When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and route the hoses according to
Cable, Wire and Hose Routing section in the Appendix
chapter.
• Tighten the banjo bolts on the hose fittings.
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Fill the brake line after installing the brake hose (see
Brake Fluid Change).
Suspension
Front Fork Inspection
• Holding the brake lever, pump the front fork up and down
manually to check for smooth operation.
PERIODIC MAINTENANCE 2-33
Front Fork Oil Change (each fork leg)
Halaman 54
2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Tuck up the fork boots [A].
• Visually inspect the front fork for oil leakage, scoring or
scratches on the outer surface of the inner tube [B].
If necessary, repair any damage.
• Nick or rust damage can sometimes be repaired by using
a wet-stone to remove sharp edges or raised areas which
cause seal damage.
If the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repaired
or replaced.
• If the fork is not smooth, confirm the cause.
NOTICE
If the inner tube is badly bent or creased, replace
it.
Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
Front Fork Oil Change (each fork leg)
• Loosen the front fork upper clamp bolt [A] and the fork top
plug [B].
• Remove the front fork (see Front Fork Removal in the
Suspension chapter).
• Thoroughly clean the fork before disassembly.
NOTICE
Be careful not scratch the inner tube and not to
damage the dust seal.
Avoid scratching or damaging the inner tube or the
dust seal. Use a mild detergent and sponge out dirt
with plenty of water.
• Loosen the clamp screw [A], and pull out the fork boot [B].
Front Fork Oil Change (each fork leg)
Halaman 55
Periodic Maintenance Procedures
• Remove:
Top Plug [A] with O-ring
Spring Collar [B]
Washer [C]
Fork Spring [D]
• Prepare a drain pan [A] and drain the fork oil.
NOTE
○Pump the fork tube several times to discharge the oil.
• Hold the outer tube vertically in a vise and compress the
fork completely.
• Wait until the oil level stabilizes.
• Use the fork oil level gauge [A] to measure the distance
between the top of the inner tube to the oil level.
Special Tool - Fork Oil Level Gauge: 57001-1290
○Set the oil level gauge stopper [B] so that the distance [C]
from the bottom of the stopper to the lower end of the pipe
is the standard oil level distance.
○A correct measurement can not be obtained unless the
level gauge pipe is placed in the center of the inner tube.
Oil Level (fully compressed, without spring)
Standard:
KLX140A Model
95 ±2 mm (3.74 ±0.08 in.)
KLX140B Model
105 ±2 mm (4.13 ±0.08 in.)
○Place the stopper of the level gauge at the top [D] of the
inner tube [E] and pull the handle slowly to draw out the
excess oil from fork into the gauge, thus attaining the stan-
dard level.
○If not oil is drawn out, there is not enough oil in the fork.
Pour in some more oil and measure again.
PERIODIC MAINTENANCE 2-35
Drive Chain Guide, Guide Roller, Chain Slipper Wear
Halaman 56
2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Rear Shock Absorber Inspection
• Bounce [A] the rear of the motorcycle up and down and
check for smooth suspension stroke.
• Remove the rear frame (see Rear Frame Removal in the
Frame chapter).
• Check for a broken or collapsed spring.
• Check the shock for a bent shaft or oil leaks.
If the shock does not smoothly or damaged, replace or
repair defective parts.
Swingarm and Uni-Trak Linkage Inspection
• Check the uni-trak component parts for wear periodically,
or whenever excessive play is suspected.
• Raise the rear wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
• Push and pull on the swingarm [A], up and down, to check
for wear.
A small amount of play on the swingarm is normal and no
corrective action is needed. However, if excessive play is
felt, remove the uni-trak parts from the frame and check
for wear.
Swingarm and Uni-Track Linkage Pivot Lubricate
• Refer to the Swingarm Bearing Installation and Rocker
Arm Bearing Installation in Suspension chapter.
Drive Chain Guide, Guide Roller, Chain Slipper
Wear
• Visually inspect the drive chain guide [A] and replace it if
excessively worn or damaged.
• Visually inspect the upper and lower chain guide rollers
[A] and replace them if excessively worn or damaged.
Steering Adjustment
Halaman 57
Periodic Maintenance Procedures
• Visually inspect the chain slipper [A] on the swingarm [B]
and replace it if worn or damaged.
Steering
Steering Inspection
• Raise the front wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
• With the front wheel pointing straight ahead, alternately
nudge each end of the handlebar. The front wheel should
swing fully left and right from the force of gravity until the
fork hits the stop.
If the steering binds or catches before the stop, check the
routing of the cables, hoses and harnesses.
If the steering feels tight, adjust or lubricate the steering.
• Feel for steering looseness by pushing and pulling the
forks.
If you feel looseness, adjust the steering.
Steering Adjustment
• Raise the front wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
• Remove:
Number Plate [A]
Handlebar Clamp Bolts [B]
Handlebar Clamps [C]
Handlebar [D] (from holder)
PERIODIC MAINTENANCE 2-37
Steering Adjustment
Halaman 58
2-38 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Remove the bolts [A], and take off the ignition switch [B]
with choke knob (KLX140A8F ∼AAF/B8F ∼BAF).
• Remove the bolts [A], and take off the choke knob bracket
[B] (KLX140ABF/BBF).
• Loosen the front fork upper clamp bolts [A], and remove
the steering stem head nut [B] and steering stem head
[C].
• Turn the steering stem nut [A] with the steering stem nut
wrench [B] to obtain the proper adjustment.
If the steering is too tight, loosen the stem nut a fraction of
a turn; if the steering is too loose, tighten the nut a fraction
of a turn.
Special Tool - Steering Stem Nut Wrench: 57001-1100
NOTE
○Turn the stem nut 1/8 turn at a time maximum.
• Install the steering stem head.
• Tighten the following:
Torque - Steering Stem Head Nut: 64 N·m (6.5 kgf·m, 47
ft·lb)
Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
• Check the steering again.
If the steering is too tight or too loose, repeat the adjust-
ment as mentioned above.
• Install the handlebar (see Handlebar Installation in the
Steering chapter).
Side Stand Inspection
Halaman 59
Periodic Maintenance Procedures
Stem Bearing Lubrication
• Remove the steering stem (see Steering Stem, Stem
Bearing Removal in the Steering chapter).
• Using a high-flash point solvent, wash the upper and
lower tapered rollers in the cages, and wipe the upper
and lower outer races, which are press-fitted into the
frame head pipe, clean off grease and dirt.
• Visually check the outer races and the rollers.
Replace the bearing assemblies if they show wear or
damage.
• Pack the upper and lower tapered roller bearings [A] in
the cages with grease, and apply a light coat of grease to
the upper and lower outer races.
• Install the steering stem, and adjust the steering (see
Steering Adjustment).
Frame
Frame Inspection
• Clean the frame with steam cleaner.
• Visually inspect the frame and rear frame for cracks,
dents, bending, or warp.
If there is any damage to the frame, replace it.
WARNING
A repaired frame may fail in use, possibly causing
an accident resulting in injury or death. If the frame
is bent, dented, cracked, or warped, replace it.
Side Stand Inspection
• See if the side stand [A] moves smoothly and retracts fully.
If not, clean and grease the pivot [B] and sliding portion
[C].
• Check the side stand spring [D] for damage.
If necessary, replace the spring.
PERIODIC MAINTENANCE 2-39
Lubrication
Halaman 60
2-40 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Electrical System
Spark Plug Cleaning and Inspection
• Remove the spark plug cap [A].
• Remove the spark plug [B], using the spark plug wrench
[C].
Special Tool - Spark Plug Wrench: 57001-1262
Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-0005
• Clean the spark plug, preferably in a sandblasting device,
and then clean off any abrasive particles. The plug may
also be cleaned using high-flash point solvent and a wire
brush or other suitable tool.
If the spark plug electrodes are corroded or damaged or
if the insulator is cracked, replace the plug. Use the stan-
dard spark plug.
• Measure the gap [A] with a wire-type thickness gauge.
If the gap is incorrect, carefully bend the side electrode
[B] with a suitable tool to obtain the correct gap.
Spark Plug Gap
Standard:
0.6 ∼0.7 mm (0.02 ∼0.03 in.)
• Install the spark plug.
Torque - Spark Plug: 13 N·m (1.3 kgf·m, 115 in·lb)
• Insert the plug cap, and confirm for the spark plug not to
come off.
Cable Inspection
Lubrication
• Before lubricating each part, clean off any rusty spots with
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
NOTE
○Whenever the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubri-
cation.
Points: Lubricate with Grease.
Clutch Inner Cable Upper and Lower Ends [A]
Hot Start Inner Cable Upper End
Throttle Inner Cable Upper End
Tightness Inspection
Halaman 61
Periodic Maintenance Procedures
Cables: Lubricate with Rust Inhibitor.
Throttle Cables
Clutch Cable
Hot Starter Cable
• With the cable disconnected at the both ends, the cable
should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
Nut, Bolt, and Fastener Tightness Inspection
Tightness Inspection
• Check the tightness of the bolts and nuts listed here in
accordance with the Periodic Maintenance Chart. Also,
check to see that each cotter pin is in place and in good
condition.
NOTE
○For the engine fasteners, check the tightness of them
when the engine is cold (at room temperature).
PERIODIC MAINTENANCE 2-41
Tightness Inspection
Halaman 62
2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
If there are loose fasteners, retorque them to the specified
torque following the specified tightening sequence. Refer
to the Torque and Locking Agent section of the General
Information chapter for torque specifications. For each
fastener, first loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
Nut, Bolt and Fastener to be checked
Wheels:
Spoke Nipples
Front Axle Nut
Nut Cotter Pin
Rear Axle Nut Cotter Pin
Rear Axle Nut
Final Drive:
Chain Adjuster Locknut
Rear Sprocket Nuts
Brakes:
Front Master Cylinder Clamp Bolts
Brake Lever Pivot Nut
Front Caliper Mounting Bolts
Brake Pedal Pivot Bolt
Rear Brake Joint Cotter Pin
Rear Master Cylinder Mounting Bolts
Rear Caliper Mounting Bolts
Suspension:
Front Fork Clamp Bolts
Front Fender Bolts
Rear Shock Absorber Mounting Bolts, Nuts
Swingarm Pivot Nut
Steering:
Steering Stem Head Nut
Handlebar Clamp Bolts
Engine:
Throttle Cable Adjuster Locknuts
Engine Mounting Bolts, Nuts
Shift Pedal Bolt
Muffler Mounting Bolts
Exhaust Pipe Holder Nuts
Clutch Cable Adjuster Locknut
Clutch Lever Pivot Nut
Others:
Footpeg Cotter Pins
Rear Frame Bolts
Side Stand Bolt
Fuel System
Halaman 63
Fuel System
Table of Contents
Exploded View........................................................................................................................
3-2
Specifications .........................................................................................................................
3-8
Special Tool ............................................................................................................................
3-9
Throttle Grip and Cable ..........................................................................................................
3-10
Free Play Inspection .........................................................................................................
3-10
Free Play Adjustment........................................................................................................
3-10
Throttle Cable Replacement .............................................................................................
3-10
Throttle Cable Lubrication.................................................................................................
3-11
Throttle Cable Inspection..................................................................................................
3-11
Choke Cable Removal......................................................................................................
3-11
Choke Cable Installation...................................................................................................
3-12
Choke Cable Lubrication...................................................................................................
3-12
Choke Cable Inspection....................................................................................................
3-12
Carburetor ..............................................................................................................................
3-13
Idle Speed Inspection .......................................................................................................
3-13
Idle Speed Adjustment......................................................................................................
3-13
Service Fuel Level Inspection...........................................................................................
3-13
Float Height Inspection .....................................................................................................
3-14
Carburetor Removal..........................................................................................................
3-15
Carburetor Installation.......................................................................................................
3-16
Fuel Inspection..................................................................................................................
3-16
Carburetor Disassembly ...................................................................................................
3-16
Carburetor Cleaning..........................................................................................................
3-18
Carburetor Inspection .......................................................................................................
3-18
Carburetor Assembly ........................................................................................................
3-20
Air Cleaner..............................................................................................................................
3-21
Air Cleaner Housing Removal/Installation ........................................................................
3-21
Element Removal..............................................................................................................
3-21
Element Installation...........................................................................................................
3-22
Element Cleaning and Inspection .....................................................................................
3-22
Fuel Tank................................................................................................................................
3-23
Fuel Tank Removal ...........................................................................................................
3-23
Fuel Tank Installation ........................................................................................................
3-24
Fuel Tap Removal.............................................................................................................
3-24
Fuel Tap Installation..........................................................................................................
3-24
Fuel Tank, Filter and Tap Cleaning ...................................................................................
3-24
Fuel Tap and Filter Inspection...........................................................................................
3-24
FUEL SYSTEM 3-1
3
Exploded View
Halaman 64
## 3-2 FUEL SYSTEM
### Exploded View
GC023778WS C
Exploded View
Halaman 65
FUEL SYSTEM 3-3
### Exploded View
| No. | Fastener | Torque | Remarks |
| --- | --------------------------- | :----------------------- | :------- |
| | | **N·m** | **kgf·m** | **ft·lb** |
| 1 | Carburetor Holder Adapter Bolts | 8.8 | 0.90 | 78 in·lb |
2. Throttle Cable
3. Choke Cable
4. Throttle Grip
5. Carburetor Cap
6. Retainer
7. Circlip
8. Jet Needle
9. Throttle Valve
10. Idle Adjusting Screw
11. Needle Jet
12. Needle Jet Holder
13. Pilot Jet
14. Main Jet
15. Float Valve Needle
16. Float
17. Carburetor Drain Plug
18. Fuel Hose
CL: Apply cable lubricant.
G: Apply grease.
R: Replacement Parts
Exploded View
Halaman 66
3-4 FUEL SYSTEM
Exploded View
GC02376BW5 C
Exploded View
Halaman 67
FUEL SYSTEM 3-5
Exploded View
| No. | Fastener | N·m | kgf·m | ft·lb | Remarks |
|:----|:--------------------------------|------:|------:|:------|:--------|
| 1 | Air Cleaner Housing Mounting Bolt | 5.2 | 0.53 | 46 in·lb | |
2. Air Cleaner Element
3. Air Cleaner Drain Plug
4. Carburetor Clamp
AD: Apply adhesive cement.
G: Apply grease.
O: High-quality foam air filter oil.
Exploded View
Halaman 68
## 3-6 FUEL SYSTEM
Exploded View
GC023339BW5 C
Exploded View
Halaman 69
FUEL SYSTEM 3-7
Exploded View
| No. | Fastener | Torque | Remarks |
| :-- | :-------------------- | :---------------------: | :------ |
| | | N·m | kgf·m | ft·lb | |
| 1 | Fuel Tank Cover Screws | 5.0 | 0.51 | 44 in·lb | |
AD: Apply adhesive cement
R: Replacement Parts.
Specifications
Halaman 70
3-8 FUEL SYSTEM
Specifications
Item
Standard
Throttle Grip and Cable
Throttle Grip Free Play
2 ∼3 mm (0.08 ∼0.12 in.)
Carburetor
Make/Type
KEIHIN PB20
Idle Speed
1 400 ±100 r/min (rpm)
Main Jet
#95
Main Air Jet
#180
Jet Needle
NNAA
Throttle Valve Cutaway
3.0
Slow Jet
#38/38
Pilot Air Screw
Non-Adjustable
Service Fuel Level
3.0 ±1 mm (0.12 ±0.04 in.)
(below the bottom edge of the carburetor body)
Float Height
11.7 ±2 mm (0.461 ±0.08 in.)
Air Cleaner
Air Cleaner Element Oil
High quality form air filter oil
Special Tool
Halaman 71
Special Tool
Fuel Level Gauge:
57001-1017
FUEL SYSTEM 3-9
Throttle Cable Replacement
Halaman 72
3-10 FUEL SYSTEM
Throttle Grip and Cable
If the throttle grip has excessive free play due to cable
stretch or misadjustment, there will be a delay in throttle re-
sponse. Also, the throttle valve may not open fully at full
throttle. On the other hand, if the throttle grip has no play,
the throttle will be hard to control, and the idle speed will
be erratic. Check the throttle grip play periodically in accor-
dance with the Periodic Maintenance Chart, and adjust the
play if necessary.
The throttle cable routing is shown in Cable, Wire and
Hose Routing Section in the Appendix chapter.
Free Play Inspection
• Refer to the Throttle Grip Free Play Inspection in the Pe-
riodic Maintenance chapter.
Free Play Adjustment
• Refer to the Throttle Grip Free Play Adjustment in the
Periodic Maintenance chapter.
Throttle Cable Replacement
• Tuck up the dust cover [A].
• Remove the throttle cable housing cap screws [B], and
take off the cap [C].
• Loosen the locknut [A], and screw in the adjuster [B].
• Remove the throttle cable [C] from the grip.
• Remove the fuel tank (see Fuel Tank Removal).
• Loosen the cap [A], and Remove the throttle valve (see
Carburetor Disassembly).
Choke Cable Removal
Halaman 73
Throttle Grip and Cable
• Lubricate the cable.
• Apply grease to the tips of the cables.
• Insert the throttle valve assembly.
• Run the throttle cable in accordance with the Cable, Wire
and Hose Routing section in the Appendix chapter.
• Install the grip to the handlebar, and install the cable hous-
ing [A].
• Align the mating surface [B] to the punch mark [C] on the
handlebar.
• Install the throttle cable to the cable housing.
• After the installation, adjust the cable properly.
WARNING
Operation with incorrectly routed or improperly ad-
justed cables could result in an unsafe riding con-
dition. Be sure the cables are routed correctly and
properly adjusted.
Throttle Cable Lubrication
• Whenever the throttle cable is removed or in accordance
with the Periodic Maintenance Chart, lubricate the these
cables (see Lubrication in the Periodic Maintenance
chapter).
○Apply a little grease to the cable upper or lower ends.
○Use a commercially available pressure cable lubricator to
lubricate these cables.
Throttle Cable Inspection
• Refer to the Cable Inspection in the Periodic Maintenance
chapter.
Choke Cable Removal
• Remove the number plate [A], and tuck up the boot [B].
• Loosen the adjuster [C] and locknut [D].
• Remove the cable from the bracket.
• Remove the fuel tank (see Fuel Tank Removal).
• Free the boot [A] from the choke holder [B].
• Free the tip [C] from the carburetor, and pull out the choke
cable [D] from the cable holder.
FUEL SYSTEM 3-11
Choke Cable Inspection
Halaman 74
3-12 FUEL SYSTEM
Throttle Grip and Cable
Choke Cable Installation
• Install the choke cable in accordance with the Cable, Wire
and Hose Routing section in the appendix chapter.
• After the installation, adjust the cable properly.
WARNING
Operation with incorrectly routed or improperly ad-
justed cables could result in an unsafe riding con-
dition. Be sure the cables are routed correctly and
properly adjusted.
• Adjust the choke knob operation as the following proce-
dures.
○Pull the choke knob [A] fully.
○Turn the adjuster [B] to adjust the hardness of the knob
operation.
If the adjuster too tight ,the knob operation becomes
heavy.
If the adjuster too loose, the position of the knob cannot
be fixed.
Choke Cable Lubrication
• Whenever the choke cable is removed or in accordance
with the Periodic Maintenance Chart, lubricate the these
cable (see Lubrication in the Periodic Maintenance chap-
ter).
Choke Cable Inspection
• Refer to the Cable Inspection in the Periodic Maintenance
chapter.
Service Fuel Level Inspection
Halaman 75
Carburetor
Since the carburetor regulates and mixes the fuel and air
going to the engine, there are two general types of carbure-
tor trouble: too rich a mixture (too much fuel), and too lean
a mixture (too little fuel). Such trouble can be caused by
dirt, wear, maladjustment or improper fuel level in the float
chamber. A dirty or damaged air cleaner can also alter the
fuel to air ratio.
Idle Speed Inspection
• Refer to the Idle Speed Inspection in the Periodic Main-
tenance chapter.
Idle Speed Adjustment
• Refer to the Idle Speed Adjustment in the Periodic Main-
tenance chapter.
Service Fuel Level Inspection
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Always stop the
engine and do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove:
Fuel Tank (see Fuel Tank Removal)
Carburetor (see Carburetor Removal)
• Hold the carburetor in true vertical position on a stand.
• Put the fuel tank on a bench, and connect the fuel tap to
the carburetor with a fuel hose.
• Connect the fuel gauge [A] to the carburetor drain [B] us-
ing a suitable hose [C].
Special Tool - Fuel Level Gauge: 57001-1017
• Hold the gauge vertically against the side of the carburetor
body so that the "middle" line [D] is several millimeters
higher than the bottom edge [E] of the carburetor body.
• Turn the fuel tap to the ON position to feed fuel to the
carburetor, then turn out the drain plug [E] a few turns.
• Wait until the fuel level in the gauge settles.
• Keeping the gauge vertical, slowly lower the gauge until
the "middle" line is even with the bottom edge of the car-
buretor body.
NOTE
○Do not lower the "middle" line below the bottom edge of
the carburetor body. If the gauge is lowered and then
raised again, the fuel level measure shows somewhat
higher than the actual fuel level. If the gauge is lowered
too far, dump the fuel out of it into a suitable container
and start the procedure over again.
FUEL SYSTEM 3-13
Float Height Inspection
Halaman 76
3-14 FUEL SYSTEM
Carburetor
• Check the fuel level in the gauge.
Service Fuel Level (below the bottom edge of carburetor
body)
Standard:
3.0 ± 1 mm (0.12 ± 0.04 in.)
• Screw the carburetor drain plug.
• Turn the fuel tap to the OFF position and remove the fuel
level gauge.
If the fuel level is incorrect inspect, the float, the float valve
needle and the contacting surface between the carburetor
body and its float valve needle.
If they are damaged,
replace them with new ones.
○This carburetor cannot adjust the fuel level.
• Install the carburetor.
Float Height Inspection
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Always stop the
engine and do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove the carburetor (see Carburetor Removal).
• Drain the fuel of the carburetor.
• Remove the screws [A], and take off the float bowl [B].
• Measure the height between the float bowl mating surface
[A] (with the gasket removed) and the float upper surface
[B].
Float Height
Standard: 11.7 ± 2 mm (0.461 ± 0.08 in.)
If the float level is incorrect, inspect the float, the float
valve needle and the contacting surface between the car-
buretor body and its float valve needle. If they are dam-
aged, replace them with new ones.
○This carburetor cannot adjust the float level.
Carburetor Removal
Halaman 77
Carburetor
NOTE
○Measure the height with the carburetor upside down.
○Do not push the needle rod [A] in during the float height
measurement.
• Install:
Float Bowl
Carburetor (see Carburetor Installation)
Carburetor Removal
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Always stop the
engine and do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove:
Side Covers (see Side Covers Removal in the Frame
chapter)
Seat (see Seat Removal in the Frame chapter)
Fuel Tank (see Fuel Tank Removal)
Choke Cable Lower End (see Choke Cable Removal)
Carburetor Holder (see Carburetor Holder Removal in
the Engine Top End chapter)
• Loosen the clamp screw [A], and pull out the carburetor
from the air cleaner.
• After removing the carburetor, push a clean, lint-free cloth
into the cylinder head opening and the air cleaner duct to
keep dirt or other foreign material from entering.
FUEL SYSTEM 3-15
Carburetor Disassembly
Halaman 78
3-16 FUEL SYSTEM
Carburetor
• Unscrew the cap [A] and pull out the throttle cable lower
end with the throttle valve, spring and jet needle as a set.
WARNING
If dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck, possibly
causing accident. Replace the air cleaner element
according to the maintenance chart.
NOTICE
If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.
If the throttle valve is not removed from the cable,
wrap clean cloths around the throttle valve to avoid
damaging to it.
Carburetor Installation
• Installation is the reverse of removal.
• Fit the slit [A] and the projection [B], and insert the throttle
valve assembly [C] into the carburetor body.
• After installing the carburetor, perform the following.
○Check fuel leakage from the carburetor.
WARNING
Fuel spilled from the carburetor is hazardous.
○Adjust the following.
Idle Speed (see Idle Speed Adjustment in the Periodic
Maintenance chapter)
Throttle Grip Free Play (see Throttle Grip Free Play Ad-
justment in the Periodic Maintenance chapter)
Fuel Inspection
• Refer to the Fuel Inspection in the Periodic Maintenance
chapter.
Carburetor Disassembly
• Remove the carburetor (see Carburetor Removal).
• Push the whole of spring [A] to the cap [B] side, and hold
it.
• Free the cable lower end [C] from the throttle valve [D].
Carburetor Disassembly
Halaman 79
Carburetor
• Remove the retainer place [A] and the jet needle [B] with
the clip [C].
• Remove the following parts from the carburetor body.
Carburetor Holder Adapter [A]
Idle Adjusting Screw [B]
Spring [C]
O-ring [D]
Pilot Jet [A]
Needle Jet [B]
Needle Jet Holder [C]
Main Jet [D]
Float Valve Needle [E]
Float [F]
Pin [G]
O-ring [H]
Float Bowl [I]
FUEL SYSTEM 3-17
Carburetor Inspection
Halaman 80
3-18 FUEL SYSTEM
Carburetor
Carburetor Cleaning
WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause severe
burns.
Clean the carburetor in a well ventilated
area, and take care that there are no sparks or flame
anywhere near the working area; this includes any
appliance with a pilot light. Do not use gasoline or
a low-flash point solvent to clean the carburetor.
• Make sure the fuel tap is in the OFF position.
• Remove the carburetor (see Carburetor Removal).
• Drain the fuel in the carburetor.
• Disassemble the carburetor (see Carburetor Disassem-
bly).
NOTICE
Do not use compressed air on an assembled carbu-
retor, the float may be deformed by the pressure.
Remove as many rubber or plastic parts from the
carburetor as possible before cleaning the car-
buretor with cleaning solution.
This will prevent
damage or deterioration of the parts. Do not use
strong carburetor cleaning solution which could at-
tack the plastic parts; instead, use mild high-flash
point cleaning solution safe for plastic parts.
Do not use wire or any other hard instrument to
clean carburetor parts, especially jets, as they may
be damaged.
• Immerse all the metal parts in carburetor cleaning solu-
tion.
• Rinse the parts in water.
• After the parts are cleaned, dry them with compressed air.
• Blow through the air and fuel passages with compressed
air.
• Assemble the carburetor, and install it on the motorcycle.
Carburetor Inspection
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Always stop the
engine and do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove the carburetor (see Carburetor Removal).
• Before disassembling the carburetor, check the fuel level.
If the fuel level is incorrect, inspect the rest of the carbu-
retor before correcting it.
Carburetor Inspection
Halaman 81
Carburetor
• Check that the throttle valve [A] moves smoothly and re-
turn back with the spring tension. The surface of the valve
must not be excessively worn.
If the throttle valve does not move smoothly, or if it is very
loose in the carburetor body. Replace the carburetor.
If the spring tension is weak, replace it.
• Turn the choke cable bracket to check that the choke but-
terfly valve [A] move smoothly and return with spring ten-
sion.
If the choke butterfly valve do not move smoothly, replace
the carburetor.
NOTE
○Do not remove the air screw from the carburetor or
change the air screw setting, or you will lose the best
setting.
• Disassemble the carburetor (see Carburetor Disassem-
bly).
• Clean the carburetor (see Carburetor Cleaning).
• Check that the O-rings on the float bowl, drain plug and
the intake pipe are in good condition.
If any of the O-rings are not in good condition, replace
them.
• Remove the float valve needle.
• Check the float valve needle [A].
If the needle is worn [B] as shown in the figure, replace
the valve needle.
• Push the rod [C] in the valve needle, and then release it
[D].
If the rod does not spring out, replace the valve needle.
• Check the main jet [A], needle jet holder [B] and pilot jet
[C] for any damage.
If they are damaged, replace them with new ones.
FUEL SYSTEM 3-19
Carburetor Assembly
Halaman 82
3-20 FUEL SYSTEM
Carburetor
• Inspect the outside of the throttle valve [A] for scratches
and abnormal wear.
If the valve is badly scratched or worn, replace it.
• Inspect the inside of the carburetor body for these same
faults.
If it is badly scratched or worn, replace the entire carbu-
retor.
[B] Sliding Surface
• Check the jet needle [A] and needle jet [B] for wear.
A worn needle jet holder or jet needle should be replaced.
• Disassemble the carburetor, and clean the fuel, air pas-
sages with high flash-point solvent and compressed air.
• Stuff the lint-free, clean cloths into the air cleaner housing
to keep dirt or other foreign material from entering.
WARNING
If dirt or dust is allowed to pass through into the car-
buretor, the throttle valve may become stuck, pos-
sibly causing accident. Replace the air cleaner ele-
ment according to the maintenance chart.
Carburetor Assembly
• Clean the disassembly parts before assembling.
• Clean the fuel and air passages with high flash point sol-
vent and compressed air.
• Install the needle jet [A] into the carburetor so that the
smaller diameter end [B] of the jet goes in first.
• Carefully screw in the needle jet holder. It will seat against
the needle jet, pushing the end of the jet into the carbu-
retor bore.
NOTICE
Do not force the needle jet holder [A] and main jet
[B] or overtighten them. The needle jet or the car-
buretor body could be damaged requiring replace-
ment.
Element Removal
Halaman 83
Air Cleaner
Air Cleaner Housing Removal/Installation
• Remove:
Side Covers (see Side Cover Removal in the Frame
chapter)
Seat (see Seat Removal in the Frame chapter)
Battery (see Battery Removal in the Electrical System
chapter)
Muffler Body (see Muffler Removal in the Engine Top
End chapter)
Rear Fender (see Rear Fender Removal in the Frame
chapter)
Flap (see Flap Removal in the Frame chapter)
Rear Frame (see Rear Frame Removal in the Frame
chapter)
• Remove the air cleaner housing mounting bolt [A] and
breather hose [B].
• Loosen the clamp screw [C] and remove the air cleaner
housing from the carburetor.
• Remove the air cleaner housing to right side.
• Installation is the reverse of removal.
Torque - Air Cleaner Housing Mounting Bolt: 5.2 N·m (0.53
kgf·m, 46 in·lb)
Element Removal
• Remove the left side cover (see Side Cover Removal in
the Frame chapter).
• Remove the bolts [A] and take off the air cleaner cover
[B].
• Remove the wing bolt [A] and take off the element [B].
• Stuff a clean, lint-free cloth into the carburetor so no dirt
is allowed to enter the carburetor.
• Wipe out the inside of the air cleaner housing with a clean
damp towel.
NOTICE
Check inside of the intake tract and carburetor for
dirt. If dirt is present, clean the intake tract and car-
buretor thoroughly. You may also need to replace
the element and seal the housing and intake tract.
FUEL SYSTEM 3-21
Element Cleaning and Inspection
Halaman 84
3-22 FUEL SYSTEM
Air Cleaner
Element Installation
• When installing the element, coat the lip of the element
with a thick layer of all purpose grease [A] to assure a
complete seal against the air cleaner element base. Also,
coat the base where the lip of the element fits.
• Apply grease to all connections and screw holes in the air
cleaner housing and intake tract.
• Take out the cloth from the carburetor securely.
• Install the element [A].
• Tighten the wing bolt [B].
• Install the seat (see Seat Installation in the Frame chap-
ter).
Element Cleaning and Inspection
• Refer to the Air Cleaner Element Cleaning and Inspection
in the Periodic Maintenance chapter.
Fuel Tank Removal
Halaman 85
Fuel Tank
Fuel Tank Removal
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Always stop the
engine and do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove:
Seat (see Seat Removal in the Frame chapter)
Bolts [A] (both sides)
Screws [B]
Fuel Tank Cap [C] (with the breather hose)
• Remove the fuel tank cover [D].
○Install the fuel tank cap.
• If necessary, remove the fuel tank cover screws [A] on
both sides, and separate each other.
• Turn the fuel tap lever [A] to the OFF position.
• Pull the fuel hose [B] off the fuel tap.
• Remove the fuel tank mounting bolt [A].
• Take off the fuel Tank, and remove the rubber band [B].
FUEL SYSTEM 3-23
Fuel Tap and Filter Inspection
Halaman 86
3-24 FUEL SYSTEM
Fuel Tank
Fuel Tank Installation
• Inspect the rubber dampers [A] on the frame.
If the dampers are damaged or deteriorated, replace them
with new ones.
• Connect the fuel hose to the fuel tap securely.
• Set the fuel tank on the frame.
• Install the rubber band, the fuel tank bolt and other re-
moved parts.
Torque - Fuel Tank Cover Screws: 5.0 N·m (0.51 kgf·m, 44
in·lb)
• Insert the fuel tank breather hose into the steering stem.
Fuel Tap Removal
• Remove the fuel tank (see Fuel Tank Removal).
• Drain the fuel.
• Remove the mounting bolts [A] and take off the fuel tap
[B].
Fuel Tap Installation
• Replace the O-ring [A] with a new one.
• Insert the filter part into the tank, and tighten the bolts [B].
Fuel Tank, Filter and Tap Cleaning
• Refer to the Fuel Tank, Filter and Tap Cleaning in the
Periodic Maintenance chapter.
Fuel Tap and Filter Inspection
• Refer to the Fuel Tap and Filter Inspection in the Periodic
Maintenance chapter.
Engine Top End
Halaman 87
Engine Top End
Table of Contents
Exploded View...................................
4-2
Specifications ....................................
4-6
Special Tools .....................................
4-9
Camshaft Chain Tensioner ................
4-11
Camshaft Chain Tensioner
Removal....................................
4-11
Camshaft Chain Tensioner
Installation.................................
4-11
Camshaft ...........................................
4-13
Camshaft Removal ......................
4-13
Camshaft Installation ...................
4-14
Camshaft Chain Removal............
4-15
Camshaft Chain Installation.........
4-15
Cylinder Head....................................
4-17
Cylinder Compression
Measurement ............................
4-17
Cylinder Head Removal...............
4-18
Cylinder Head Installation............
4-18
Cylinder Head Cleaning...............
4-19
Cylinder Head Warp Inspection ...
4-19
Valves................................................
4-20
Valve Clearance Inspection ........
4-20
Valve Clearance Adjustment........
4-20
Valve Removal.............................
4-20
Valve Installation..........................
4-20
Valve Guide Removal ..................
4-21
ENGINE TOP END 4-1
Valve Guide Installation ...............
4-21
Valve/Guide Clearance
Measurement (Wobble
Method).....................................
4-22
Valve Seat Inspection ..................
4-22
Valve Seat Repair ........................
4-23
Cylinder, Piston..................................
4-28
Cylinder Removal.........................
4-28
Piston Removal............................
4-28
Cylinder and Piston Installation....
4-29
Cylinder Wear ..............................
4-30
Piston Wear .................................
4-31
Piston/Cylinder Clearance ...........
4-31
Boring, Honing Performance........
4-31
Piston Ring, Piston Ring Groove
Wear..........................................
4-32
Piston Ring Groove Width............
4-32
Piston Ring Thickness .................
4-32
Piston Ring End Gap ...................
4-33
Carburetor Holder..............................
4-34
Carburetor Holder Removal.........
4-34
Carburetor Holder Installation......
4-34
Muffler................................................
4-35
Muffler Removal...........................
4-35
Muffler Installation........................
4-35
Spark Arrester Cleaning...............
4-35
4
Exploded View
Halaman 88
4-2 ENGINE TOP END
Exploded View
2
MO
M
10 S
11 S
M
1
G R
E O
G R
3
L 13
L 12
MO
R
9 L
R
MO
G R
6 L h
7
8
G R
4 L
MO
5
R
R
MO
GE02379BW5 C
Exploded View
Halaman 89
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Valve Adjusting Cap Bolts
8.8
0.90
78 in·lb
2
Valve Adjusting Screw Locknuts
8.8
0.90
78 in·lb
3
Camshaft Chain Cover Bolts
8.8
0.90
78 in·lb
4
Camshaft Chain Guide Bolt
12
1.2
106 in·lb
L
5
Camshaft Chain Plate Screw
5.2
0.53
46 in·lb
6
Camshaft Sprocket Bolt
24
2.4
18
Lh
7
Chain Tensioner Cap Bolt
5.2
0.53
46 in·lb
8
Chain Tensioner Mounting Bolts
5.2
0.53
46 in·lb
9
Carburetor Holder Bolts
8.8
0.90
78 in·lb
L
10
Cylinder Head Bolts (M6)
15
1.5
11
S
11
Cylinder Head Bolts (M8)
22
2.2
16
S, M
12
Rocker Shaft Holder Plate Screws
5.2
0.53
46 in·lb
L
13
Breather Plate Mounting Bolts
8.8
0.90
78 in·lb
L
EO: Apply engine Oil.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil.
Lh: Left hand thred.
G: Apply grease.
S: Follow the specific tightening sequence.
L: Apply a non-Permanent locking agent.
R: Replacement Parts
ENGINE TOP END 4-3
Exploded View
Halaman 90
# 4-4 ENGINE TOP END
## Exploded View
(1 L)
(2)
(9)
(R)
(9)
(6)
(R)
(4)
(R)
(5)
(A)
(B)
(R)
(7)
(R)
(L 3)
(B)
(8)
(10)
(5)
(A)
(3 L)
GE02437BW5 C
Exploded View
Halaman 91
ENGINE TOP END 4-5
Exploded View
| No. | Fastener | | Torque | | Remarks |
| :-- | :-------------------------- | :---- | :------------- | :----- | :-------------------------------------- |
| | | N·m | kgf·m | ft·lb | |
| 1 | Exhaust Pipe Cover Bolts | 8.8 | 0.90 | 78 in·lb | L |
| 2 | Exhaust Pipe Holder Nuts | 14.7 | 1.5 | 11 | |
| 3 | Muffler End Cover Bolts | 8.8 | 0.90 | 78 in·lb | L |
| 4 | Muffler Joint Clamp Bolt | 17 | 1.7 | 13 | |
| 5 | Muffler Mounting Bolts | 26 | 2.7 | 19 | |
6. Exhaust Pipe
7. Muffler Body
8. Spark Arrester
9. KLX140A8F ~ A9F
10. KLX140AAF ~/BAF ~
R: Replacement parts.
L: Apply a non-permanent locking agent.
Specifications
Halaman 92
# 4-6 ENGINE TOP END
## Specifications
| Item | Standard | Service Limit |
| :--- | :--- | :--- |
| **Camshafts** | | |
| Cam Height: | | |
| Exhaust | 36.138 ~ 36.252 mm (1.4228 ~ 1.4272 in.) | 36.04 mm (1.419 in.) |
| Intake | 36.397 ~ 36.511 mm (1.4329 ~ 1.4374 in.) | 36.30 mm (1.429 in.) |
| Rocker Arm Inside Diameter | 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in.) | 12.05 mm (0.474 in.) |
| Rocker Shaft Diameter | 11.983 ~ 11.994 mm (0.4718 ~ 0.4722 in.) | 11.96 mm (0.471 in.) |
| **Cylinder Head** | | |
| Cylinder Compression | (Usable range) 824 ~ 1 275 kPa (8.40 ~ 13.0 kgf/cm², 119 ~ 184.9 psi) | --- |
| Cylinder Head Warp | --- | 0.05 mm (0.002 in.) |
| **Valves** | | |
| Valve Clearance: | | |
| Exhaust | 0.11 ~ 0.15 mm (0.004 ~ 0.006 in.) | --- |
| Intake | 0.04 ~ 0.08 mm (0.002 ~ 0.003 in.) | --- |
| Valve Head Thickness: | | |
| Exhaust | 1.15 ~ 1.45 mm (0.045 ~ 0.057 in.) | 0.5 mm (0.02 in.) |
| Intake | 0.60 ~ 0.90 mm (0.024 ~ 0.035 in.) | 0.4 mm (0.02 in.) |
| Valve Stem Bend | TIR 0.01 mm (0.0004 in.) or less | TIR 0.05 mm (0.002 in.) |
| Valve Stem Diameter: | | |
| Exhaust | 4.958 ~ 4.973 mm (0.1952 ~ 0.1958 in.) | 4.93 mm (0.194 in.) |
| Intake | 4.975 ~ 4.990 mm (0.1959 ~ 0.1965 in.) | 4.95 mm (0.195 in.) |
| Valve Guide Inside Diameter | | |
| Exhaust | 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in.) | 5.08 mm (0.200 in.) |
| Intake | 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in.) | 5.08 mm (0.200 in.) |
| Valve/Valve Guide Clearance | | |
| (Wobble Method): | | |
| Exhaust | 0.07 ~ 0.13 mm (0.003 ~ 0.005 in.) | 0.31 mm (0.012 in.) |
| Intake | 0.02 ~ 0.09 mm (0.001 ~ 0.004 in.) | 0.26 mm (0.010 in.) |
| Valve Seat Cutting Angle | 45°, 32°, 60° | --- |
| Valve Seat Surface: | | |
| Outside Diameter: | | |
| Exhaust | 22.9 ~ 23.1 mm (0.90 ~ 0.91 in.) | --- |
| Intake | 26.4 ~ 26.6 mm (1.04 ~ 1.05 in.) | --- |
| Width: | | |
| Exhaust | 0.8 ~ 1.2 mm (0.03 ~ 0.05 in.) | --- |
| Intake | 0.8 ~ 1.2 mm (0.03 ~ 0.05 in.) | --- |
| Valve Spring Free Length: | | |
| Exhaust | 36.43 mm (1.434 in.) | 34.5 mm (1.36 in.) |
| Intake | 36.43 mm (1.434 in.) | 34.5 mm (1.36 in.) |
| **Cylinders, Pistons** | | |
| Cylinder Inside Diameter | 58.000 ~ 58.012 mm (2.2835 ~ 2.2839 in.) | 58.08 mm (2.287 in.) |
| Piston Diameter | 57.970 ~ 57.982 mm (2.2823 ~ 2.2828 in.) | 57.82 mm (2.276 in.) |
| Piston/Cylinder Clearance | 0.024 ~ 0.036 mm (0.0009 ~ 0.0014 in.) | --- |
Specifications
Halaman 93
Specifications
Item
Standard
Service Limit
Oversize Piston and Rings
+ 0.5 mm (0.02in.)
+ 1.0 mm (0.04 in.)
– – –
Piston Ring/Groove Clearance:
Top
0.04 ∼0.08 mm (0.002 ∼0.003 in.)
0.16 mm (0.0063 in.)
Second
0.03 ∼0.07 mm (0.001 ∼0.003 in.)
0.15 mm (0.0059 in.)
Piston Ring Groove Width:
Top
0.81 ∼0.83 mm (0.032 ∼0.033 in.)
0.91 mm (0.036 in.)
Second
0.80 ∼0.82 mm (0.031 ∼0.032 in.)
0.90 mm (0.035 in.)
Piston Ring Thickness:
Top
0.75 ∼0.77 mm (0.0295 ∼0.0303 in.)
0.68 mm (0.027 in.)
Second
0.75 ∼0.77 mm (0.0295 ∼0.0303 in.)
0.68 mm (0.027 in.)
Piston Ring End Gap:
Top
0.15 ∼0.30 mm (0.006 ∼0.012 in.)
0.6 mm (0.02 in.)
Second
(KLX140A8F ∼A9F/B8F ∼B9F) 0.30 ∼
0.45 mm (0.012 ∼0.018 in.)
0.8 mm (0.03 in.)
(KLX140AAF ∼ABF/BAF ∼BBF) 0.20 ∼
0.35 mm (0.008 ∼0.014 in.)
0.7 mm (0.028 in.)
Oil
0.20 ∼0.70 mm (0.008 ∼0.028 in.)
1.0 mm (0.04 in.)
ENGINE TOP END 4-7
Specifications
Halaman 94
# 4-8 ENGINE TOP END
## Specifications
---
**Cam Height**
Cam Height [A]
---
**Camshaft Runout**
---
**Valve Head Thickness**
Valve Stem Diameter [A]
Valve Head Thickness [B]
45° [C]
---
**Valve Stem Bend**
Dial Gauge [A]
Special Tools
Halaman 95
ENGINE TOP END 4-9
**Special Tools**
**Compression Gauge, 20 kgf/cm²:**
**57001-221**
ST570221ST C
**Valve Spring Compressor Assembly:**
**57001-241**
ST570241ST C
**Valve Seat Cutter, 45° - φ24.5:**
**57001-1113**
ST571113ST C
**Valve Seat Cutter, 32° - φ25:**
**57001-1118**
ST571118ST C
**Valve Seat Cutter, 32° - φ28:**
**57001-1119**
ST571119ST C
**Valve Seat Cutter Holder Bar:**
**57001-1128**
ST571128ST C
**Valve Spring Compressor Adapter, φ22:**
**57001-1202**
ST571202ST C
**Valve Guide Arbor, φ5:**
**57001-1203**
ST571203ST C
**Valve Guide Reamer, φ5:**
**57001-1204**
ST571204ST C
**Valve Seat Cutter, 45° - φ22:**
**57001-1205**
ST571205ST C
Special Tools
Halaman 96
4-10 ENGINE TOP END
Special Tools
Valve Seat Cutter Holder, φ5:
57001-1208
ST571208ST C
Spark Plug Wrench, Hex 16:
57001-1262
ST571262ST C
Compression Gauge Adapter, M10 × 1.0:
57001-1317
ST571317ST C
Valve Seat Cutter, 60° - φ25:
57001-1328
ST571328ST C
Valve Seat Cutter, 60° - φ27:
57001-1409
ST571409ST C
Filler Cap Driver:
57001-1454
ST571454ST C
Piston Pin Puller Assembly:
57001-910
ST570910ST C
Camshaft Chain Tensioner Installation
Halaman 97
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
NOTICE
This is a non-return type cam chain tensioner. The
push rod does not return to its original position
once it moves out to take up camshaft chain slack.
Observe all the rules listed below:
When removing the tensioner, do not take out the
mounting bolts only halfway.
Retightening the
mounting bolts from this position could damage
the tensioner and the camshaft chain.
Once the
bolts are loosened, the tensioner must be removed
and reset as described in "Camshaft Chain Ten-
sioner Installation". Do not turn over the crankshaft
while the tensioner is removed. This could upset
the cam chain timing, and damage the valves.
• Remove the fuel tank (see Fuel Tank Removal in the Fuel
System chapter).
• Loosen the cap bolt [A].
• Remove the mounting bolts [B] and take off the camshaft
chain tensioner [C].
Camshaft Chain Tensioner Installation
• While compressing the push rod [A], turn [B] it clockwise
with a suitable screwdriver [C] until the rod stops.
NOTICE
Do not turn the rod counterclockwise at installation.
This could detach the rod and the tensioner cannot
be reinstalled.
• While holding the rod in position with the screwdriver or a
holder plate [A], install the tensioner on the cylinder block.
[B] 8.5 mm (0.33 in.)
[C] 3.5 mm (0.14 in.)
[D] 7 mm (0.28 in.)
[E] 16 mm (0.63 in.)
ENGINE TOP END 4-11
Camshaft Chain Tensioner Installation
Halaman 98
4-12 ENGINE TOP END
Camshaft Chain Tensioner
• Install the O-ring in the tensioner body.
• Install the tensioner so that the arrow mark [A] faces up-
ward, and tighten the mounting bolts.
Torque - Chain Tensioner Mounting Bolts: 5.2 N·m (0.53
kgf·m 46 in·lb)
• Remove the screwdriver or the holder plate [B] and tighten
the cap.
Torque - Chain Tensioner Cap Bolt: 5.2 N·m (0.53 kgf·m 46
in·lb)
Camshaft Removal
Halaman 99
Camshaft
Camshaft Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Camshaft Chain Cover [A]
Valve Adjusting Caps [B]
• Remove the plug [A] and the cap [B] on the alternator
cover.
Special Tool - Filler Cap Driver: 57001-1454
• Turn the crankshaft bolt counterclockwise [C] so that the
“T” mark on the alternator rotor watching the plug hole [D].
• Check the mark [A] on the sprocket aligns with the pro-
jection [B] on the cylinder head. Be sure to position the
piston TDC at the end of the compression stroke by turn-
ing the crankshaft. (Align the mark when the intake valve
again comes up after it went down once.)
• Holding the crankshaft bolt with a wrench, loosen the
camshaft sprocket bolt (left-hand thread) [C].
• Remove:
Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Removal)
Camshaft Sprocket [A]
NOTE
○Does not lose the pin [B], when the camshaft sprocket
removed.
○Hold the camshaft chain with suitable tool so that the
chain does not drop into the engine.
• Remove the screws [A], and rocker shaft holder [B].
ENGINE TOP END 4-13
Camshaft Installation
Halaman 100
4-14 ENGINE TOP END
Camshaft
• Remove the rocker shaft [A] and the rocker arm [B] on
both sides.
○Set the rocker arms to each shaft so that they can be
installed later in the same position.
• Pull out the camshaft [C].
NOTICE
The crankshaft may be turned while the camshaft is
removed.
Always pull the chain taut while turning the crank-
shaft. This avoids kinking the chain on the lower
(crankshaft) sprocket. A kinked chain could dam-
age both the chain and the sprocket.
Camshaft Installation
• Blow through the oil passage [B] with compressed air [A].
• Apply engine oil to all cam parts, journal and bearing.
○If the camshaft is replaced with a new one, apply a thin
coat of molybdenum disulfide grease to the new cam part
surfaces and journal.
• Install the camshaft [A] so that the roller groove [B] of it
come to upside.
• Apply molybdenum disulfide oil to the rocker shaft surface
[A] and cam portion of the rocker arm [B], and then install
them at the original position.
○Install the rocker shafts so that the small diameter side
face rocker shaft holder [C].
• Apply a non-permanent locking agent to the rocker shaft
holder plate screws.
• Install the rocker shaft holder.
Torque - Rocker Shaft Holder Plate Screws: 5.2 N·m (0.53
kgf·m, 46 in·lb)
Camshaft Chain Installation
Halaman 101
Camshaft
• Engage the camshaft sprocket [A] with the chain [B].
Then, align the "Top" mark [C] on the sprocket with the
projection [D] on the cylinder head after aligning the
notch of the magneto cover with “T” mark on the magneto
rotor watching the bolt hole of the cover.
NOTE
○Pull the tension side (exhaust side) of the chain up to
remove slack.
• Apply a non-permanent locking agent to the camshaft
sprocket bolt [E] and tighten it (left-hand thread).
Torque - Camshaft Sprocket Bolt: 24 N·m (2.4 kgf·m, 17.5
ft·lb)
• Install the camshaft chain tensioner (see Camshaft Chain
Tensioner Installation).
• Check the valve clearance (see Valve Clearance adjust-
ment).
Torque - Camshaft Chain Cover Bolts: 8.8 N·m (0.90 kgf·m,
78 in·lb)
Camshaft Chain Removal
• Remove:
Camshaft Sprocket (see Camshaft Removal, but except
the valve adjusting caps)
Alternator Cover and Alternator Rotor (see Alternator
Rotor Removal in the Electrical System chapter)
• Remove the camshaft chain plate [A].
• Remove the camshaft chain [B].
Camshaft Chain Installation
• Insert the camshaft chain from the cylinder head, and en-
gage the chain with the engine sprocket.
• Install the camshaft chain plate.
Torque - Camshaft Chain plate Screw: 5.2 N·m (0.53 kgf·m,
46 in·lb)
• Install the alternator rotor (see Alternator Rotor Installa-
tion in the Electrical System chapter).
• Align the projection [A] on the crankcase with the "T" mark
[B] on the rotor.
ENGINE TOP END 4-15
Camshaft Chain Installation
Halaman 102
4-16 ENGINE TOP END
Camshaft
• Engage the camshaft sprocket [A] to the chain [B]. Then
align the mark [C] on the sprocket with the projection [D]
on the cylinder head.
NOTE
○Pull the tension side (exhaust side) of the chain up to
remove slack.
• Apply a non-permanent locking agent to the camshaft
sprocket bolt [E] and tighten it (left-hand thread).
Torque - Camshaft Sprocket Bolt: 24 N·m (2.4 kgf·m, 17.5
ft·lb)
• Install:
Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Installation)
Alternator Cover (see Electrical System chapter)
• Replace the camshaft chain cover O-ring with a new one,
and apply grease to the O-ring.
• Install the camshaft chain cover.
Torque - Camshaft Chain Cover Bolts: 8.8 N·m (0.90 kgf·m,
78in·lb)
Cylinder Compression Measurement
Halaman 103
Cylinder Head
Cylinder Compression Measurement
NOTE
○Use the battery which is fully charged
• Start the engine.
• Thoroughly warm up the engine so that the engine oil be-
tween the piston and cylinder wall will help seal compres-
sion as it does during normal running.
• Stop the engine.
• Remove the spark plug cap [A] and the spark plug [B] with
the spark plug wrench [C].
Special Tool - Spark Plug Wrench, Hex 16: 57001-1262
Owner’s Tool - Spark Plug Wrench: 92110-1206
• Attach the compression gauge [A] and the adapter [B]
firmly into the spark plug hole.
Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221
Compression Gauge Adapter, M10 × 1.0:
57001-1317
• With the throttle fully open, turn the engine with the starter
motor until the compression gauge stops rising; the com-
pression is the highest reading obtainable.
Cylinder Compression
Usable Range: 824 ∼1 275 kPa (8.40 ∼13.0 kgf/cm²,
119 ∼184.9 psi)
• Install the spark plug.
Torque - Spark Plug: 13 N·m (1.3 kgf·m, 115 in·lb)
• Pull the spark plug cap lightly to make sure the installation
of the spark plug cap.
The following table should be consulted if the obtainable compression reading is not within the us-
able range.
Problem
Diagnosis
Remedy (Action)
Carbon accumulation on piston and in
cylinder head (combustion chamber) is
suspected due to damaged valve stem
or piston oil rings.
Remove the carbon deposits and replace
damaged parts if necessary.
The cylinder
compression is
higher than the
usable range
Incorrect cylinder head gasket
thickness.
The cylinder
compression is
lower than the
usable range
Exhaust gas leakage around cylinder
head.
Replace the damaged gasket and check
cylinder head warp.
Incorrect seating surface of valve.
Repair seating surface if possible.
Valve clearance is too narrow.
Adjust the valve clearance.
Piston/cylinder clearance is too wide.
Replace the piston and/or cylinder.
Piston seizure.
Inspect the cylinder and piston; repair or
replace them if necessary.
Bad condition of piston ring and/or
piston ring grooves.
ENGINE TOP END 4-17
Replace the gasket with a standard one.
Replace the piston and/or the piston
rings.
Cylinder Head Installation
Halaman 104
4-18 ENGINE TOP END
Cylinder Head
Cylinder Head Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Carburetor (see Carburetor Removal in the Fuel System
chapter)
Exhaust Pipe (see Muffler Removal)
Spark Plug Cap [A]
• Remove:
Camshaft Chain Cover Bolts [A]
Camshaft Chain Cover [B]
Camshaft Sprocket (see Camshaft Removal)
• Remove:
6 mm Cylinder Head Bolts [A]
8 mm Cylinder Head Bolts [B]
Front [C]
• Remove the cylinder head [A].
NOTE
○If necessary, tap lightly with a plastic hammer [B] as
shown.
Cylinder Head Installation
• Install the dowel pins [A].
• Replace the gasket [B] and O-ring [C] with new ones.
• Apply grease to the O-ring.
Cylinder Head Warp Inspection
Halaman 105
Cylinder Head
• Apply engine oil to both sides of the washers [A] and
molybdenum disulfide grease to the threads of the 8 mm
cylinder head bolts [B].
• Tighten the 8 mm bolts following the tightening sequence
as shown.
Tighten them first to the torque of 15 N·m
(1.5 kgf·m, 11 ft·lb), and then tighten them to the speci-
fied torque.
Torque - 8 mm Cylinder Head Bolts: 22 N·m (2.2 kgf·m, 16
ft·lb)
• Tighten the 6 mm bolts [5 ∼6].
Front [A]
Torque - 6 mm Cylinder Head Bolts: 15 N·m (1.5 kgf·m, 11
ft·lb)
• Install:
Camshaft Sprocket and Camshaft Chain Cover (see
Camshaft Installation)
Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Installation)
• Install the other removed parts.
Cylinder Head Cleaning
• Remove:
Cylinder Head (see Cylinder Head Removal)
Valves (see Valve Removal)
• Scrape the carbon out of the combustion chamber and
exhaust port with a scraper or a suitable tool.
• Clean the cylinder head with high-flash point solvent.
• Blow out any particles which may obstruct the oil passage
[A] in the cylinder head using compressed air.
Front [B]
• Install the valves (see Valve Installation).
Cylinder Head Warp Inspection
• Clean the cylinder head (see Cylinder Head Cleaning).
• Lay a straightedge [A] across the lower surface of the
cylinder head at the positions shown.
• Use a thickness gauge [A] to measure the space between
the straightedge [B] and the head.
Cylinder Head Warp
Standard:
– – –
Service Limit:
0.05 mm (0.02 in.)
If the cylinder head is warped more than the service limit,
replace it.
If the cylinder head is warped less than the service limit,
repair the head by rubbing the lower surface on emery
paper secured to a surface plate (first No. 200, then No.
400).
ENGINE TOP END 4-19
Valve Installation
Halaman 106
4-20 ENGINE TOP END
Valves
Valve Clearance Inspection
• Refer to the Valve Clearance Inspection in the Periodic
Maintenance chapter.
Valve Clearance Adjustment
• Refer to the Valve Clearance Adjustment in the Periodic
Maintenance chapter.
Valve Removal
• Remove the cylinder head (see Cylinder Head Removal).
• Remove the rocker shafts and rocker arms (see Camshaft
Removal).
NOTE
○Mark and record the rocker shafts, rocker arms, and
valves locations so that they can be installed in their
original positions to keep the valve clearance un-
changed.
• Using the valve spring compressor assembly, remove the
valves.
Special Tools - Valve Spring Compressor Assembly: 57001
-241 [A]
Valve Spring Compressor Adapter,
22:
57001-1202 [B]
Valve Installation
• Replace the oil seal [A] with a new one.
• Apply a thin coat of molybdenum disulfide grease to the
valve stem [B] before valve installation.
• Check the following:
Valve moves smoothly up and down in the guide.
Valve seats properly in the valve seat.
• Install the spring [C] so that the rought coil end (blue paint
side) faces the spring retainer [D] (upwards).
• Put the spring retainer on the springs, and fit the split
keepers [E] between the retainer and the stem while com-
pressing the valve spring.
Spring Seat [F]
Special Tool - Valve Spring Compressor Assembly: 57001
-241
Valve Spring Compressor Adapter,
22:
57001-1202
Valve Guide Installation
Halaman 107
Valves
Valve Guide Removal
• Remove:
Valve (see Valve Removal)
Oil Seal
Spring Seat
• Heat the area around the valve guide to 120 ∼150°C (248
∼302°F).
NOTICE
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head and
heat the oil.
• Hammer lightly on the valve guide arbor [A] to remove the
guide from the top of the head.
Special Tools - Valve Guide Arbor,
5: 57001-1203
Valve Guide Installation
• Apply thin coat of oil to the valve guide outer surface.
• Heat the area around the valve guide hole to about 120 ∼
150 °C (248 ∼302 °F).
NOTICE
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head and
heat the oil.
• Drive the valve guide from the top of the head using the
valve guide arbor.
Special Tool - Valve Guide Arbor,
5: 57001-1203
• Ream the valve guide with valve guide reamer [A] even if
the old guide is reused.
Special Tool - Valve Guide Reamer,
5: 57001-1204
ENGINE TOP END 4-21
Valve Seat Inspection
Halaman 108
4-22 ENGINE TOP END
Valves
Valve/Guide Clearance Measurement (Wobble
Method)
○If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve/valve guide clearance
with the wobble method as indicated below.
• Insert a new valve [A] into the guide [B] and set a dial
gauge against the stem perpendicular to it as close as
possible to the cylinder head mating surface.
• Move the stem back and forth [C] to measure the valve
wobble.
• Repeat the measurement in a direction at 90° angle to the
first measurement.
If the reading exceeds the service limit, replace the guide.
NOTE
○The reading is greater than the actual valve/valve guide
clearance because the measurment is taken outside of
the guide.
Valve/Valve Guide Clearance (Wobble Method)
Standard:
Exhaust
0.07 ∼0.13 mm (0.003 ∼0.005 in.)
Intake
0.02 ∼0.09 mm (0.001 ∼0.004 in.)
Service Limit:
Exhaust
0.31 mm (0.012 in.)
Intake
0.26 mm (0.010 in.)
Valve Seat Inspection
• Remove the valve (see Valve Removal).
• Check the valve seating surface [A] between the valve [B]
and valve seat [C].
○Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter is too large or too small, repair the
seat (see Valve Seat Repair).
Valve Seating Surface Outside Diameter
Standard:
Exhaust
22.9 ∼23.1 mm (0.90 ∼0.91 in.)
Intake
26.4 ~ 26.6 mm (1.04 ∼1.05 in.)
• Check the seating surface width of the valve seat.
○Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a
vernier caliper.
Good [F]
If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat (see Valve Seat Repair).
Valve Seating Surface Width
Standard:
Intake, Exhaust
0.8 ∼1.2 mm (0.03 ∼0.05 in.)
Valve Seat Repair
Halaman 109
Valves
Valve Seat Repair
• For the instructions on how to use the valve seat cutter
[A], follow the operation manual provided by the to man-
ufacturer.
Special Tools - Valve Seat Cutter Holder,
5: 57001-1208
[B]
Valve Seat Cutter Holder Bar: 57001-1128
[C]
Exhaust:
Valve Seat Cutter, 45° -
22:
57001-1205
Valve Seat Cutter, 32° -
25:
57001-1118
Valve Seat Cutter, 60° -
25:
57001-1328
Intake :
Valve Seat Cutter, 45° -
24.5:
57001-1113
Valve Seat Cutter, 32° -
28:
57001-1119
Valve Seat Cutter, 60° -
27:
57001-1409
If the tool manufacturer’s instructions are not available,
operate in accordance with the following procedure.
Seat Cutter Operation Care
1. This valve seat cutter is developed to grind the valve for
repair. Therefore the cutter must not be used for other
purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the dia-
mond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.
NOTE
○Do not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate
the cutter in one hand. Do not apply too much force to
the diamond portion.
NOTE
○Prior to grinding, apply engine oil to the cutter and dur-
ing the operation, wash off any ground particles sticking
to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin coat of
engine oil before storing.
ENGINE TOP END 4-23
Valve Seat Repair
Halaman 110
4-24 ENGINE TOP END
Valves
Marks Stamped on the Cutter
The marks stamped on the back of the cutter [A] represent
the following.
60° ........................... Cutter angle [B]
37.5ϕ ....................... Outer diameter of cutter [C]
Repair Operating Procedures
• Clean the seat area carefully.
• Coat the seat with machinist’s dye.
• Fit a 45° cutter into the holder and slide it into the valve
guide.
• Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.
NOTICE
Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylin-
der head must be replaced.
Widened Width [A] of engagement by machining with
45° cutter
Ground Volume [B] by 32° cutter
32° [C]
Correct Width [D]
Ground Volume [E] by 60° cutter
60° [F]
• Measure the outside diameter of the seating surface with
a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind until the diameter is within the spec-
ified range.
Original Seating Surface [B]
○Remove all pittings of flaws from 45° ground surface.
○Alter grinding with 45° cutter, apply thin coat of machin-
ist’s dye to 45° [A] seating surface. This makes seating
surface distinct and 32° and 60° grinding operation eas-
ier.
○When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
Valve Seat Repair
Halaman 111
Valves
If the outside diameter [A] of the seating surface is too
large, make the 32° grind described below.
If the outside diameter of the seating surface is within the
specified range, measure the seat width as described be-
low.
• Grind the seat at a 32° angle [B] until the seat O.D. is
within the specified range.
○To make the 32° grind, fit a 32° cutter into the holder, and
slide it into the valve guide.
○Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
NOTICE
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to pre-
vent overgrinding.
○After making the 32° grind, return to the seat O.D. mea-
surement step above.
• To measure the seat width, use a vernier caliper to mea-
sure the width of the 45° angle portion of the seat at sev-
eral places around the seat.
If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seat
O.D. measurement step above.
If the seat width is too wide, make the 60° [A] grind de-
scribed below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
• Grind the seat at a 60° angle until the seat width is within
the specified range.
○To make the 60° grind, fit a 60° cutter into the holder, and
slide it into the valve guide.
○Turn the holder, while pressing down lightly.
○After making the 60° grind, return to the seat width mea-
surement step above.
Correct Width [B]
• Lap the valve to the seat, once the seat width and O.D.
are within the ranges specified above.
○Put a little coarse grinding compound on the face of the
valve in a number of places around the valve head.
○Spin the valve against the seat until the grinding com-
pound produces a smooth, matched surface on both the
seat and the valve.
○Repeat the process with a fine grinding compound.
Rapper [A]
Valve [C]
Valve Seat [B]
ENGINE TOP END 4-25
Valve Seat Repair
Halaman 112
4-26 ENGINE TOP END
Valves
• The seating area should be marked about in the middle
of the valve face.
If the seat area is not in the right place on the valve, check
to be sure the valve is the correct part. If it is, it may have
been refused too much; replace it.
• Be sure to remove all grinding compound before assem-
bly.
• When the engine is assembled, be sure to adjust the valve
clearance (see Valve Clearance Adjustment).
Valve Seat Repair
Halaman 113
ENGINE TOP END 4-27
## Valves
### Valve Seat Repair
- **START**
- Machinist's dye on seat
- **45° Grind**
- Tool: 45° Cutter
- Purpose: make seating area smooth and round.
- **Measure Seating Area O.D.**
- Tool: Vernier Caliper
- Purpose: check seat O.D. against spec.
- **Results**
- **OK**
- (Continue to Measure Seat Width)
- **Too small**
- **45° Grind**
- Tool: 45° Cutter
- Purpose: increase O.D. of seat area to spec.
- (Loop back to Measure Seating Area O.D.)
- **Too big**
- Machinist's dye on seat
- **32° Grind**
- Tool: 32° Cutter
- Purpose: reduce O.D. of seat area to spec.
- (Loop back to Measure Seating Area O.D.)
- **Measure Seat Width**
- Tool: Vernier Caliper
- Purpose: check seat width against spec.
- **Results**
- **OK**
- (Continue to Lap Valve)
- **Too narrow**
- **45° Grind**
- Tool: 45° Cutter
- Purpose: increase width of seat area beyond spec. to increase O.D.
- (Loop back to Measure Seat Width)
- **Too wide**
- Machinist's dye on seat
- **60° Grind**
- Tool: 60° Cutter
- Purpose: reduce seat width to specification.
- (Loop back to Measure Seat Width)
- **Lap Valve**
- Tools: Valve Lapper, Grinding Compound
- Purpose: perfectly match valve and seat area; check valve head for damage.
- **FINISHED**
Piston Removal
Halaman 114
4-28 ENGINE TOP END
Cylinder, Piston
Cylinder Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
Front Camshaft Chain Guide [A]
• Tap the cylinder [A] lightly with a plastic mallet to separate
from the crankcase.
• Remove the cylinder base gasket [B].
Piston Removal
• Remove the cylinder (see Cylinder Removal).
• Place a clean cloth [A] under the piston and remove the
piston pin snap ring [B].
NOTICE
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.
• Remove the piston pin.
Special Tool - Piston Pin Puller Assembly: 57001-910 [A]
Adapter [B]
• Remove the piston.
• Carefully spread the piston ring opening with your thumbs
and then push up on the opposite side [A] of the ring to
remove it.
• Remove the oil ring in the same procedure.
Cylinder and Piston Installation
Halaman 115
Cylinder, Piston
Cylinder and Piston Installation
NOTE
○If a new piston or cylinder is used, check piston to cylin-
der clearance (see Piston/Cylinder Clearance), and use
new piston ring.
• Apply engine oil to the inner surface of the connecting rod
small end.
• The "EX↑" mark on the piston head must point toward the
front of the engine.
• Fit a new piston pin snap ring into the side of the piston
so that the ring opening [A] does not coincide with the slit
[B] of the piston pin hole.
○When installing the piston pin snap ring, compress it only
enough to install it and no more.
NOTICE
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.
NOTE
○The oil ring rails have no "top" or "bottom".
• Install the oil ring expander [A] in the bottom piston ring
groove so the ends [B] butt together.
• Install the oil ring steel rails, one above the expander and
one below it.
○Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
○Release the rail into the bottom piston ring groove.
• Do not mix up the top ring and second ring.
• Install the top ring [A] so that the "R" mark [B] faces up.
• Install the second ring [C] so that the "RN" mark [D] faces
up.
• Install:
Dowel Pins [A]
New Cylinder Base Gasket [B]
ENGINE TOP END 4-29
Cylinder Wear
Halaman 116
4-30 ENGINE TOP END
Cylinder, Piston
• The piston ring openings must be positioned as shown in
the figure. The openings of the oil ring steel rails must be
about 30 ∼90° of angle from the opening of the top ring.
Top Ring [A]
Second Ring [B]
Oil Ring Steel Rails [C]
Oil Ring Expander [D]
• Apply grease to the O-rings [A], and install it as shown.
NOTE
○To prevent misidentification as oil leak, wipe up the ex-
cessive grease.
• Install the oil pipe [B] to the cylinder [C]
• Apply molybdenum disulside oil to the cylinder bore [D]
and the piston side surface.
• Install the cylinder.
○Insert the pisiton to the cylinder bore while compressing
the pisiton rings.
• Install the other removed parts.
Cylinder Wear
• Since there is a difference in cylinder wear in different di-
rections, take a side-to-side and a front-to-back measure-
ment at each of the three locations (total of six measure-
ments) shown in the figure.
10 mm (0.4 in.) [A]
40 mm (1.6 in.) [B]
20 mm (0.8 in.) [C]
If any of the cylinder inside diameter measurements ex-
ceeds the service limit, replace the cylinder.
Cylinder Inside Diameter
Standard:
58.000 ∼58.012 mm (2.2835 ∼2.2839
in.), and less than 0.01 mm (0.0004
in.) difference between any two
measurements.
Service Limit:
58.08 mm (2.287 in.) , or 0.05 mm
(0.002 in.) difference between any two
measurements.
Boring, Honing Performance
Halaman 117
Cylinder, Piston
Piston Wear
• Measure the outside diameter [A] of each piston 5 mm
(0.2 in.) [B] up from the bottom of the piston at a right
angle to the direction of the piston pin.
If the measurement is smaller than service limit, replace
the piston.
Piston Diameter
Standard:
57.970 ∼57.982 mm (2.2823 ∼2.2828 in.)
Service Limit:
57.82 mm (2.276 in.)
Piston/Cylinder Clearance
• Subtract the piston diameter from the cylinder inside di-
ameter to get the piston/cylinder clearance.
Piston/Cylinder Clearance
Standard:
0.024 ∼0.036 mm (0.0009 ∼0.0014 in.)
If the piston/cylinder clearance is less than the specified
range, use a smaller piston or increase the cylinder inside
diameter by honing.
If the piston/cylinder clearance is greater than specified
range, use a larger piston.
If only a piston is replaced, the clearance may exceed the
standard slightly. But it must not be less than the minimum
in order to avoid piston seizure.
Boring, Honing Performance
When boring and honing a cylinder, note the following.
○There are two sizes of oversize pistons available. Over-
size pistons require oversize rings.
Oversize Pistons and Rings
0.50 mm (0.0197 in.)
Oversize
1.0 mm (0.0393 in.)
Oversize
○Before boring a cylinder, first measure the exact diame-
ter of the service data section, oversize piston, and then,
according to the standard clearance in the determine the
rebore diameter. However, if the amount of boring neces-
sary would make the inside diameter greater than 1.0 mm
(0.04 in.) oversize, the cylinder block must be replaced.
○Cylinder inside diameter must not vary more than 0.01
mm (0.0004 in.) at any point.
○Be wary of measurements taken immediately after boring
since the heat affects cylinder diameter.
○In the case of a rebored cylinder and oversize piston, the
service limit for the cylinder is the diameter that the cylin-
der was bored to plus 0.10 mm (0.004 in.) and the service
limit for the piston is the oversize piston original diameter
minus 0.20 mm (0.008 in.). If the exact figure for the re-
bored diameter is unknown, it can be roughly determined
by measuring the diameter at the base of the cylinder.
ENGINE TOP END 4-31
Piston Ring Thickness
Halaman 118
4-32 ENGINE TOP END
Cylinder, Piston
Piston Ring, Piston Ring Groove Wear
• Check for uneven groove wear by inspecting the ring seat-
ing.
The rings should fit perfectly parallel to groove surfaces.
If not, replace the piston and all the piston rings.
• With the piston rings in their grooves, make several mea-
surements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Ring Groove Clearance
Standard:
Top
0.04 ~ 0.08 mm (0.002 ~ 0.003 in.)
Second
0.03 ~ 0.07 mm (0.001 ~ 0.003 in.)
Service Limit:
Top
0.16 mm (0.0063 in.)
Second
0.15 mm (0.0059 in.)
If the piston ring groove clearance is greater than the ser-
vice limit, measure the ring thickness and groove width as
follows to decide whether to replace the rings, the piston
or both.
Piston Ring Groove Width
• Measure the groove width at several points around the
piston with a vernier caliper.
Piston Ring Groove Width
Standard:
Top
0.81 ~ 0.83 mm (0.032 ~ 0.033 in.)
Second
0.80 ~ 0.82 mm (0.031 ~ 0.032 in.)
Service Limit:
Top
0.91 mm (0.036 in.)
Second
0.90 mm (0.035 in.)
If any of the groove widths exceeds the service limit, re-
place the piston.
Piston Ring Thickness
• Measure the thickness at several points around the rings
with a micrometer.
Piston Ring Thickness (Top, Second)
Standard:
0.75 ~ 0.77 mm (0.0295 ~ 0.0303 in.)
Service Limit:
0.68 mm (0.027 in.)
If any of the measurements is less than the service limit
on either of the rings, replace the rings as a set.
NOTE
○When using new rings in a used piston, check for un-
even groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.
Piston Ring End Gap
Halaman 119
Cylinder, Piston
Piston Ring End Gap
• Place the piston ring [A] inside the cylinder, using the pis-
ton to locate the ring squarely in place. Plase the piston
ring close to the bottom of the cylinder, where cylinder
wear is minimal.
• Measure the gap [B] between the ends of the ring with a
thickness gauge.
Piston Ring End Gap
Standard:
Top
0.15 ~ 0.30 mm (0.006 ~ 0.012 in.)
Second
(KLX140A8F ∼A9F/B8F ∼B9F) 0.30 ∼
0.45 mm (0.012 ∼0.018 in.)
(KLX140AAF ∼ABF/BAF ∼BBF) 0.20
∼0.35 mm (0.008 ∼0.014 in.)
Oil
0.20 ~ 0.70 mm (0.008 ~ 0.028 in.)
Service Limit:
Top
0.6 mm (0.02 in.)
Second
(KLX140A8F ∼A9F/B8F ∼B9F) 0.8 mm
(0.03 in.)
(KLX140AAF ∼ABF/BAF ∼BBF) 0.7
mm (0.028 in.)
Oil
1.0 mm (0.04 in.)
If the ring end gap exceeds the service limit, replace the
ring.
ENGINE TOP END 4-33
Carburetor Holder Installation
Halaman 120
4-34 ENGINE TOP END
Carburetor Holder
Carburetor Holder Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Carburetor Holder Bolts [A]
• Loosen the clamp screw [B], and pull out the carburetor
holder [C].
Carburetor Holder Installation
• Replace the O-ring [A] with a new one.
• Apply grease to the new O-ring, and install the carburetor
holder [B].
• Apply a non-permanent locking agent to the carburetor
holder bolts [C].
Torque - Carburetor Holder Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
Spark Arrester Cleaning
Halaman 121
Muffler
Muffler Removal
WARNING
The muffler can become extremely hot during nor-
mal operation and cause severe burns. Do not re-
move the muffler while it is hot.
• Remove:
Right Side Cover (see Side Covers Removal in the
Frame chapter)
Muffler Mounting Bolts [A]
• Loosen the muffler clamp bolt [B], and pull out the muffler
[C] backward.
• Remove the exhaust pipe holder nuts [A], and remove the
exhaust pipe [B].
Muffler Installation
• Replace the exhaust pipe gasket and the muffler gasket
with new ones.
Torque - Exhaust Pipe Holder Nuts: 14.7 N·m (1.5 kgf·m, 11
ft·lb)
Muffler Joint Clamp Bolt: 17 N·m (1.7 kgf·m, 13
ft·lb)
Muffler Mounting Bolt: 14.7 N·m (1.5 kgf·m, 11
ft·lb)
• Thoroughly warm up the engine, wait until the engine
cools down, and then retighten all the bolts and nuts.
Spark Arrester Cleaning
• Refer to the Spark Arrester Cleaning in the Periodic Main-
tenance chapter.
ENGINE TOP END 4-35
Clutch
Halaman 123
Clutch
Table of Contents
Exploded View........................................................................................................................
5-2
Specifications .........................................................................................................................
5-4
Special Tool ............................................................................................................................
5-5
Clutch Lever and Cable..........................................................................................................
5-6
Clutch Lever Free Play Inspection....................................................................................
5-6
Clutch Lever Free Play Adjustment ..................................................................................
5-6
Clutch Cable Removal ......................................................................................................
5-6
Clutch Cable Lubrication and Inspection ..........................................................................
5-6
Clutch Cover...........................................................................................................................
5-7
Clutch Cover Removal......................................................................................................
5-7
Clutch Cover Installation...................................................................................................
5-7
Clutch .....................................................................................................................................
5-8
Clutch Removal.................................................................................................................
5-8
Clutch Hub Disassembly...................................................................................................
5-8
Clutch Hub Assembly........................................................................................................
5-9
Clutch Installation..............................................................................................................
5-9
Friction and Steel Plate Damage, Wear............................................................................
5-10
Friction and Steel Plate Warp ...........................................................................................
5-10
Clutch Spring Free Length Measurement.........................................................................
5-10
Clutch Housing Finger Damage........................................................................................
5-10
Clutch Hub Spline Damage...............................................................................................
5-11
CLUTCH 5-1
5
Exploded View
Halaman 124
## 5-2 CLUTCH
Exploded View
R
M
3
CL
HG
L 4
HG
R
G R
G
MO
EO
2 1 L
M
MO
GF02167BWS C
Exploded View
Halaman 125
CLUTCH 5-3
Exploded View
| No. | Fastener | Torque | Remarks |
| :-- | :-------------------------- | :----------------------- | :------- |
| | | N·m | kgf·m | ft·lb | |
| 1 | Clutch Hub Bolt | 65 | 6.6 | 48 | L |
| 2 | Clutch Spring Bolts | 8.8 | 0.90 | 78 in·lb | |
| 3 | Clutch Cover Bolts | 8.8 | 0.90 | 78 in·lb | |
| 4 | Oil Seal Retaining Plate Bolts | 9.8 | 1.0 | 87 in·lb | L |
EO: Apply engine oil.
CL: Apply cable lubricant.
G: Apply grease.
HG: Apply high-temperature grease.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Specifications
Halaman 126
5-4 CLUTCH
Specifications
Item
Standard
Service Limit
Clutch Lever
Free Play
2 ∼3 mm (0.08 ∼0.12 in.)
– – –
Clutch
Friction plate thickness
(small inside diameter)
2.92 ∼3.08 mm (0.115 ∼0.121 in.)
2.6 mm (0.10 in.)
(large inside diameter)
3.50 ∼3.60 mm (0.138 ∼0.142 in.)
3.2 mm (0.13 in.)
Friction and steel plate warp
0.15 mm (0.0059 in.) or less
0.3 mm (0.01 in.)
Clutch spring free length
40.2 mm (1.58 in.)
38.4 mm (1.51 in.)
Special Tool
Halaman 127
Special Tool
Clutch Holder:
57001-1554
CLUTCH 5-5
Clutch Cable Lubrication and Inspection
Halaman 128
5-6 CLUTCH
Clutch Lever and Cable
Due to friction plate wear and clutch cable stretch over
a long period of use, the clutch must be adjusted in accor-
dance with the Periodic Maintenance Chart.
WARNING
The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns. Never touch the engine or exhaust chamber
during clutch adjustment.
Clutch Lever Free Play Inspection
• Refer to the Clutch Lever Free Play Inspection in the Pe-
riodic Maintenance chapter.
Clutch Lever Free Play Adjustment
• Refer to the Clutch Lever Free Play Adjustment in the
Periodic Maintenance chapter.
Clutch Cable Removal
• Tuck the rubber boot [A].
• Loosen the locknut [B] and screw in the adjuster [C].
• Align the slots [D] in the clutch lever, locknut, and adjuster
and then free the cable from the lever.
• Free the clutch inner cable tip from the clutch release
lever after opening the tab of the clutch cable holder.
• Pull the clutch cable out of the frame.
Clutch Cable Lubrication and Inspection
• Whenever the cable is removed, or in accordance with
the Periodic Maintenance Chart, lubricate the clutch ca-
ble (see General Lubrication in the Periodic Maintenance
chapter).
• Apply a thin coat of grease to the cable ends.
• Use the pressure cable lubber to lubricate the cable.
○With the cable disconnected at both ends, the cable
should move freely in the cable housing.
Clutch Cover Installation
Halaman 129
Clutch Cover
Clutch Cover Removal
• Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).
• Remove:
Exhaust Pipe Cover
Brake Pedal Pivot Bolt [A]
• Remove the clutch cover bolts [A].
• Clear the clutch cable [B] from the clutch release lever [C].
• Remove the other bolts [A] and the clutch cover [B].
NOTE
○Do not remove the clutch release lever and shaft as-
sembly unless it is absolutely necessary. If removed,
the oil seal replacement may be required. Apply grease
to the oil seal lips.
Clutch Cover Installation
• Replace the gasket [A] with a new one.
• Install the dowel pins [B] and the bearing [C].
• Apply molybdenum disulfide grease to the clutch pusher
[A].
• Inspect the oil seal [B].
If the oil seal is damaged, replace it with a new one.
○Apply a non-permanent locking agent to the oil seal re-
taining plate bolts [C].
Torque - Oil Seal Retaining Plate Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)
• Install the clutch cover and clutch cable.
Torque - Clutch Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
• Install other removed parts.
• Pour in the specified engine oil (see Engine Oil Change
in the Periodic Maintenance chapter).
• Inspect and adjust the clutch lever free play.
CLUTCH 5-7
Clutch Hub Disassembly
Halaman 130
5-8 CLUTCH
Clutch
Clutch Removal
• Remove the clutch cover (see Clutch Cover Removal).
NOTE
○If the primary gear and oil pump gear are to be re-
moved, loosen the primary gear nut before clutch re-
moval (see Primary Gear and Oil Pump Gear Removal
in the Crankshaft/Transmission chapter).
• Remove the bearing [A]
• Remove the clutch hub bolt [B] with the clutch holder [C].
Special Tool - Clutch Holder: 57001-1554
• Remove:
Clutch Hub Assembly [A]
Spacer [B]
Clutch Housing [C]
Collar [D]
Spacer [E]
Clutch Hub Disassembly
• Remove:
Clutch Spring Bolts [A]
Clutch Spring Plate [B]
Clutch Springs [C]
Clutch Holder [D]
Steel Plates [E]
Friction Plates [F]
NOTE
○The outside friction plate is different from other friction
plates. However, it is impossible to identify it on exter-
nals.
○Mark the outside friction plate so that it can be rein-
stalled in its original position.
Clutch Installation
Halaman 131
Clutch
Clutch Hub Assembly
• Clutch hub installation is the reverse of disassembly.
• Install the spring seat [A], and then the spring [B] with the
concave side facing to the clutch hub.
• When installing the friction plates and steel plates, first in-
stall the friction plate [C] whose inside diameter is larger
than the others and then install a steel plate [D] and alter-
nating them.
○Install the marked friction plate at disassembled to the
outside.
○When replace the friction plates with new ones, mark the
outside friction plate so that the two kinds of friction plates
do not mix up at opening the package.
NOTE
○Set the large inside diameter friction plate to move 1/2
pitch according to the clutch housing.
• Install the clutch spring plate and then tighten the clutch
spring bolts with specified torque.
Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
NOTICE
If new dry friction plates and steel plates are in-
stalled, apply engine oil to the surfaces of each
plate to avoid clutch plate seizure.
Clutch Installation
• Apply molybdenum disulfide oil to the input shaft and col-
lar.
• Install:
Spacer [A]
Collar [B]
Clutch Housing [C]
Spacer [D]
Clutch Hub Assembly [E]
• Apply a non-permanent locking agent to the clutch hub
bolt.
• Tighten the clutch hub bolt, while holding the clutch spring
bolts with the suitable clutch holder.
Special Tool - Clutch Holder: 57001-1554
Torque - Clutch Hub Bolt: 65 N·m (6.6 kgf·m, 48 ft·lb)
• Install the clutch cover (see Clutch Cover Installation).
CLUTCH 5-9
Clutch Housing Finger Damage
Halaman 132
5-10 CLUTCH
Clutch
Friction and Steel Plate Damage, Wear
• Visually inspect the friction and steel plates for signs of
seizure, overheating (discoloration), or uneven wear.
• Measure the thickness of the friction plates [A] at several
points.
If any plates show signs of damage, or if they have worn
past the service limit, replace them with new ones.
Friction Plate Thickness
Standard:
(small inside diameter)
2.92 ∼3.08 mm
(0.115 ∼0.121 in.)
(large inside diameter)
3.50 ∼3.60 mm
(0.138 ∼0.142 in.)
Service Limit:
(small inside diameter)
2.6 mm (0.10 in.)
(large inside diameter)
3.2 mm (0.13 in.)
Friction and Steel Plate Warp
• Place friction plate or steel plate [B] on a surface plate,
and measure the gap between the surface plate [A] with
a thickness gauge [C]. The gap is the amount of friction
or steel plate warp.
If any plate is warped over the service limit, replace it with
a new one.
Friction and Steel Plate Warp
Standard:
0.15 mm (0.0059 in.) or less
Service Limit:
0.3 mm (0.01 in.)
Clutch Spring Free Length Measurement
• Measure the free length of the clutch springs [A].
If any spring is shorter than the service limit, it must be
replaced.
Clutch Spring Free Length
Standard:
40.2 mm (1.58 in.)
Service Limit:
38.4 mm (1.51 in.)
Clutch Housing Finger Damage
• Visually inspect the clutch housing fingers [A] where the
friction plate tangs hit them.
If they are badly worn or if there are groove cuts where the
tangs hit, replace the housing. Also, replace the friction
plates if their tangs are damaged.
Clutch Hub Spline Damage
Halaman 133
Clutch
Clutch Hub Spline Damage
• Visually inspect where the teeth on the steel plates wear
against the clutch hub splines.
If there are notches worn into the clutch hub splines [A],
replace the clutch hub. Also, replace the steel plates if
their teeth are damaged.
CLUTCH 5-11
Engine Lubrication System
Halaman 135
Engine Lubrication System
Table of Contents
Exploded View........................................................................................................................
6-2
Engine Oil Flow Chart.............................................................................................................
6-4
Specifications .........................................................................................................................
6-5
Special Tools ..........................................................................................................................
6-6
Engine Oil and Oil Filter..........................................................................................................
6-7
Oil Level Inspection...........................................................................................................
6-7
Engine Oil Change............................................................................................................
6-7
Oil Filter Change...............................................................................................................
6-7
Oil Screen Removal..........................................................................................................
6-8
Oil Screen Installation.......................................................................................................
6-8
Oil Pump.................................................................................................................................
6-9
Oil Pump Removal............................................................................................................
6-9
Oil Pump Installation.........................................................................................................
6-9
Oil Pump Inspection..........................................................................................................
6-9
Oil Pressure............................................................................................................................
6-10
Oil Pressure Measurement ...............................................................................................
6-10
ENGINE LUBRICATION SYSTEM 6-1
6
Exploded View
Halaman 136
6-2 ENGINE LUBRICATION SYSTEM
Exploded View
GG02117BW5 C
Exploded View
Halaman 137
ENGINE LUBRICATION SYSTEM 6-3
**Exploded View**
| No. | Fastener | | Torque | | Remarks |
| :-- | :---------------------------------- | :---- | :----- | :---------- | :------ |
| | | N·m | kgf·m | ft·lb | |
| 1 | Engine Oil Drain Plug | 18 | 1.8 | 13 | |
| 2 | Clutch Cover Bolts | 8.8 | 0.90 | 78 in·lb | |
| 3 | Oil Filter Cover Bolts | 8.8 | 0.90 | 78 in·lb | |
| 4 | Oil Pump Mounting Screws (L = 18) | 5.2 | 0.53 | 46 in·lb | |
| 5 | Oil Pump Mounting Screws (L = 30) | 5.2 | 0.53 | 46 in·lb | |
| 6 | Oil Seal Retaining Plate Bolts | 9.8 | 1.0 | 87 in·lb | L |
G: Apply grease.
EO: Apply engine oil.
R: Replacement Parts
Engine Oil Flow Chart
Halaman 138
# 6-4 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart
* :Oil Flow
* :Blowby Gas
1. Oil Screen
2. Oil Pump
3. Oil Pipe
4. Oil Filter
5. Crankshaft
6. Crankshaft Oil Seal
7. Camshaft
8. Camshaft Chain Tunnel
9. Clutch Cover
10. Engine Breather Hose
Specifications
Halaman 139
Specifications
Item
Standard
Engine Oil
Type
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity
SAE 10W-40
Capacity
0.93 L (0.98 US qt) (when filter is not removed)
0.95 L (1.00 US qt) (when filter is removed)
1.10 L (1.16 US qt) (when engine is completely dry)
Level
Between upper and lower level lines
Oil Pressure Measurement
Oil pressure
29 ∼59 kPa (0.3 ∼0.6 kgf/cm², 4.3 ∼8.5 psi)
oil temperature 90°C (194°F), 4 000 r/min (rpm)
ENGINE LUBRICATION SYSTEM 6-5
Special Tools
Halaman 140
## 6-6 ENGINE LUBRICATION SYSTEM
### Special Tools
**Oil Pressure Gauge, 5 kgf/cm²:**
**57001-125**
**Oil Pressure Cap:**
**57001-1555**
**Oil Pressure Gauge Adapter, M10 x 1.25:**
**57001-1182**
Oil Filter Change
Halaman 141
Engine Oil and Oil Filter
WARNING
Vehicle operation with insufficient, deteriorated,
or contaminated engine oil will cause accelerated
wear and may result in engine seizure, accident,
and injury. Check the oil level before each use and
change the oil and filter according to the periodic
maintenance chart.
Oil Level Inspection
• Situate the motorcycle so that it is vertical.
• Remove the oil filler gauge [A], wipe its gauge dry, and
tighten it into the filler opening.
• Unscrew the oil filler gauge and check that the engine oil
level is between the upper [A] and lower [B] levels in the
gauge.
• Replace the O-ring [C] with a new one.
NOTE
○If the motorcycle has just been used, wait several min-
utes for all the oil to drain down.
○If the oil has just been changed, start the engine and
run it for several minutes at idle speed. This fills the oil
filter with oil. Stop the engine, then wait several minutes
until the oil settles.
NOTICE
Racing the engine before the oil reaches every part
can cause engine seizure.
If the oil level is too high, remove the excess oil, using a
syringe or other suitable device.
If the oil level is too low, add the correct amount of oil.
Use the same type and make of oil that is already in the
engine.
NOTE
○If the engine oil type and make are unknown, use any
brand of the specified oil to top off the level rather than
running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.
Engine Oil Change
• Refer to the Engine Oil Change in the Periodic Mainte-
nance chapter.
Oil Filter Change
• Refer to the Oil Filter Change in the Periodic Maintenance
chapter.
ENGINE LUBRICATION SYSTEM 6-7
Oil Screen Installation
Halaman 142
6-8 ENGINE LUBRICATION SYSTEM
Engine Oil and Oil Filter
Oil Screen Removal
• Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).
• Remove:
Clutch Cover (see Clutch Cover Removal in the Clutch
chapter)
Oil Screen [A]
Oil Screen Installation
• Clean the oil screen [A] with high-flash point solvent and
remove any particles stuck to it.
○Clean thoroughly whenever the oil screen is removed.
WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause severe
burns. Clean the screen in a well-ventilated area,
and take care that there are no sparks or flame
anywhere near the working area; this includes any
appliance with a pilot light. Do not use gasoline or
a low-flash point solvent to clean the screen.
NOTE
○While cleaning the screen, check for any metal particles
that might indicate internal engine damage.
• Inspect the screen carefully for net tearing or other dam-
ages.
If the screen is damaged, replace it with a new one.
• Apply engine oil to the rubber portion on the oil screen [A].
• Insert the oil screen to the crankcase.
○Upturn the “UP” mark [B], and turn the narrow side [C] to
interior.
• Install the clutch cover (see Clutch Cover Installation in
the Clutch chapter).
Oil Pump Inspection
Halaman 143
Oil Pump
Oil Pump Removal
• Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).
• Remove:
Clutch Cover (see Clutch Cover Removal in the Clutch
chapter)
Clutch (see Clutch Removal in the Clutch chapter)
Primary Gear (see Primary Gear Removal in the Crank-
shaft/Transmission chapter)
• Remove the mounting screws [A] and remove the oil
pump assembly [B].
○Turn the pump gear so that the pump mounting screws
can be removed through the pump gear holes.
Oil Pump Installation
• Replace the O-rings [A] with new ones.
• Install the dowel pin [B].
• Install the oil pump assembly [A].
○The lower bolt is longer than the other ones.
Torque - Oil Pump Mounting Screws: 5.2 N·m (0.53 kgf·m,
46 in·lb)
• Install the other removed parts.
Oil Pump Inspection
• Visually inspect the oil pump body [A] and the gear [B].
If there is any damage or uneven wear, replace the oil
pump assembly.
• Turn the gear by hand to inspect the condition of the oil
pump.
If the rotation of the pump is noisy, dose not turn smoothly
or has any rough spots, replace the oil pump assembly.
NOTICE
Do not disassemble the oil pump, because the indi-
vidual parts of pump are not supplied.
ENGINE LUBRICATION SYSTEM 6-9
Oil Pressure Measurement
Halaman 144
6-10 ENGINE LUBRICATION SYSTEM
Oil Pressure
Oil Pressure Measurement
• Remove the bolts [A] and oil filter cover [B].
• Move the spring and the O-ring of the oil filter cover to the
oil pressure cap.
Special Tools - Oil Pressure Cap: 57001-1555
• Attach the oil pressure cap [A], the oil pressure gauge
adapter [B] and the oil pressure gauge [C].
Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Oil Pressure Gauge Adapter, M10 × 1.25:
57001-1182
Oil Pressure Cap: 57001-1555
• Start the engine and warm up the engine thoroughly.
• Run the engine at the specified speed, and read the oil
pressure value.
If the oil pressure is much lower than the standard, check
the oil pump, and crankshaft oil seal of the clutch cover.
If the value is much higher than the standard, check the
oil pump screen and the oil filter first, and oil passages for
dirt or clogging.
Oil Pressure (oil temperature 90°C (194°F), 4 000 r/min
(rpm))
Standard:
29 ∼59 kPa (0.3 ∼0.6 kgf/cm², 4.3 ∼8.5 psi)
• Stop the engine, and remove the oil pressure cap, gauge
and adapter.
WARNING
Hot oil can cause severe burns. Beware of hot en-
gine oil that will drain through the oil passage when
the oil pressure gauge adapter is removed.
• Replace the O-ring with a new one, and apply grease to
the O-ring.
• Install the spring to the oil filter cover.
• Install the oil filter cover.
○The arrow mark on the cover is upward.
Torque - Oil Filter Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
Engine Removal/Installation
Halaman 145
ENGINE REMOVAL/INSTALLATION 7-1
# Engine Removal/Installation
## Table of Contents
Exploded View ................................................................................ 7-2
Special Tool ................................................................................... 7-4
Engine Removal/Installation ........................................................... 7-5
Engine Removal ..................................................................... 7-5
Engine Installation .................................................................. 7-7
7
Exploded View
Halaman 146
# 7-2 ENGINE REMOVAL/INSTALLATION
## Exploded View
* R 2
* 5
* 8
* A
* B
* 5
* 5
* 1 R
* 5
* 7
* R 6
* 3 R
* 9
* A
* B
* 4 R
* 10
GH02149BW5 C
Exploded View
Halaman 147
ENGINE REMOVAL/INSTALLATION 7-3
**Exploded View**
| No. | Fastener | Torque | Remarks |
|-----|---------------------------------|----------------------------------------------------------------------|---------|
| | | **N·m** | **kgf·m** | **ft·lb** | |
| 1 | Upper Engine Mounting Nut (M10) | 49 | 5.0 | 36 | R |
| 2 | Middle Engine Mounting Nut (M10)| 49 | 5.0 | 36 | R |
| 3 | Front Engine Mounting Nuts (M10)| 49 | 5.0 | 36 | R |
| 4 | Rear Engine Mounting Nut (M10) | 49 | 5.0 | 36 | R |
| 5 | Engine Bracket Bolts (M8) | 29 | 3.0 | 21 | |
| 6 | Engine Bracket Nuts (M8) | 29 | 3.0 | 21 | R |
7. Upper Engine Mounting Bolt (L = 160)
8. Middle Engine Mounting Bolt (L = 105)
9. Front Engine Mounting Bolts (L = 77)
10. Rear Engine Mounting Bolt (L = 105)
Special Tool
Halaman 148
7-4 ENGINE REMOVAL/INSTALLATION
Special Tool
Jack:
57001-1238
Engine Removal
Halaman 149
Engine Removal/Installation
Engine Removal
• Place the jack [A] under the frame to support the motor-
cycle.
Special Tool - Jack: 57001-1238
• Squeeze the brake lever slowly and hold it with a band
[A].
WARNING
Motorcycle may fall over unexpectedly resulting in
an accident or injury. Be sure to hold the front brake
when removing the engine.
NOTICE
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. The engine
or the motorcycle could be damaged.
• Drain in the engine oil (see Engine Oil Change in the Pe-
riodic Maintenance chapter).
• Remove:
Engine Guard (see Engine Guard Removal in the Frame
chapter)
Seat (see Seat Removal in the Frame chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Carburetor (see Carburetor Removal in the Fuel System
chapter)
Muffler (see Muffler Removal in the Engine Top End
chapter)
Engine Sprocket (see Engine Sprocket Removal in the
Final Drive chapter)
• Remove the brake pedal pivot bolt [A].
• Remove the breather tube and the spark plug cap only
the cylinder head.
ENGINE REMOVAL/INSTALLATION 7-5
Engine Removal
Halaman 150
7-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
• Remove the bolts [A].
• Take off the clutch cable lower end [B] from the clutch
lever [C].
• Remove the starter motor cable [A] and the engine ground
[B].
• Disconnect the alternator lead connector [A], and clear
the clamp.
• Remove the bolt [A], and take off the shift change lever
[B] from the shift shaft .
• Remove:
Upper Engine Mounting Bolt/Nut [A]
Upper Engine Bracket Bolts [B] (both sides)
Upper Engine Bracket [C] (both sides)
Middle Engine Mounting Bolt/Nut [D]
Middle Engine Bracket Bolts [E] (both sides)
Middle Engine Bracket [F] (both sides)
Engine Installation
Halaman 151
Engine Removal/Installation
• Remove:
Front Engine Mounting Bolts/Nuts [A]
Front Engine Bracket Bolts/Nuts [B]
Front Engine Bracket [C] (both sides)
Rear Engine Mounting Bolt/Nut [D]
• Remove the engine toward right.
Engine Installation
• Replace the engine mounting nuts and bracket nuts with
new ones.
• Install the engine body and the engine brackets, and
tighten lightly all mounting bolts and nuts temporarily.
○Install all nuts to right side.
○Insert the rear engine mounting bolt first.
• Tighten the engine mounting nuts.
Torque - Engine Mounting Nuts [A]: 49 N·m (5.0 kgf·m, 36
ft·lb)
• Tighten the engine bracket bolts and nuts.
Torque - Engine Bracket Bolts [A](both sides): 29 N·m (3.0
kgf·m, 21 ft·lb)
Engine Bracket Nuts [B]: 29 N·m (3.0 kgf·m, 21
ft·lb)
• Install the other removed parts.
• Run the cables, hoses and leads according to the Cable,
Wire and Hose Routing section in the Appendix chapter.
• Fillthe engine oil (see Engine Oil Change in the Periodic
Maintenance chapter).
• Adjust:
Throttle Cable (see Throttle Grip Free Play Adjustment
in the Periodic Maintenance chapter)
Clutch Cable (see Clutch Lever Free Play Adjustment in
the Periodic Maintenance chapter)
Drive Chain (see Drive Chain Slack Adjustment in the
Periodic Maintenance chapter)
• Adjust the idling (see Idle Speed Adjustment in the Peri-
odic Maintenance chapter).
• Check the operation of the clutch lever.
• Check the brake effectiveness.
WARNING
After servicing, it takes several applications of the
brake pedal before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake pedal is obtained by pumping the pedal until
the pads are against the disc.
ENGINE REMOVAL/INSTALLATION 7-7
Crankshaft/Transmission
Halaman 153
Crankshaft/Transmission
Table of Contents
Exploded View........................................................................................................................
8-2
Specifications .........................................................................................................................
8-6
Special Tools ..........................................................................................................................
8-7
Crankcase ..............................................................................................................................
8-8
Crankcase Disassembly ...................................................................................................
8-8
Crankcase Assembly ........................................................................................................
8-9
Crankshaft ..............................................................................................................................
8-13
Crankshaft Removal .........................................................................................................
8-13
Crankshaft Installation ......................................................................................................
8-13
Crankshaft Disassembly ...................................................................................................
8-13
Connecting Rod Big End Seizures....................................................................................
8-13
Connecting Rod Big End Radial Clearance......................................................................
8-13
Connecting Rod Big End Side Clearance.........................................................................
8-13
Crankshaft Runout............................................................................................................
8-13
Primary Gear ..........................................................................................................................
8-15
Primary Gear and Oil Pump Gear Removal......................................................................
8-15
Primary Gear and Oil Pump Gear Installation...................................................................
8-15
External Shift Mechanism.......................................................................................................
8-16
Shift Pedal Ball Joint Installation.......................................................................................
8-16
External Shift Mechanism Removal..................................................................................
8-16
External Shift Mechanism Inspection................................................................................
8-16
Transmission ..........................................................................................................................
8-17
Transmission Shaft Removal ............................................................................................
8-17
Transmission Shaft Installation .........................................................................................
8-17
Transmission Disassembly ...............................................................................................
8-17
Transmission Assembly ....................................................................................................
8-17
Shift Fork Bending ............................................................................................................
8-19
Shift Fork/Gear Groove Wear ...........................................................................................
8-20
Shift Fork Guide Pin/Drum Groove Wear..........................................................................
8-20
Gear Dog and Gear Dog Hole Damage............................................................................
8-20
Ball Bearing, and Oil Seal.......................................................................................................
8-21
Ball Bearing Replacement ................................................................................................
8-21
Ball Bearing Wear.............................................................................................................
8-21
Oil Seal Inspection............................................................................................................
8-21
CRANKSHAFT/TRANSMISSION 8-1
8
Exploded View
Halaman 154
8-2 CRANKSHAFT/TRANSMISSION
Exploded View
(1) MO Lh
(E0)
(MO)
(E0)
(E0)
(3)
(4 L)
(E0)
(R)
(5)
(6)
(G)
(G)
(E0)
(2)
(M)
(7)
(M)
(E0)
(7)
(M)
(E0)
(7)
(E0)
(R)
(M)
(E0)
(M)
(7)
G102297BW5 C
Exploded View
Halaman 155
CRANKSHAFT/TRANSMISSION 8-3
Exploded View
| No. | Fastener | N·m | Torque | | Remarks |
| :-- | :------------------------ | :--- | :------ | :-------- | :------ |
| 1 | Primary Gear Nut | 98 | 10 | 72 ft·lb | Lh, MO |
| 2 | Crankcase Bolts (L = 50) | 8.8 | 0.90 | 78 in·lb | |
| 3 | Crankcase Bolts (L = 60) | 8.8 | 0.90 | 78 in·lb | |
| 4 | Bearing Retaining Screws | 5.2 | 0.53 | 46 in·lb | L |
| 5 | Engine Oil Drain Plug | 18 | 1.8 | 13 ft·lb | |
| 6 | Neutral Switch | 15 | 1.5 | 11 ft·lb | |
7. KLX140AAF ~/BAF ~
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement parts.
Exploded View
Halaman 156
8-4 CRANKSHAFT/TRANSMISSION
Exploded View
GI02256BW5 C
Exploded View
Halaman 157
CRANKSHAFT/TRANSMISSION 8-5
**Exploded View**
| No. | Fastener | Torque | Remarks |
| :-- | :------------------------------ | :-------: | :-------: | :-------: | :------ |
| | | **N·m** | **kgf·m** | **ft·lb** | |
| 1 | Shift Drum Cam Bolt | 12 | 1.2 | 106 in·lb | L |
| 2 | Gear Set Lever Mounting Nut | 9.8 | 1.0 | 87 in·lb | |
| 3 | Shift Return Spring Pin (Bolt) | 29 | 3.0 | 21 | L |
| 4 | Shift Pedal Ball Joint Clamp Bolt | 12 | 1.2 | 106 in·lb | |
| 5 | Shift Linkage Rod Locknut | 9.8 | 1.0 | 87 in·lb | |
EO: Apply engine oil.
L: Apply a non-permanent locking agent.
R: Replacement parts.
Specifications
Halaman 158
# 8-6 CRANKSHAFT/TRANSMISSION
## Specifications
| Item | Standard | Service Limit |
|---|---|---|
| **Crankshaft, Connecting Rods** | | |
| Connecting Rod Big End: | | |
| Radial Clearance | 0.005 ~ 0.017 mm (0.0002 ~ 0.0007 in.) | 0.07 mm (0.003 in.) |
| Side Clearance | 0.1 ~ 0.2 mm (0.004 ~ 0.008 in.) | 0.4 mm (0.016 in.) |
| Crankshaft Runout | TIR 0.03 mm (0.001 in.) or less | TIR 0.08 mm (0.003 in.) |
| **Transmission** | | |
| Shift Fork Ear Thickness | 4.9 ~ 5.0 mm (0.19 ~ 0.20 in.) | 4.8 mm (0.19 in.) |
| Gear Shift Fork Groove Width | 5.05 ~ 5.15 mm (0.199 ~ 0.203 in.) | 5.25 mm (0.207 in.) |
| Shift Fork Guide Pin Diameter | 5.9 ~ 6.0 mm (0.23 ~ 0.24 in.) | 5.8 mm (0.23 in.) |
| Shift Drum Groove Width | 6.05 ~ 6.20 mm (0.238 ~ 0.244 in.) | 6.3 mm (0.25 in.) |
Special Tools
Halaman 159
CRANKSHAFT/TRANSMISSION 8-7
## Special Tools
* **Outside Circlip Pliers:**
57001-144
(Image of outside circlip pliers)
* **Bearing Driver Set:**
57001-1129
(Image of a bearing driver set)
* **Crankshaft Jig:**
57001-1174
(Image of a crankshaft jig)
* **Gear Holder:**
57001-1602
(Image of a gear holder)
* **Liquid Gasket, TB1105B:**
92104-002
(Image of liquid gasket tube)
* **Liquid Gasket, TB1216:**
92104-1063
(Image of liquid gasket tube)
* **Liquid Gasket, TB1215:**
92104-1065
(Image of liquid gasket tube)
Crankcase Disassembly
Halaman 160
8-8 CRANKSHAFT/TRANSMISSION
Crankcase
Crankcase Disassembly
• Remove the engine (see Engine Removal in the Engine
Removal/Installation chapter)
• Set the engine on a clean surface and hold the engine
steady while parts are being removed.
• Remove:
Camshaft Chain (see Camshaft Chain Removal in the
Engine Top End chapter)
Cylinder Head (see Cylinder Head Removal in the En-
gine Top End chapter)
Cylinder (see Cylinder Removal in the Engine Top End
chapter)
Piston (see Piston Removal in the Engine Top End chap-
ter)
Alternator (see Alternator Removal in the Electrical Sys-
tem chapter)
Starter Motor (see Starter Motor Removal in the Electri-
cal System chapter)
Clutch (see Clutch Removal in the Clutch chapter)
Oil Pump Gear and Primary Gear (see Primary Gear
Removal in the Clutch chapter)
Oil Pump (see Oil Pump Removal in the Engine Lubri-
cation chapter)
External Shift Mechanism (see External Shift Mecha-
nism Removal)
Gear Set Lever [A]
Shift Drum Cam [B]
• Remove the output shaft sleeve [A] and O-ring [B].
• Remove all the crankcase bolts [A] on both sides.
Crankcase Assembly
Halaman 161
Crankcase
• Insert a suitable tool to the pry points [A], and split the
crankcase.
• Remove the left crankcase half.
• Disassemble the transmission system from the right
crankcase half (see Transmission Disassembly).
• Support the left crankcase half [A] with a suitable retainer.
• Remove the crankshaft [B] from the left crankcase half
using a press.
NOTICE
Do not remove the ball bearings and the oil seals
unless it is necessary. If they are removed, replace
them with new ones.
Crankcase Assembly
NOTICE
Right and left crankcase halves are machined at the
factory in the assembled state, so if replaced, they
must be replaced as a set.
• Chip off the old gasket from the mating surfaces of the
crankcase halves and clean them off with high-flash point
solvent.
• Using compressed air, blow out the oil passages in the
crankcase halves.
WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause severe
burns. Clean the engine parts 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 parts.
CRANKSHAFT/TRANSMISSION 8-9
Crankcase Assembly
Halaman 162
8-10 CRANKSHAFT/TRANSMISSION
Crankcase
• Support the crankcase bearing boss with a suitable re-
tainer [A].
• Using a press and the bearing driver set [C], install a new
bearing [B] until it bottoms out.
Special Tool - Bearing Driver Set: 57001-1129
• Apply a non-permanent locking agent to the bearing re-
taining screws.
• Tighten the input shaft and the shift drum bearing retain-
ing screws securely in the right crankcase half.
Torque - Bearing Retaining screws: 5.2 N·m (0.53 kgf·m, 46
in·lb)
NOTICE
Support the crankcase bearing boss when the bear-
ings are pressed, or the crankcase could be dam-
aged.
• Press the output shaft bearing [B] in the left crankcase
half [A].
Special Tool - Bearing Driver Set: 57001-1129
• Put in the output shaft oil seal [C], being careful of the
proper direction as shown.
• Using compressed air [A], blow out the oil passage in the
right crankshaft [B].
• Positioning the connecting rod [A] big end at BDC, put in
the crankshaft jig [B] between the crankshaft flywheels.
• Press the crankshaft [C] in the right crankcase half [D].
Special Tool - Crankshaft Jig: 57001-1174
• Assemble the transmission system (see Transmission
Assembly).
Crankcase Assembly
Halaman 163
Crankcase
• Apply liquid gasket to the mating surface [A] of the left
crankcase half.
NOTE
○Don’t apply liquid gasket to this area [B].
Sealant - Liquid Gasket, TB1105B: 92104-002
Liquid Gasket, TB1216: 92104-1063
Liquid Gasket, TB1215: 92104-1065
• Using a suitable tool on the left crankcase to press around
the hole for the crankshaft, fit the crankcase halves to-
gether with a press on the tool.
• Remove the crankshaft jig.
• Install the crankcase bolts [A] in the left and right
crankcase half and tighten them, starting with the nearest
ones to the crankshaft, then farther ones.
Torque - Crankcase Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
• Check to see that the crankshaft, drive shaft, and output
shaft all turn freely (in the neutral position).
If the crankshaft will not turn, probably the crankshaft is
not centered; tap the mount portion [A] of the crankcase
with a plastic hammer to reposition it.
• Apply a non-permanent locking agent to the shift drum
cam bolt [A] and tighten it.
Torque - Shift Drum Cam Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)
• Install the gear set lever and tighten the nut [B].
Torque - Gear Set Lever Mounting Nut: 9.8 N·m (1.0 kgf·m,
87 in·lb)
• Install the external shift mechanism (see External Shift
Mechanism Installation).
• Check to see that gears shift smoothly from 1st to 5th
gear, and 5th to 1st while spinning the output shaft.
• Set the shift drum in the neutral position.
CRANKSHAFT/TRANSMISSION 8-11
Crankcase Assembly
Halaman 164
8-12 CRANKSHAFT/TRANSMISSION
Crankcase
• Replace the O-ring [B] on the output shaft with a new one.
• Apply grease to the inside of the output shaft collar [A].
Crankshaft Runout
Halaman 165
Crankshaft
Crankshaft Removal
• Refer to the Crankcase Disassembly in this chapter.
Crankshaft Installation
• Refer to the Crankcase Assembly in this chapter.
Crankshaft Disassembly
If the crankshaft is damaged, replace it as a set. Not for
sale to each part of the crankshaft.
Connecting Rod Big End Seizures
• In case of seizure, replace the crankshaft assembly.
Connecting Rod Big End Radial Clearance
• Support the crankshaft on both sides, and place a dial
gauge [A] against the connecting rod big end.
• Push [B] the connecting rod first towards the gauge and
then in the opposite direction. The difference between
two gauge readings is the radial clearance.
Connecting Rod Big End Radial Clearance
Standard:
0.005 mm ∼0.017 mm
(0.0002 ∼0.0007 in.)
Service Limit:
0.07 mm (0.003 in.)
If the radial clearance exceeds the service limit, replace
the crankshaft assembly.
Connecting Rod Big End Side Clearance
• Measure connecting rod big end side clearance [A].
Connecting Rod Big End Side Clearance
Standard:
0.1 ∼0.2 mm (0.004 ∼0.008 in.)
Service Limit:
0.4 mm (0.02 in.)
If the clearance exceeds the service limit, replace the
crankshaft assembly.
Crankshaft Runout
• Supporting the crankshaft on both sides, place a dial
gauge as shown and turn the crankshaft slowly.
The
maximum difference in gauge reading is the crankshaft
runout.
9 mm (0.35 in.) [A]
Crankshaft Runout
Standard:
TIR 0.03 mm (0.001 in.) or less
Service Limit:
TIR 0.1 mm (0.003 in.)
If the runout at either point exceeds the service limit, re-
place the crankshaft assembly with a new one or align the
crankshaft so that the runout falls within the service limit.
CRANKSHAFT/TRANSMISSION 8-13
Crankshaft Runout
Halaman 166
8-14 CRANKSHAFT/TRANSMISSION
Crankshaft
• First correct the horizontal misalignment by striking the
projecting crank half [A] with a plastic, soft lead, or brass
hammer as shown.
• Recheck the runout with a dial gauge and repeat the
process until the runout falls within the service limit.
• Next, correct the vertical misalignment by either driving a
wedge [A] in between the crank halves or by squeezing
them in a vice, depending on the nature of the misalign-
ment.
NOTICE
Do not hammer the crank half at the point [B].
Primary Gear and Oil Pump Gear Installation
Halaman 167
Primary Gear
Primary Gear and Oil Pump Gear Removal
• Remove the clutch cover (see Clutch Cover Removal in
the Clutch chapter).
• Hold the primary gear with the gear holder [A].
Special Tool - Gear Holder: 57001-1602
• Loosen the primary gear nut [B] (Left hand thread).
• Remove:
Clutch (see Clutch Removal in the Clutch chapter)
Primary Gear Nut
Primary Gear [C]
Oil Pump Assembly (see Oil Pump Removal in the En-
gine Lubrication System)
Oil Pump Drive Gear
Woodruff Key
Primary Gear and Oil Pump Gear Installation
• Set the woodruff key securely in the slot.
• Apply molybdenum disulfide oil to the seating surface of
primary gear nut.
• Install:
Oil Pump Drive Gear [A]
Oil Pump Assembly (see Oil Pump Installation in the En-
gine Lubrication chapter)
Primary Gear [B]
• Install the clutch (see Clutch Installation in the Clutch
chapter).
• Temporarily tighten the primary gear nut.
• Hold the primary gear with the gear holder [A].
Special Tool - Gear Holder: 57001-1602
• Tighten the primary gear nut [B].
Torque - Primary Gear Nut: 98 N·m (10 kgf·m, 72 ft·lb)
• Install the clutch cover (see Clutch Cover Installation in
the Clutch chapter).
CRANKSHAFT/TRANSMISSION 8-15
External Shift Mechanism Inspection
Halaman 168
8-16 CRANKSHAFT/TRANSMISSION
External Shift Mechanism
Shift Pedal Ball Joint Installation
• Install the shift pedal ball joint [A].
○Align the punch marks [B].
○Align the shift pedal and the footpeg upper surface to the
same level.
• Install the rubber boot [A] of the shift pedal ball joint over
the rib [B].
• Be sure the sealing lip of the rubber boot fits into the
groove of the ball joint.
External Shift Mechanism Removal
• Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).
• Remove:
Clutch Cover (see Clutch Cover Removal in the Clutch
chapter)
Clutch (see Clutch Removal in the Clutch chapter)
Shift Pedal (see Shift Pedal Removal)
• Turn the shift drum and position the neutral groove [A] as
shown.
• Remove the shift shaft [B] while pushing backward [C] the
shift mechanism arm [D].
External Shift Mechanism Inspection
• Examine the shift shaft [A] for any damage.
If the shaft is bent, straighten or replace it.
If the splines [B] are damaged, replace the shaft.
If the springs [C] [D] are damaged in any way, replace
them.
If the shift pawl [E] is damaged in any way, replace the
shift shaft assembly.
• Check the return spring pin [A] is not loose.
If it is loose, unscrew it to apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Shift Shaft Return Spring Pin: 29 N·m (3.0 kgf·m,
22 ft·lb)
• Check the gear set lever [B], and their springs [C] for
breaks or distortion.
If the lever or springs are damaged in any way, replace
them.
• Visually inspect the shift drum cam [D].
If the cam is badly worn or if it shows any damage, replace
it.
Transmission Assembly
Halaman 169
Transmission
Transmission Shaft Removal
• Split the crankcase (see Crankcase Disassembly)
• Pull out the shift rod [A] allowing the shift fork guide pins
to free from the shift drum [B].
• Remove the shift forks [C].
• Remove the shift drum.
• Pull out the drive shaft [D] and output shaft [E] together
with their gears meshed.
Transmission Shaft Installation
• Apply engine oil to the sliding portions of every gear and
bearing.
• Install the drive shaft [A], output shaft [D], and shift drum
[C] in the right crankcase with their gears [B] meshed.
• Apply a small amount of engine oil to the shift fork fingers
and fit each shift fork into the groove of the proper gear.
• The shift forks can be identified by their shape or mark.
Install them noting the direction shown.
○Install each shift forks with its mark facing the engine left
side.
Marks:0051 (Drive Shaft)
NR (Right Output Shaft)
NL (Left Output Shaft)
• Fit each shift fork guide pin into the corresponding groove
in the shift drum.
• Apply a little engine oil to the shift rods and slide them into
the shift forks.
• Assemble the crankcase (see Crankcase Assembly).
Transmission Disassembly
• Remove the transmission shafts (see Transmission Shaft
Removal).
• Remove the circlips, washers and gears.
Special Tool - Outside Circlip Pliers: 57001-144
Transmission Assembly
• Replace any circlips with new ones.
• Install the circlips [A] so that the opening [B] is aligned
with a spline groove [C].
NOTE
○Take care not to damage the circlips. First, expand the
circlip opening, and fit onto the shaft. Next, push the
circlip into the suitable place with the gear.
• Check that each gear spins or slides freely on the trans-
mission shafts without binding after assembly.
• Be sure that all parts are put back in the correct sequence
and all circlips and washers are properly in place.
CRANKSHAFT/TRANSMISSION 8-17
Transmission Assembly
Halaman 170
## 8-18 CRANKSHAFT/TRANSMISSION
### Transmission
**KLX140A8F ~ A9F/B8F ~ B9F**
---
| | |
| :--- | :--- |
| **1.** Drive gear-1st | **8.** Output gear-3rd |
| **2.** Drive gear-2nd | **9.** Output gear-4th |
| **3.** Drive gear-3rd | **10.** Output gear-Top |
| **4.** Drive gear-4th | **11.** Spacer |
| **5.** Drive gear-Top | **12.** Circlip |
| **6.** Output gear-1st | **13.** Washer |
| **7.** Output gear-2nd | **14.** Shim |
<br>
<p align="right">GI13074BW3 C</p>
Shift Fork Bending
Halaman 171
Transmission
KLX140AAF ∼ABF/BAF ∼BBF
1. Drive gear-1st
2. Bushing
3. Drive gear-4th
4. Spacer
5. Snap Ring
6. Drive gear-3rd
7. Bushing
8. Drive gear-Top
9. Drive gear-2nd
10. Spacer
Shift Fork Bending
• Visually inspect the shift forks, and replace any fork that is
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
90° [A]
CRANKSHAFT/TRANSMISSION 8-19
11. Output Shaft
12. Bushing
13. Output gear-1st
14. Shim
15. Output gear-4th
16. Spacer
17. Output gear-Top
18. Output gear-2nd
19. Bushing
Gear Dog and Gear Dog Hole Damage
Halaman 172
8-20 CRANKSHAFT/TRANSMISSION
Transmission
Shift Fork/Gear Groove Wear
• Measure the thickness of the shift fork ears [A], and mea-
sure the width [B] of the gear grooves.
Shift Fork Ear Thickness
Standard:
4.9 ∼5.0 mm (0.19 ∼0.20 in.)
Service Limit:
4.8 mm (0.19 in.)
Gear Groove Width
Standard:
5.05 ∼5.15 mm (0.199 ∼0.203 in.)
Service Limit:
5.25 mm (0.207 in.)
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
If the gear groove is worn exceeding the service limit, the
gear must be replaced.
Shift Fork Guide Pin/Drum Groove Wear
• Measure the diameter of each shift fork guide pin [A], and
measure the width of each shift drum groove [B].
Shift Fork Guide Pin Diameter
Standard:
5.9 ∼6.0 mm (0.23 ∼0.24 in.)
Service Limit:
5.8 mm (0.23 in.)
Shift Drum Groove Width
Standard:
6.05 ∼6.20 mm (0.238 ∼0.244 in.)
Service Limit:
6.3 mm (0.25 in.)
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
If any shift drum groove is worn exceeding the service
limit, the drum must be replaced.
Gear Dog and Gear Dog Hole Damage
• Visually inspect the gear dogs [A] and gear dog holes [B].
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
• Visually inspect the gear teeth [C] on the transmission
gears.
Replace lightly damaged gear teeth with an oilstone. The
gear must be replaced if the teeth are badly damaged.
When gear is repaired or replaced, the driving gear should
also be inspected and repaired or replaced if necessary.
Oil Seal Inspection
Halaman 173
Ball Bearing, and Oil Seal
Ball Bearing Replacement
NOTICE
Do not remove the ball bearings unless it is neces-
sary. Removal may damaged them.
• Remove the ball bearing and/or needle bearing outer race
with a press or puller.
NOTE
○In the absence of the above mentioned tools, satisfac-
tory results may be obtained by heating the case to ap-
proximately 93°C (200°F) max, and tapping the bearing
in or out.
NOTICE
Do not heat the case with a torch. This will warp the
case. Soak the case in oil and heat the oil.
• Install the new bearing until its outer race stops at the
bottom of the case with a press and the bearing driver set
[A].
Special Tool - Bearing Driver Set: 57001-1129
Ball Bearing Wear
NOTICE
Do not remove the bearings for inspection.
Re-
moval may damage them.
• Inspect the ball bearings.
○Since the ball bearings are made to extremely close toler-
ances, the wear must be judged by feel rather than mea-
surement. Clean each bearing in high-flash point solvent,
dry it (do not spin the bearing while it is dry), and oil it with
engine oil to it.
○Spin [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.
• Check the needle bearing.
○The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
inspect the bearing for abrasion, color change, or other
damage.
If there is any doubt as to the condition of a needle bear-
ing, replace it.
Oil Seal Inspection
• Inspect the oil seals.
Replace the seal if the lips are deformed, discolored (in-
dicating that the rubber has deteriorated), hardened or
otherwise damaged.
CRANKSHAFT/TRANSMISSION 8-21
Wheels/Tires
Halaman 175
WHEELS/TIRES 9-1
# Wheels/Tires
## Table of Contents
Exploded View ................................................................................. 9-2
Specifications ................................................................................. 9-4
Special Tools ................................................................................... 9-5
Wheels (Rims) ................................................................................ 9-6
Front Wheel Removal ............................................................... 9-6
Front Wheel Installation .......................................................... 9-6
Rear Wheel Removal ................................................................ 9-7
Rear Wheel Installation ........................................................... 9-7
Wheels Inspection .................................................................... 9-8
Spoke Tightness Inspection .................................................... 9-8
Rim Runout Inspection ............................................................ 9-8
Axle Inspection ........................................................................ 9-8
Tires.................................................................................................. 9-9
Tire Removal ............................................................................ 9-9
Tire Installation ....................................................................... 9-10
Air Pressure Inspection/Adjustment...................................... 9-11
Hub Bearings................................................................................ 9-12
Hub Bearing Removal ............................................................. 9-12
Hub Bearing Installation ......................................................... 9-12
Hub Bearing Inspection .......................................................... 9-12
Hub Bearing Lubrication ......................................................... 9-13
9
Exploded View
Halaman 176
# 9-2 WHEELS/TIRES
## Exploded View
* **Diagram Labels:**
* **Numbers:** 1, 2, 3, 4, 5, 6, 7, 8, 9, 10
* **Codes:** HG, R, WL
GJ02170BW5 C
Exploded View
Halaman 177
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Front Axle Nut
79
8.1
58
R
2
Rear Axle Nut
79
8.1
58
R
3. Spoke Nipples
4. Spokes
5. Rims
6. Front Axle
7. Rear Axle
8. Rear Sprocket
9. Front Brake Disc
10. Rear Brake Disc
HG: Apply high temperature grease.
WL: Apply soap and water solution, or rubber lubricant.
R: Replacement Parts.
WHEELS/TIRES 9-3
Specifications
Halaman 178
9-4 WHEELS/TIRES
Specifications
Item
Standard
Service Limit
Wheels (Rims)
Rim Size:
Front
(KLX140A) 17 × 1.40
– – –
(KLX140B) 19 × 1.40
– – –
Rear
(KLX140A) 14 × 1.60
– – –
(KLX140B) 16 × 1.85
– – –
Rim Runout:
Axial
TIR 0.8 mm (0.031 in.) or less
TIR 2.0 mm (0.08 in.)
Radial
TIR 1.2 mm (0.047 in.) or less
TIR 2.0 mm (0.08 in.)
Axle Runout/100 mm (3.94 in.)
0.1 mm (0.004 in.) or less
0.2 mm (0.008 in.)
Tires
Air Pressure (when cold):
Front and Rear
100 kPa (1.02 kgf/cm², 14.5 psi)
– – –
Standard Tire:
Front:
Size
(KLX140A) 70/100-17 40M
– – –
(KLX140B) 70/100-19 42M
– – –
Make
IRC
– – –
Type
IX05H, Tube
– – –
Rear:
Size
(KLX140A) 90/100-14 49M
– – –
(KLX140B) 90/100-16 52M
– – –
Make
IRC
– – –
Type
IX05H, Tube
– – –
Special Tools
Halaman 179
WHEELS/TIRES 9-5
Special Tools
Inside Circlip Pliers:
57001-143
Bearing Driver Set:
57001-1129
Rim Protector:
57001-1063
Jack:
57001-1238
Bead Breaker Assembly:
57001-1072
Front Wheel Installation
Halaman 180
9-6 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal
• Stabilize the motorcycle with the jack.
Special Tool - Jack: 57001-1238
• Apply the rear brake to rear wheel does not turn.
• Remove the cotter pin [A] and the front axle nut [B].
• Raise the front wheel off the ground with the jack.
• Pull out the axle [C], and remove the wheel.
○Take care not to damage the front caliper.
• Take off the cap [A] on both sides.
NOTICE
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so the disc does not
touch the ground.
• Insert a wood wedge between the disc brake pads this
prevents them from being moved out of their proper posi-
tion, should the brake lever be squeezed accidentally.
Front Wheel Installation
• Apply high-temperature grease to the oil seal [A] on both
sides.
• Install the cap [B] on both sides and install the wheel.
○Take care not to damage the front caliper.
• Replace the front axle nut with a new one.
• Insert the axle [A] from left side, and tighten the axle nut
[B].
Torque - Front Axle Nut: 79 N·m (8.1 kgf·m, 58 ft·lb)
• Insert a new cotter pin [C] to the front axle, and bend it to
both sides.
• Remove the jack.
• Check the front brake for good braking power and no
brake drag.
WARNING
After servicing, it takes several applications of the
brake lever before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake lever is obtained by pumping the lever until
the pads are against the disc.
Rear Wheel Installation
Halaman 181
Wheels (Rims)
Rear Wheel Removal
• Raise the rear wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
• Remove the rear caliper (see Rear Caliper Removal in
the Brakes chapter).
• Remove the cotter pin [A] and the rear axle nut [B].
• Remove the axle [C], and take off the chain adjuster [D]
on both sides.
• Disengage the drive chain from the rear sprocket.
○Hang the chain on the swingaem.
• Remove the rear wheel.
○Take care not to damage the rear caliper.
• Take off the cap [A] on both sides.
NOTICE
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so the disc does not
touch the ground.
• Insert a wood wedge between the brake pads. This pre-
vents them from being moved out of their proper position,
should the brake pedal be squeezed accidentally.
Rear Wheel Installation
• Install the brake holder onto the swingarm.
○Fit the groove [A] of the holder and the projection [B] of
the swingarm.
WHEELS/TIRES 9-7
Axle Inspection
Halaman 182
9-8 WHEELS/TIRES
Wheels (Rims)
• Apply high-temperature grease to the oil seal [A] on both
sides, and install the cap [B] on both sides.
• Engage the drive chain with the rear sprocket, and set the
rear wheel to the motorcycle.
• Replace the rear axle nut with a new one.
• Insert the axle from the left side, and tighten the axle nut.
Torque - Rear Axle Nut: 79 N·m (8.1 kg·m, 58 ft·lb)
• Insert a new cotter pin to the rear axle, and bend it along
both sides.
• Remove the jack.
• Install the rear caliper (see Rear Caliper Install in the
Brakes chapter).
• Check the rear brake for good braking power and no
brake drag.
WARNING
After servicing, it takes several applications of the
brake pedal before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake pedal is obtained by pumping the pedal until
the pads are against the disc.
Wheels Inspection
• Raise the front/rear wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
• Spin the wheel lightly, and check for roughness or binding.
If the roughness or binding is found, replace the hub bear-
ings.
• Visually inspect the front and rear axles for damage.
If the axle is damaged or bent, replace it.
Spoke Tightness Inspection
• Refer to the Spoke Tightness Inspection in the Periodic
Maintenance chapter.
Rim Runout Inspection
• Refer to the Rim Runout Inspection in the Periodic Main-
tenance chapter.
Axle Inspection
• Visually inspect the front and rear axle for damages.
If the axle is damaged or bent, replace it.
• Place the axle in V blocks that are 100 mm (3.937 in.)
[A] apart, and set a dial gauge [B] on the axle at a point
halfway between the blocks. Turn [C] the axle to measure
the runout. The difference between the highest and low-
est dial readings is the amount of runout.
If the runout exceeds the service limit, replace the axle.
Axle Runout/100 mm (3.94 in.)
Standard:
0.1 mm (0.004 in.) or less
Service Limit: 0.2 mm (0.008 in.)
Tire Removal
Halaman 183
Tires
Tire Removal
NOTICE
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so the disc does not
touch the ground.
• Remove the wheel from the motorcycle (see Wheels Re-
moval).
• To maintain front wheel balance, mark [A] the valve stem
position on the tire with chalk so that the tire can be rein-
stalled in the same position.
• Remove the valve cap [B].
• Take out the valve core [A] to let out the air.
• Remove the valve stem nut [B].
○When handling the rim, be careful not to damage the rim
flanges.
• Loosen the bead protector nut [A].
• Lubricate the tire beads and rim flanges on both sides with
a soap and water solution or rubber lubricant. This helps
the tire beads slip off the rim flanges.
NOTICE
Never lubricate with mineral oil (engine oil) or gaso-
line because they will cause deterioration of the tire.
• Break the beads away from both sides of the rim with the
bead breaker [A].
Special Tool - Bead Breaker Assembly: 57001-1072
WHEELS/TIRES 9-9
Tire Installation
Halaman 184
9-10 WHEELS/TIRES
Tires
• Step on the side of the tire opposite valve stem, pry the
tire off the rim with the tire iron [A] of the bead breaker
protecting the rim with rim protectors [B].
Special Tools - Rim Protector: 57001-1063
Bead Breaker Assembly: 57001-1072
NOTICE
Take care not to inset the tire irons so deeply that
the tube gets damaged.
• Remove the bead protector and tube when one side of
the tire is pried off.
• Pry the tire off the rim.
Tire Installation
NOTE
○The Tires should be installed so that the ID serial NO.
[A] faces to left side.
• Inspect the rim and tire, and replace them if necessary.
• Install the tube band and tube.
• Apply a soap and water solution, or rubber lubricant to the
rim flange and tire beads.
• Position the front tire on the rim so that the valve [A] is
at the tire balance mark [B] (the chalk mark made during
removal, or the white paint mark on a new tire. see Tire
Removal).
• Insert the valve stem into the rim, and screw the nut on
loosely.
• Fit the rim protectors and use tire irons to install the tire
bead.
NOTE
○To prevent rim damage, be sure to place the rim protec-
tors at any place the tire irons are applied.
• Pry one side of the tire back onto the rim. Fit the bead
protector into the tire.
• Pry the other side of the tire onto the rim, starting at the
side opposite the valve.
○Take care not to insert the tire irons so deeply that the
tube is damaged.
• Install the other side of the tire bead onto the rim in the
same manner.
• Check that the tube is not pinched between the tire and
rim.
Air Pressure Inspection/Adjustment
Halaman 185
Tires
• Tighten the bead protector nut [A] and valve stem nut [B],
and put on the valve cap [C].
• Check and adjust the air pressure after installing.
Air Pressure Inspection/Adjustment
• Refer to the Air Pressure Inspection/Adjustment in the Pe-
riodic Maintenance chapter.
WHEELS/TIRES 9-11
Hub Bearing Inspection
Halaman 186
9-12 WHEELS/TIRES
Hub Bearings
Hub Bearing Removal
• Remove the wheel (see Wheel Removal).
NOTICE
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
• Remove the oil seals and the circlip.
Special Tool - Inside Circlip Pliers: 57001-143
• Remove the hub bearing by tapping evenly around the
bearing inner race as shown.
[A] Bar
[B] Distance Collar
[C] Hub Bearing
Hub Bearing Installation
• Before installing the wheel bearings [A], blow any dirt or
foreign particles out of the hub with compressed air to
prevent contamination of the bearings.
• Replace the bearings with new ones.
• Install them using the bearing driver set [B] so that the
marked or shielded sides face out.
○Press in the bearings until they are bottomed.
Special Tool - Bearing Driver Set: 57001-1129
• Replace the circlips and oil seals with new ones.
• Press in the oil seals [A] so that the seal surface is flush
[B] with the end of the hole.
Special Tool - Bearing Driver set: 57001-1129 [C]
• Apply high temperature grease to the oil seal lips.
Hub Bearing Inspection
NOTE
○It is not necessary to remove any bearings for inspec-
tion. If any bearings are removed, they will need to be
replaced with new ones.
• Spin [A] it by hand to check its condition.
If it is noisy, does not spin smoothly, or has any rough
spots, it must be replaced.
• Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Hub Bearing Lubrication
Halaman 187
Hub Bearings
Hub Bearing Lubrication
NOTE
○Since the hub bearings are packed with grease and
sealed, lubrication is not required.
WHEELS/TIRES 9-13
Final Drive
Halaman 189
FINAL DRIVE 10-1
# Final Drive
## Table of Contents
* Exploded View .................................................................... 10-2
* Specifications ..................................................................... 10-4
* Special Tool ....................................................................... 10-5
* Drive Chain ........................................................................ 10-6
* Drive Chain Slack Inspection ........................................... 10-6
* Drive Chain Slack Adjustment ......................................... 10-6
* Wheel Alignment Inspection ............................................ 10-6
* Wheel Alignment Adjustment .......................................... 10-6
* Drive Chain Wear Inspection ........................................... 10-6
* Drive Chain Lubrication ................................................... 10-6
* Drive Chain Removal ...................................................... 10-7
* Drive Chain Installation ................................................... 10-8
* Sprockets .......................................................................... 10-8
* Engine Sprocket Removal ............................................... 10-8
* Engine Sprocket Installation ........................................... 10-8
* Rear Sprocket Removal .................................................. 10-9
* Rear Sprocket Installation .............................................. 10-9
* Sprocket Wear Inspection .............................................. 10-9
* Rear Sprocket Warp Inspection ...................................... 10-9
10
Exploded View
Halaman 190
# 10-2 FINAL DRIVE
Exploded View
GK02199BW5 C
Exploded View
Halaman 191
FINAL DRIVE 10-3
Exploded View
| No | Fastener | N·m | Torque kgf·m | ft·lb | Remarks |
|----|-------------------------|-----|--------------|-----------|---------|
| 1 | Rear Sprocket Nuts | 32 | 3.3 | 24 | R |
| 2 | Drive Chain Cover Bolts | 8.8 | 0.90 | 78 in·lb | |
3. Engine Sprocket
4. Output Shaft
5. Chain Guide
6. Chain Slipper
7. Swingarm
8. Chain Guide
9. Locknut
10. Adjusting Bolt
11. Chain Adjuster
12. Drive Chain
13. Rear Sprocket
14. Upper Chain Guide Roller
15. Lower Chain Guide Roller
16. KLX140A8F ~ A9F/B8F ~ B9F
G: Apply grease.
HO: Apply heavy oil.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Specifications
Halaman 192
# 10-4 FINAL DRIVE
## Specifications
| Item | Standard | Service Limit |
| :-------------------- | :-------------------------------------- | :---------------------------- |
| **Drive Chain** | | |
| Chain Slack | 35 ~ 41 mm (1.4 ~ 1.6 in.) | --- |
| Chain 20-link Length | 254.0 ~ 254.6 mm (10.00 ~ 10.02 in.) | 260 mm (10.2 in.) |
| Standard Chain: | | |
| Make | DAIDO | --- |
| Type | DID428H | --- |
| Length| (KLX140A) 122 Links<br>(KLX140B) 126 Links | --- |
| **Sprocket** | | |
| Rear Sprocket Warp | TIR 0.4 mm (0.016 in.) or less | TIR 0.5 mm (0.020 in.) |
Special Tool
Halaman 193
Special Tool
Outside Circlip Pliers:
57001-144
FINAL DRIVE 10-5
Drive Chain Removal
Halaman 194
10-6 FINAL DRIVE
Drive Chain
Drive Chain Slack Inspection
• Refer to the Drive Chain Slack Inspection in the Periodic
Maintenance chapter.
Drive Chain Slack Adjustment
• Refer to the Drive Chain Slack Adjustment in the Periodic
Maintenance chapter.
Wheel Alignment Inspection
• Check that the rear end [A] of the chain adjuster aligns
with the same swing arm mark [B] as the other side ad-
juster.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.
Wheel Alignment Adjustment
• This procedure is the same as Drive Chain Slack Adjust-
ment (see Drive Chain Slack Adjustment in the Periodic
Maintenance chapter).
Drive Chain Wear Inspection
• Refer to the Drive Chain Wear Inspection in the Periodic
Maintenance chapter.
Drive Chain Lubrication
• Refer to the Drive Chain Lubrication in the Periodic Main-
tenance chapter.
Drive Chain Removal
• Remove the bolts [A] with the collar and the engine
sprocket cover [B] with the chain guide [C].
• Remove the clip [A] from the master link using pliers, and
remove the chain from the rear sprocket.
• Take the chain off the motorcycle.
Drive Chain Installation
Halaman 195
Drive Chain
Drive Chain Installation
WARNING
For safety, use only the standard chain.
• Fit the drive chain back onto the sprockets with the ends
at the rear sprocket.
• Install the master link from the frame side.
• Install the clip [A] so that the closed end of the "U" points
in the direction of chain rotation [B]. (The open end of the
"U" points in the reverse direction of chain rotation).
• Adjust the drive chain slack (see Drive Chain Slack Ad-
justment in the Periodic Maintenance chapter).
• Check the brake for good braking power, and no brake
drag.
WARNING
A rear brake that cannot be fully operated with the
pedal can cause a crash resulting in serious injury
or death. If a full brake pedal is not obtained, disas-
semble and inspect the brake parts for wear. Worn
brake parts diminish brake performance, can dam-
age brake components and lead to brake failure or
cause the brake to lock, resulting in a crash that
may cause serious injury or death.
FINAL DRIVE 10-7
Rear Sprocket Removal
Halaman 196
10-8 FINAL DRIVE
Sprockets
Engine Sprocket Removal
• Remove:
Drive Chain Cover Bolts [A] with Collar
Drive Chain Cover [B]
Drive Chain Guide [C]
• Remove the circlip [A] and the engine sprocket [B] with
the drive chain [C].
Special Tool - Outside Circlip Pliers: 57001-144
• Take off the sprocket from the chain.
Engine Sprocket Installation
• Replace the O-ring with a new one, and install the collar
[A].
• Install the engine sprocket [B] so that the marked [C] side
faces outward.
• Replace the circlip with a new one.
• Install the drive chain cover with the chain guide.
○Run the neutral switch lead [A] to between [B] the ribs of
the chain guide [C].
Torque - Drive Chain Cover Bolts : 8.8 N·m (0.90 kgf·m, 78
in·lb)
Rear Sprocket Removal
• Remove the rear wheel (see Rear wheel Removal in the
Wheels/Tires chapter).
NOTICE
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
• Unscrew the rear sprocket nuts [A], and remove the rear
sprocket [B].
Rear Sprocket Warp Inspection
Halaman 197
Sprockets
Rear Sprocket Installation
• Install the rear sprocket [A] so that the marked [B] side
faces outward.
• Replace the rear sprocket nuts with new ones.
• Install the rear sprocket nuts.
Torque - Rear Sprocket Nuts: 32 N·m (3.3 kgf·m, 24 ft·lb)
Sprocket Wear Inspection
• Refer to the Sprocket Wear Inspection in the Periodic
Maintenance chapter.
Rear Sprocket Warp Inspection
• Refer to the Rear Sprocket Warp Inspection in Periodic
Maintenance chapter.
FINAL DRIVE 10-9
Brakes
Halaman 199
Brakes
Table of Contents
Exploded View........................................................................................................................
11-2
Specifications .........................................................................................................................
11-6
Special Tool ............................................................................................................................
11-7
Brake Lever, Brake Pedal.......................................................................................................
11-8
Brake Lever Adjustment....................................................................................................
11-8
Brake Pedal Position Adjustment......................................................................................
11-8
Brake Pedal Removal .......................................................................................................
11-8
Brake Pedal Installation ....................................................................................................
11-8
Brake Fluid .............................................................................................................................
11-9
Fluid Level Inspection .......................................................................................................
11-9
Fluid Change.....................................................................................................................
11-9
Bleeding the Brake Line....................................................................................................
11-10
Calipers ..................................................................................................................................
11-12
Caliper Removal ...............................................................................................................
11-12
Caliper Installation ............................................................................................................
11-12
Caliper Disassembly .........................................................................................................
11-13
Fluid Seal Damage ...........................................................................................................
11-13
Dust Seal and Cover Damage ..........................................................................................
11-13
Piston Cylinder Damage ...................................................................................................
11-13
Caliper Holder Shaft Wear................................................................................................
11-13
Brake Pad Inspection........................................................................................................
11-13
Master Cylinder ......................................................................................................................
11-14
Front Master Cylinder Removal ........................................................................................
11-14
Front Master Cylinder Installation .....................................................................................
11-14
Rear Master Cylinder Removal.........................................................................................
11-14
Rear Master Cylinder Installation......................................................................................
11-15
Front Master Cylinder Disassembly..................................................................................
11-15
Rear Master Cylinder Disassembly...................................................................................
11-15
Master Cylinder Assembly ................................................................................................
11-15
Master Cylinder Inspection (Visual Inspection).................................................................
11-16
Brake Disc ..............................................................................................................................
11-17
Brake Disc Removal ........................................................................................................
11-17
Brake Disc Installation .....................................................................................................
11-17
Brake Disc Inspection .......................................................................................................
11-17
Brake Hose.............................................................................................................................
11-18
Brake Hose Removal/Installation......................................................................................
11-18
Brake Hose Inspection......................................................................................................
11-18
BRAKES 11-1
11
Exploded View
Halaman 200
11-2 BRAKES
Exploded View
GL02325BWS C
Exploded View
Halaman 201
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Front Master Cylinder Clamp Bolts
8.8
0.90
78 in·lb
S
2
Brake Hose Banjo Bolts
25
2.5
18
3
Brake Pad Bolts
17
1.7
13
4
Caliper Bleed Valve
7.8
0.80
69 in·lb
5
Front Caliper Mounting Bolts
34
3.5
25
6
Brake Disc Mounting Bolts
9.8
1.0
87 in·lb
L
7
Brake Lever Pivot Bolt Locknut
5.9
0.60
52 in·lb
8
Brake Lever Pivot Bolt
5.9
0.60
52 in·lb
Si
9
Brake Reservoir Cap Screws
1.5
0.15
13 in·lb
10
Brake Lever Adjuster Locknut
5.9
0.60
52 in·lb
11. Front Brake Reservoir
12. Brake Lever
13. Brake Lever Adjuster
14. Brake Hose
15. Front Caliper
16. Brake Pad
17. Piston
18. Front Disc
B: Apply brake fluid.
L: Apply a non-permanent locking agent.
R: Replacement Parts.
S: Tighten the fasteners following the specified sequence.
Si: Apply Silicone grease.
BRAKES 11-3
Exploded View
Halaman 202
# 11-4 BRAKES
## Exploded View
* 9
* A
* 11
* 2
* 12
* 7 G L
* R G
* B
* Si
* 3
* R
* 5
* 13
* 4 L
* 14
* Si
* 6
* 15
* 16
* 8 L
* 1
* R
* A
* 10
GL02326BWS C
Exploded View
Halaman 203
BRAKES 11-5
Exploded View
| No. | Fastener | Torque | Re-marks |
|-----|-------------------------------------|---------------------------------------|----------|
| | | N·m | kgf·m | ft·lb | |
| 1 | Brake Hose Banjo Bolts | 25 | 2.5 | 18 | |
| 2 | Rear Master Cylinder Mounting Bolts | 10 | 1.0 | 89 in·lb | |
| 3 | Rear Master Cylinder Push Rod Locknut | 17 | 1.7 | 13 | |
| 4 | Caliper Bleed Valve | 7.8 | 0.80 | 69 in·lb | L |
| 5 | Brake Pad Bolts | 17 | 1.7 | 13 | |
| 6 | Rear Caliper Mounting Bolts | 25 | 2.5 | 18 | |
| 7 | Brake Pedal Pivot Bolt | 25 | 2.5 | 18 | G,L |
| 8 | Brake Disc Mounting Bolts | 9.8 | 1.0 | 87 in·lb | L |
| 9 | Brake Reservoir Cap Bolts | 1.5 | 0.15 | 13 in·lb | |
10. Brake Hose
11. Rear Master Cylinder
12. Brake Pedal
13. Rear Caliper
14. Piston
15. Brake Pads
16. Rear Disc
B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Apply Silicone grease.
Specifications
Halaman 204
## 11-6 BRAKES
### Specifications
| Item | Standard | Service Limit |
| :------------------------ | :---------------------------------------- | :--------------------------------- |
| **Brake Adjustment** | | |
| Lever/Pedal Free Play | Adjustable (to suit rider) | – – – |
| **Brake Fluid** | | |
| Recommended Type: | DOT3 or DOT4 | – – – |
| Front/Rear | | |
| **Brake Pads** | | |
| Lining thickness: | | |
| Front | 4.5 mm (0.18 in.) | 1 mm (0.04 in.) |
| Rear | 3.7 mm (0.15 in.) | 1 mm (0.04 in.) |
| **Brake Discs** | | |
| Thickness: | | |
| Front/Rear | 2.85 ~ 3.15 mm (0.112 ~ 0.124 in.) | 2.5 mm (0.10 in.) |
| Runout: | | |
| Front/Rear | TIR 0.15 mm (0.0059 in.) or less | TIR 0.3 mm (0.01 in.) |
Special Tool
Halaman 205
Special Tool
Jack:
57001-1238
BRAKES 11-7
Brake Pedal Installation
Halaman 206
11-8 BRAKES
Brake Lever, Brake Pedal
Brake Lever Adjustment
• Refer to the Brake Lever and Pedal Position Adjustment
in the Periodic Maintenance chapter.
Brake Pedal Position Adjustment
• Refer to the Brake Lever and Pedal Position Adjustment
in the Periodic Maintenance chapter.
Brake Pedal Removal
• Remove:
Cotter Pin [A]
Joint Pin [B] with Washer
• Remove the mounting bolt [C] and take off the brake pedal
and the return spring [D].
Brake Pedal Installation
• Replace the O-rings [A] with a new one.
• Apply grease to the O-rings and the shaft portion [B] of
the brake pedal pivot bolt.
• Apply a non-permanent locking agent to the thread [C].
• Install the brake pedal with the return spring [A] as shown.
Torque - Brake Pedal Pivot Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
• Check the brake pedal position.
• Install the joint pin, washer and a new cotter pin.
○Bend the ends of the cotter pin along the circumference.
Fluid Change
Halaman 207
Brake Fluid
WARNING
When working with the disc brake, observe the pre-
cautions listed below.
1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been left
unsealed or that has been open for a long time.
3. Do not mix two types and brands of fluid for use in
the brake. This lowers the brake fluid boiling point
and could cause the brake to be ineffective. It may
also cause the rubber brake parts to deteriorate.
4. Don’t leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
5. Don’t change the fluid in the rain or when a strong
wind is blowing.
6. Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid for cleaning these parts. Gasoline, engine oil,
or any other petroleum distillate will cause deterio-
ration of the rubber parts. Oil spilled on any part will
be difficult to wash off completely and will eventually
deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful that
no disc brake fluid or any oil gets on them. Clean
off any fluid or oil that inadvertently gets on the pads
or disc with high-flash point solvent. Do not use one
which will leave an oily residue. Replace the pads
with new ones if they cannot be cleaned satisfacto-
rily.
8. Brake fluid quickly ruins painted surfaces;
any
spilled fluid should be completely wiped up imme-
diately.
9. If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.
Fluid Level Inspection
• Refer to the Brake Fluid Level Inspection in the Periodic
Maintenance chapter.
Fluid Change
• Refer to the Brake Fluid Change in the Periodic Mainte-
nance chapter.
BRAKES 11-9
Bleeding the Brake Line
Halaman 208
11-10 BRAKES
Brake Fluid
Bleeding the Brake Line
The brake fluid has a very low compression coefficient so
that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.
WARNING
Air in the brake lines diminish braking performance
and can cause an accident resulting in injury or
death.
If the brake lever or pedal has a soft or
"spongy" feeling mushy when it is applied, there
might be air in the brake lines or the brake may be
defective. Do not operate the vehicle and service
the brake system immediately.
NOTE
○The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front
brake.
• Remove the reservoir cap [A], and check that there is
plenty of fluid in the reservoir.
• With the reservoir cap off, slowly pump the brake lever
several times until no air bubbles can be seen rising up
through the fluid from the holes at the bottom of the reser-
voir.
○Bleed the air completely from the master cylinder by this
operation.
• Install the reservoir cap.
• Attach a clear plastic hose [A] to the bleed valve [B] on the
caliper, and run the other end of the hose into a container.
Bleeding the Brake Line
Halaman 209
Brake Fluid
• Bleed the brake line and the caliper as follows:
○Repeat this operation until no more air can be seen com-
ing out into the plastic hose.
1. Pump the brake lever until it becomes hard, and apply
the brake [C] and hold it.
2. Quickly open and close [D] the bleed valve while holding
the brake applied.
3. Release the brake [E].
NOTE
○The fluid level must be checked often during the bleed-
ing operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs almost out
any time during bleeding operation, the bleeding opera-
tion must be done over again from the beginning since
air will have entered the line.
○Tap the brake hose lightly from the caliper to the reser-
voir for easier bleeding.
• Remove the clear plastic hose.
• Tighten the bleed valve, and install the rubber cap.
Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
• Check the fluid level.
• After bleeding is done, check the brake for good braking
power, no brake drag and no fluid leakage.
WARNING
After servicing, it takes several applications of the
brake lever or pedal before the brake pads contact
the disc, which could result in increased stopping
distance and cause an accident resulting in injury
or death. Do not attempt to ride the motorcycle until
a firm brake lever or pedal is obtained by pumping
the lever or pedal until the pads are against the disc.
BRAKES 11-11
Caliper Installation
Halaman 210
11-12 BRAKES
Calipers
Caliper Removal
Front Brake:
Loosen the brake pad bolts [A] when you disassemble the
caliper.
• Loosen the banjo bolt [B] so as not to spill brake fluid.
• Remove the caliper mounting bolts [C].
NOTE
○If the caliper is to be disassembled after removal and if
compressed air is not available, remove the piston us-
ing the following steps before disconnecting the brake
hose [D] from the caliper.
○Remove the pads and springs.
○Apply the brake to remove the piston.
• Remove the banjo bolt and take off the brake hose [D]
from the caliper.
Rear Brake:
Loosen the brake pad bolts [A] when you disassemble the
caliper.
• Loosen the banjo bolt [B] so as not to spill brake fluid.
• Remove the caliper mounting bolts [C].
NOTE
○If the caliper is to be disassembled after removal and if
compressed air is not available, remove the piston us-
ing the following steps before disconnecting the brake
hose [D] from the caliper.
○Remove the pads and springs.
○Apply the brake to remove the piston.
• Unscrew the banjo bolt and remove the brake hose [D]
from the caliper.
NOTICE
Immediately wipe up any brake fluid that is spilled.
Caliper Installation
• Tighten the brake pad bolts if it was removed.
Torque - Brake Pad Bolts: 17 N·m (1.7 kgf·m, 13 ft·lb)
• Install the caliper and tighten the bolts.
Torque - Front Caliper Mounting Bolts: 34 N·m (3.4 kgf·m,
25 ft·lb)
Rear Caliper Mounting Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
• Install the brake hose lower end.
○Replace the washers that are on each side of hose fitting
with new ones.
Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
Brake Pad Inspection
Halaman 211
Calipers
• Bleed the brake line (see Bleeding the Brake Line).
• Check the brake for good braking power, no brake drag
and no fluid leakage.
WARNING
After servicing, it takes several applications of the
brake lever or pedal before the brake pads contact
the disc, which could result in increased stopping
distance and cause an accident resulting in injury
or death. Do not attempt to ride the motorcycle until
a firm brake lever or pedal is obtained by pumping
the lever or pedal until the pads are against the disc.
Caliper Disassembly
• Refer to the Caliper Piston Seal and Dust Seal Replace-
ment in the Periodic Maintenance chapter.
Fluid Seal Damage
The fluid seal around the piston maintains the proper
pad/disc clearance.
If this seal is not in good condition,
pad wear will increase, and constant pad drag on the disc
will raise brake and brake fluid temperature.
• Replace the fluid seals under any of the following condi-
tions: (a) fluid leakage around the pad; (b) brakes over-
heat; (c) there is a large difference in left and right pad
wear; (d) the seal is stuck to the piston. If the fluid seal is
replaced, replace the dust seal as well. Also, replace all
seals every other time the pads are changed.
Dust Seal and Cover Damage
• Check that the dust seals and covers are not cracked,
worn, swollen, or otherwise damaged.
If they show any damage, replace them.
Piston Cylinder Damage
• Visually inspect the piston and cylinder surfaces.
Replace the cylinder and piston if they are badly scored
or rusty.
Caliper Holder Shaft Wear
The caliper body must slide smoothly on the caliper holder
shafts. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and con-
stant drag on the disc will raise brake and brake fluid tem-
perature.
• Check to see if the caliper holder shafts are not badly worn
or stepped, or the rubber friction boot is not damaged.
If the shafts or rubber friction boot are damaged, replace
the shafts, rubber friction boot, and the caliper holder.
Brake Pad Inspection
• Refer to the Brake Pad Wear Inspection in the Periodic
Maintenance chapter.
BRAKES 11-13
Rear Master Cylinder Removal
Halaman 212
11-14 BRAKES
Master Cylinder
Front Master Cylinder Removal
• Remove the banjo bolt [A] to disconnect the upper brake
hose [B] from the master cylinder [C].
• When removing the brake hose, temporarily secure the
end of the brake hose to some high place to keep fluid
loss to a minimum.
• Unscrew the clamp bolts [A], and take off the master cylin-
der [B] as an assembly with the reservoir and brake lever.
Front Master Cylinder Installation
• The master cylinder clamp must be installed with the “UP”
mark [A] upward.
○Align the punch mark on the handlebar and the master
cylinder mating surface.
○Tighten the upper clamp bolt [B] first, and then the lower
clamp bolt [C]. There will be a gap at the lower part of the
clamp after tightening.
Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.90
kgf·m, 78 in·lb)
• Replace the washers that are on each side of hose fitting
with new ones.
• Tighten the brake hose banjo bolt.
Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
• Bleed the brake line (see Bleeding the Brake Line).
• Check the brake for good braking power, no brake drag,
and no fluid leakage.
Rear Master Cylinder Removal
• Remove the cotter pin [A].
• Pull off the joint pin [B] with the washer.
NOTE
○Pull off the joint pin while pressing down the brake
pedal.
• Unscrew the master cylinder mounting bolts [C], and re-
move the master cylinder [D].
Master Cylinder Assembly
Halaman 213
Master Cylinder
• Unscrew the brake hose banjo bolt [A].
• When removing the brake hose, temporarily secure the
end of the brake hose to some high place to keep fluid
loss to a minimum.
Rear Master Cylinder Installation
• Replace the cotter pin with a new one.
• Replace the washers are on each side of hose fitting with
new ones.
• Tighten the following:
Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
Rear Master Cylinder Mounting Bolts: 10 N·m (1.0
kgf·m, 89 in·lb)
• Bleed the brake line (see Bleeding the Brake Line).
• Check the brake for good braking power, no brake drag
and no fluid leakage.
• Check the brake pedal position (see Brake Lever and
Pedal Position Adjustment in the Periodic Maintenance
chapter).
Front Master Cylinder Disassembly
• Refer to the Brake Master Cylinder Cup and Dust Seal
Replacement in the Periodic Maintenance chapter.
Rear Master Cylinder Disassembly
• Refer to the Brake Master Cylinder Cup and Dust Seal
Replacement in the Periodic Maintenance chapter.
Master Cylinder Assembly
• Refer to the Brake Master Cylinder Cup and Dust Seal
Replacement in the Periodic Maintenance chapter.
BRAKES 11-15
Master Cylinder Inspection (Visual Inspection)
Halaman 214
11-16 BRAKES
Master Cylinder
Master Cylinder Inspection (Visual Inspection)
• Disassemble the front and rear master cylinders.
• Check that there are no scratches, rust or pitting on the
inner wall of each master cylinder [A] and on the outside
of each piston [B].
If a master cylinder or piston shows any damage, replace
them.
• Inspect the primary [C] and secondary [D] cups.
If a cup is worn, damaged, softened (rotted), or swollen,
the piston assembly should be replace to renew the cups.
If fluid leakage is noted at the brake lever, the piston as-
sembly should be replaced to renew the cup.
• Check the dust covers [E] for damage.
If they are damaged, replace them.
• Check the piston return springs [F] for any damage.
If a spring is damaged, replace it.
• Check that the relief [G] and supply [H] ports are not
plugged.
If the small relief port becomes plugged, the brake pads
will drag on the disc.
Blow the ports clean with com-
pressed air.
[J] Front Master Cylinder
[K] Rear Master Cylinder
Brake Disc Inspection
Halaman 215
Brake Disc
Brake Disc Removal
• Remove the wheel (see Front/Rear Wheel Removal in the
Wheels/Tires chapter).
• Unscrew the mounting bolts [A], and take off the disc [B].
Brake Disc Installation
• Install the disc on the wheel so that the mark [A] faces out.
• Apply a non-permanent locking agent to the threads of
the brake disc bolts [B].
• Tighten:
Torque - Brake Disc Mounting bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
Brake Disc Inspection
• Visually inspect the disc [A].
If it is scratched or damaged, replace the disc.
• Measure the thickness of each disc at the point where it
has worn the most.
Measuring Area [B]
Replace the disc if it has worn past the service limit.
Brake Disc Thickness
Standard:
2.85 ∼3.15 mm (0.112 ∼0.124 in.)
Service Limit:
2.5 mm (0.10 in.)
• Raise the front/rear wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
• Set up a dial gauge against the disc [A] as shown.
○For the front disc, turn the handlebar fully to one side.
• Measure the disc runout while rotating the wheel slowly
[B].
If the runout exceeds the service limit, replace the disc.
Brake Disc Runout
Standard:
TIR 0.15 mm (0.0059 in.) or less
Service Limit: TIR 0.3 mm (0.01 in.)
BRAKES 11-17
Brake Hose Inspection
Halaman 216
11-18 BRAKES
Brake Hose
Brake Hose Removal/Installation
• Refer to the Brake Hose Replacement in the Periodic
Maintenance chapter.
Brake Hose Inspection
• Refer to the Brake Hose and Connection Check in the
Periodic Maintenance chapter.
Suspension
Halaman 217
Suspension
Table of Contents
Exploded View........................................................................................................................
12-2
Specifications .........................................................................................................................
12-6
Special Tools ..........................................................................................................................
12-7
Front Fork...............................................................................................................................
12-8
Front Fork Oil Change ......................................................................................................
12-8
Front Fork Removal ..........................................................................................................
12-8
Front Fork Installation .......................................................................................................
12-9
Front Fork Disassembly (each fork leg)............................................................................
12-9
Front Fork Assembly.........................................................................................................
12-11
Inner Tube Inspection .......................................................................................................
12-12
Guide Bush Inspection......................................................................................................
12-12
Oil Seal Inspection............................................................................................................
12-12
Spring Tension Inspection.................................................................................................
12-12
Rear Suspension (Uni-Trak)...................................................................................................
12-13
Rear Shock Absorber: .........................................................................................................
12-13
Rebound Damping Adjustment (KLX140B) ......................................................................
12-13
Compression Damping Adjustment (KLX140B)................................................................
12-13
Spring Preload Adjustment (KLX140A).............................................................................
12-14
Spring Preload Adjustment (KLX140B).............................................................................
12-14
Spring Tension ..................................................................................................................
12-15
Rear Shock Absorber Removal ........................................................................................
12-15
Rear Shock Absorber Installation .....................................................................................
12-16
Spring Replacement .........................................................................................................
12-16
Rear Shock Absorber Scrapping ......................................................................................
12-17
Swingarm................................................................................................................................
12-18
Swingarm Removal...........................................................................................................
12-18
Swingarm Installation........................................................................................................
12-19
Swingarm Bearing Removal .............................................................................................
12-19
Swingarm Bearing Installation ..........................................................................................
12-19
Swingarm Bearing, Sleeve Inspection ..............................................................................
12-19
Drive Chain Guide, Guide Roller, Chain Slipper Wear......................................................
12-19
Tie-Rod, Rocker Arm..............................................................................................................
12-20
Tie-Rod Removal ..............................................................................................................
12-20
Tie-Rod Installation ...........................................................................................................
12-20
Rocker Arm Removal........................................................................................................
12-20
Rocker Arm Installation.....................................................................................................
12-21
Tie-Rod and Rocker Arm Bearing Removal......................................................................
12-21
Tie-Rod and Rocker Arm Bearing Installation...................................................................
12-22
Needle Bearing Inspection................................................................................................
12-22
Uni-Trak Maintenance ............................................................................................................
12-23
Uni-Trak Linkage Inspection .............................................................................................
12-23
Tie-Rod and Rocker Arm Sleeve Wear.............................................................................
12-23
Tie-Rod and Rocker Arm Mounting Bolt Bend..................................................................
12-23
SUSPENSION 12-1
12
Exploded View
Halaman 218
# 12-2 SUSPENSION
## Exploded View
- 1
- 2
- 3
- 4
- 5 L
- 6
- 7
- 8
- 9
- 10
- 11
- 12
- 13
- 14
- 15
- 16
- 17
- 18
- 19
- 20
- 21
GM02224BW5 C
Exploded View
Halaman 219
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Front Fork Clamp Bolt (Upper)
20
2.0
15
2
Front Fork Clamp Bolt (Lower)
25
2.5
18
3
Steering Stem Head Nut
64
6.5
47
4
Fork Top Bolt
22.5
2.3
17
5
Fork Bottom Bolt
20
2.0
15
L
6. O-ring
7. Collar
8. Spring Seat
9. Spring
10. Retaining Ring
11. Oil Seal
12. Spacer
13. Bushing
14. Cylinder
15. Piston Ring
16. Rebound Spring
17. Cylinder Base
18. Inner Tube
19. Bushing
20. Outer Tube
21. Gasket
22. Dust Seal
23. Inner Tube
24. O-ring
25. Gasket
26. Steering Stem Head
27. Steering Stem
L: Apply a non-permanent locking agent to the threads.
R: Replacement Parts
SUSPENSION 12-3
Exploded View
Halaman 220
12-4 SUSPENSION
Exploded View
Exploded View
Halaman 221
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Swingarm Pivot Shaft Nut
108
11
80
2
Rocker Arm Pivot Nut
59
6.0
44
R
3
Tie-rod Mounting Nuts
59
6.0
44
R
4
Rear Shock Absorber Mounting Bolt (Upper)
39
4.0
29
5
Rear Shock Absorber Mounting Bolt (Lower)
39
4.0
29
6
Rear Shock Absorber Mounting Nut (Lower)
29
3.0
21
R
7. Swingarm Pivot Shaft
8. Swingarm
9. Rocker Arm
10. Tie-Rod
11. KLX140A model
12. KLX140B model
G: Apply grease.
SUSPENSION 12-5
Specifications
Halaman 222
12-6 SUSPENSION
Specifications
Item
Standard
Service Limit
Front Fork
Air Pressure
Atmospheric pressure
– – –
Rebound Damping Adjustment
Non-Adjustable
– – –
Compression Damping Adjustment
Non-Adjustable
– – –
Fork Oil:
Type
SHOWA SS-8 or equivalent
– – –
Viscosity
SAE 10W-20
– – –
Capacity
(KLX140A) 296 ±2.5 mL (10.01 ±0.085
US oz)
(KLX140B) 290 ±2.5 mL (9.80 ±0.085
US oz)
Level
(KLX140A) 95 ±2 mm (3.74 ±0.08 in.)
– – –
(fully compressed, without spring) (KLX140B) 105 ±2 mm (4.13 ±0.08 in.)
– – –
Fork Spring Free Length
391.6 mm (15.42 in.)
384 mm (15.1 in.)
Rear Suspension (Uni-Trak):
Rear Shock Absorber
Rebound Damping Adjustment
(KLX140A) Non-Adjustable
– – –
(KLX140B) 10 clicks counterclockwise
(from the seated position adjuster
turned fully clockwise)
Spring Preload Adjustment
(KLX140A) 2nd step
(from the seated position adjuster
turned fully clockwise)
(Adjustable Range)
68.2 ∼101.2 mm
(2.685 ∼3.984 in.)
Spring Free Length
(KLX140A) 244.3 mm (9.62 in.)
(KLX140B) 252.0 mm (10.04 in.)
(KLX140B) 80.7 mm (3.18 in.)
(Adjusting nut lowersurface form the
mounting bolt pivot)
239 mm (9.41 in.)
247 mm (9.72 in.)
Gas Reservoir
Compression Damping
Adjustment
(KLX140A) Non-Adjustable
– – –
(KLX140B) 2nd position
(Adjustable Range)
4 positions
Gas Pressure
1 000 kPa (10 kgf/cm², 145 psi)
– – –
Tie-Rod, Rocker Arm
Sleeve Outside Diameter:
Tie-rod
19.979 ∼20.000 mm
(0.78657 ∼0.78740 in.)
Rocker Arm:
Large (to Swingarm)
19.979 ∼20.000 mm
(0.78657 ∼0.78740 in.)
Middle (to Tie-rod)
17.989 ∼18.000 mm
(0.70823 ∼0.70866 in.)
Small (to Shock Absorber)
15.950 ∼16.000 mm
(0.62795 ∼0.62992 in.)
Rocker Arm Mounting Bolt
Runout
TIR 0.1 mm (0.004 in.) or less
TIR 0.2 mm (0.008
in.)
– – –
– – –
(Adjustable Range)
20 clicks
(Adjustable Range)
5 steps
19.85 mm (0.781 in.)
19.85 mm (0.781 in.)
17.96 mm (0.707 in.)
15.92 mm (0.627 in.)
Special Tools
Halaman 223
Special Tools
Fork Cylinder Holder Handle:
57001-183
Fork Cylinder Holder Adapter:
57001-1011
Oil Seal & Bearing Remover:
57001-1058
Bearing Driver Set:
57001-1129
Front Fork Oil Seal Driver:
57001-1219
SUSPENSION 12-7
Jack:
57001-1238
Bearing Remover Shaft,
9:
57001-1265
Bearing Remover Head,
15 ×
17:
57001-1267
Hook Wrench T=3.2 R37:
57001-1522
Hook Wrench T=3.2 R35:
57001-1523
Front Fork Removal
Halaman 224
12-8 SUSPENSION
Front Fork
Front Fork Oil Change
• Refer to the Front Fork Oil Change in the Periodic Main-
tenance chapter.
Front Fork Removal
• Remove:
Number Plate [A]
Brake Hose Clamp (Lower) [B]
Front
Wheel
(see
Front
Wheel
Removal
in
the
Wheels/Tires chapter)
Front Caliper (see Front Caliper Removal in the Brake
chapter)
• Put the caliper [A] on a suitable stand [B].
• Loosen the upper [A] and lower [B] fork clamp bolts.
• Pull out to downward the fork leg [A] with a twisting motion
[B].
Front Fork Disassembly (each fork leg)
Halaman 225
Front Fork
Front Fork Installation
• Install the fork, and align the brim of the fork top plug [A]
to the upper surface of the upper fork clamp [B].
• Route the cables and hose according to the Cable, Har-
ness and Hose Routing section in the Appendix chapter.
• Install the front wheel (see Front Wheel Installation in the
Wheels/Tires chapter).
• Tighten the fork clamp bolts.
Torque - Front Fork Clamp Bolt (Upper): 20 N·m (2.0 kgf·m,
15 ft·lb)
Front Fork Clamp Bolt (Lower): 25 N·m (2.5 kgf·m,
18 ft·lb)
• Install the other removed parts.
• Check the front brake operation after installation.
Front Fork Disassembly (each fork leg)
• Loosen the front fork upper clamp bolts [A].
• Loosen the top plug [B].
• Remove the front fork (see Front Fork Removal).
• Thoroughly clean the fork before disassembly.
NOTICE
Be careful not scratch the inner tube and not to
damage the dust seal.
Avoid scratching or damaging the inner tube or the
dust seal. Use a mild detergent and sponge out dirt
with plenty of water.
• Loosen the clamp screw [A], and pull out the fork boot [B].
• Remove:
Top Plug [A] with O-ring
Spring Collar [B]
Washer [C]
Fork Spring [D]
SUSPENSION 12-9
Front Fork Disassembly (each fork leg)
Halaman 226
12-10 SUSPENSION
Front Fork
• Prepare a drain pan [A] and drain the fork oil.
NOTE
○Pump the fork tube several times to discharge the oil.
• Remove the Allen bolt [A] from the bottom of the fork.
Special Tools - Fork Cylinder Holder Handle [B]: 57001-183
Fork Cylinder Holder Adapter [C]: 57001
-1011
NOTE
○Hold the outer tube in a vise [D], stop the cylinder unit
[E] from turning by using the special tools, and unscrew
the Allen bolt.
• Remove:
Cylinder [A]
Piston Ring [B]
Rebound Spring [C]
• Remove the retaining ring [A].
• Separate the inner tube [A] and the outer tube [B].
NOTE
○From the compressed state, firmly pull down the outer
tube a few times towards the direction of elongation.
Front Fork Assembly
Halaman 227
Front Fork
• Remove the following parts from the inner tube.
Guide Bushings [A] [B]
Washer [C]
Oil Seal [D]
• Remove the cylinder base from the outer tube.
Front Fork Assembly
• When the fork tubes are not disassembled, hold the fork
inverted position for more than 20 minutes to allow the
fork oil to fully drain.
• Insert the cylinder and the rebound spring into the inner
tube.
• Install the cylinder base to the cylinder that protruded from
the inner tube.
• Replace the following parts with new ones:
Oil Seal
Washer
Guide Bushing
• Insert the inner tube into the outer tube.
• Apply a non-permanent locking agent to the fork bottom
bolt and tighten it using the fork cylinder holder.
Special Tools - Fork Cylinder Holder Handle: 57001-183
Fork Cylinder Holder Adapter: 57001-1011
Torque - Fork Bottom Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb)
• Install the oil seal [A] using the fork oil seal driver [B] until
it stops.
Tap the driver strongly.
Special Tool - Fork Oil Seal Driver: 57001-1219
• Install:
Retaining Ring
Spring (turn the small diameter side downward)
Washer
Collar
• Fill the fork oil (see Fork Oil Change in the Periodic Main-
tenance chapter).
• Tighten the top plug.
Torque - Fork Top Bolt: 22.5 N·m (2.3 kgf·m, 17 ft·lb)
• Install the fork legs (see Front Fork Installation).
SUSPENSION 12-11
Spring Tension Inspection
Halaman 228
12-12 SUSPENSION
Front Fork
Inner Tube Inspection
• Visually inspect the inner tube [A], repair any damage.
• Nick or rust damage can sometimes be repaired by using
a wet-stone to remove sharp edges or raised areas which
cause seal damage.
If the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repaired
or replaced.
• Temporarily assemble the inner [A] and outer tube [B], and
pump them back and forth manually to check for smooth
operation.
NOTICE
If the inner tube is badly bent or creased, replace
it.
Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
Guide Bush Inspection
• Visually inspect the guide bushings [A], and replace them
if necessary.
Oil Seal Inspection
• Replace the oil seal [A] with a new one whenever it has
been removed.
Spring Tension Inspection
• Since a spring becomes shorter as it weakens, check its
free length [A] to determine its condition.
If the spring of either fork leg is shorter than the service
limit, it must be replaced. If the length of a replacement
spring and that of the remaining spring vary greatly, the
remaining spring should also be replaced in order to keep
the fork legs balanced from motorcycle stability.
Fork Spring Free Length
Standard:
391.6 mm (15.42 in.)
Service Limit: 384 mm (15.1 in.)
Compression Damping Adjustment (KLX140B)
Halaman 229
Rear Suspension (Uni-Trak)
Rear Shock Absorber:
The rear suspension system of this motorcycle is Uni-trak.
It consists of a rear shock absorber, swingarm, tie-rod and
rocker arm.
To suit to various riding conditions, the spring preload of
the shock absorber can be adjusted or the spring can be re-
placed with an optional one. Besides KLX140B model can
adjust the damping force without changing the oil viscosity.
Rebound Damping Adjustment (KLX140B)
• Turn the rebound damping adjuster [A] on the rear shock
absorber lower end with the blade of a screwdriver until
you feel a click.
If the damper setting feels too soft or too stiff, adjust it in
accordance with the following table:
Seated position: adjuster turned fully clockwise [A].
Rebound Damping Adjustment (KLX140B)
Standard:
10 clicks [B]
Softer (Counterclockwise) [C]
Harder (Clockwise) [D]
*: Number of turns counterclockwise usable range - 20
or more.
Counterclockwise from the fully seated position.
NOTE
○Adjustment of the rebound damping adjuster for the rear
suspension will slightly affect the compression damping
force. Always make any damping adjustments in small
steps and test their effects before using them in com-
petition.
Compression Damping Adjustment (KLX140B)
• Turn the compression damping adjuster [A] with a flat
-head screwdriver.
If the damping feels too soft or too stiff, adjust it in accor-
dance with the following.
1st Position [B] (softest setting)
2nd Position [C]
3rd Position [D]
4th Position [E] (hardest setting)
Compression Damping Adjustment (KLX140B)
Standard:
2nd Position
NOTE
○Adjustment of the rebound damping adjuster for the rear
suspension will slightly affect the compression damping
force. Always make any damping adjustments in small
steps and test their effects before using them in com-
petition.
SUSPENSION 12-13
Spring Preload Adjustment (KLX140B)
Halaman 230
12-14 SUSPENSION
Rear Suspension (Uni-Trak)
Spring Preload Adjustment (KLX140A)
• Remove:
Seat (see Seat Removal in the Frame chapter)
Muffler Body (see Muffler Removal in the Engine Top
End chapter)
Rear Fender (see Rear Fender Removal in the Frame
chapter)
Air Cleaner Housing (see Air Cleaner Housing Re-
moval/Installation in the Fuel System chapter)
• Raise the rear wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
• Turn the adjusting nut [A] as required using the hook
wrench [B]. Turning the adjusting nut downward marks
the spring action harder and upward softer.
Special Tool - Hook Wrench T=3.2 R37: 57001-1522
Spring Preload Adjustment (KLX140A)
Standard:
2nd step
Adjustable Range:
5 steps
Spring Preload Adjustment (KLX140B)
• Remove:
Seat (see Seat Removal in the Frame chapter)
Muffler (see Muffler Removal in the Engine Top End
chapter)
Rear Fender (see Rear Fender Removal in the Frame
chapter)
Air Cleaner Housing (see Air Cleaner Housing Re-
moval/Installation in the Fuel System chapter)
• Raise the rear wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
• Using the hook wrenches [A], loosen the locknut [B] on
the rear shock absorber.
Special Tools - Hook Wrench T=3.2 R37: 57001-1522
Hook Wrench T=3.2 R35: 57001-1523
Rear Shock Absorber Removal
Halaman 231
Rear Suspension (Uni-Trak)
• Turn the adjusting nut [A] as required. Turning the ad-
justing nut downward marks the spring action harder and
upward softer.
Spring Preload Adjustment (KLX140B)
(Adjusting nut lower surface [A] from the mounting
bolt pivot [B])
Standard:
80.7 mm (3.18 in.)
Adjustable Range: 68.2 ∼101.2 mm (2.685 ∼3.984
in.)
• Tighten the locknut securely.
• After adjusting, move the spring up and down to make
sure that the spring is seated.
• Install the other removed parts.
Spring Tension
• Since the spring becomes shorter as it weakens, check
its free length [A] to determine its condition.
If the spring of either rear shock absorber is shorter than
the service limit, it must be replaced. If the length of re-
placement spring and that of the remaining spring vary
greatly, the remaing spring should also be replaced in or-
der to keep the rear shock absorbers balanced of motor-
cycle stability.
Shock Absorber Spring Free Length
Standard:
(KLX140A) 244.3 mm (9.62 in.)
(KLX140B) 252.0 mm (10.04 in.)
Service Limit:
(KLX140A) 239 mm (9.41 in.)
(KLX140B) 247 mm (9.72 in.)
Rear Shock Absorber Removal
• Remove:
Seat (see Seat Removal in the Frame chapter)
Muffler (see Muffler Removal in the Engine Top End
chapter)
Rear Fender (see Rear Fender Removal in the Frame
chapter)
Air Cleaner Housing (see Air Cleaner Housing Re-
moval/Installation in the Fuel System chapter)
• Raise the rear wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
SUSPENSION 12-15
Spring Replacement
Halaman 232
12-16 SUSPENSION
Rear Suspension (Uni-Trak)
NOTICE
When pulling out the mounting bolts, lift the rear
wheel slightly. Forcing or tapping on a bolt could
damage the bolt, sleeve and bearing.
• Remove the tie-rod rear mounting bolt and nut [A], and
turn the tie-rod [B] downward.
• Remove the rear shock absorber lower mounting bolt [C]
and nut.
• Remove the rear shock absorber upper mounting bolt and
take off the rear shock absorber.
Rear Shock Absorber Installation
• Pack the rocker arm needle bearings with grease.
• Tighten the following:
KLX140A
Torque - Rear Shock Absorber Mounting Bolt (Upper): 39
N·m (4.0 kgf·m, 29 ft·lb)
Rear Shock Absorber Mounting Nut (Lower): 29
N·m (3.0 kgf·m, 21 ft·lb)
Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
Tie-Rod Mounting Nut (Front): 59 N·m (6.0 kgf·m,
44 ft·lb)
KLX140B
Torque - Rear Shock Absorber Mounting Bolt (Upper): 39
N·m (4.0 kgf·m, 29 ft·lb)
Rear Shock Absorber Mounting Bolt (Lower): 39
N·m (4.0 kgf·m, 29 ft·lb)
Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
Tie-Rod Mounting Nut (Front): 59 N·m (6.0 kgf·m,
44 ft·lb)
• Install the other removed parts.
Spring Replacement
In addition to the standard spring, heavy and light springs
are available. If the standard spring is improper for your
purpose, select a proper one according to the rider’s weight
or course conditions.
• Remove the rear shock absorber (see Rear Shock Ab-
sorber Removal).
• Clean the threaded portion on the upper of the rear shock
absorber.
• Hold the lower of the rear shock absorber with a vise.
Rear Shock Absorber Scrapping
Halaman 233
Rear Suspension (Uni-Trak)
• Using the hook wrenches, loosen the locknut [A] and turn
the adjusting nut [B] all way up.
Special Tools - Hook Wrench T=3.2 R37: 57001-1522
Hook Wrench T=3.2 R35: 57001-1523
KLX140A model [C]
KLX140B model [D]
• Remove the rear shock absorber from the vise.
• Slide down the rubber bumper [A].
• Remove the spring guides [B] from the shock absorber
and lift off the spring [C].
• Exchange the spring for an optional part. Install the spring
so that closed coil large diameter end [A] faces upward.
• Install the spring guide.
• Adjust the spring preload (see Spring Preload Adjust-
ment).
• Install the rear shock absorber.
• Install the other removed parts.
Rear Shock Absorber Scrapping
WARNING
Since the rear shock absorber contains nitrogen
gas, do not incinerate the rear shock absorber with-
out first releasing the gas or it may explode.
Before a rear shock absorber is scrapped, drill a
hole at the point [A] shown to release the nitrogen
gas completely. Wear safety glasses when drilling
the hole, as the gas may blow out bits of drilled
metal when the hole opens.
SUSPENSION 12-17
Swingarm Removal
Halaman 234
12-18 SUSPENSION
Swingarm
Swingarm Removal
• Raise the rear wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
• Remove:
Rear
Wheel
(see
Rear
Wheel
Removal
in
the
Wheels/Tires chapter)
Rear Caliper with bracket (see Rear Caliper Removal in
the Brakes chapter)
Brake Hose Clamps [A]
• Remove:
Chain Cover Screws [A]
Chain Cover [B]
Chain Guide Bolts [C] and Screws [D]
Chain Guide Plate [E]
Chain Guide [F]
• Unscrew the rocker arm pivot nut [A] and pull out the
rocker arm pivot bolt [B].
NOTICE
When
pulling out the
mounting bolt,
lift the
swingarm wheel slightly. Forcing or tapping on a
bolt could damage the bolt, sleeve, and bearing.
• Remove the rear shock absorber (see Rear Shock Ab-
sorber Removal).
• Remove the nut [A], and pull out the swingarm pivot shaft
[B].
• Remove the swingarm backward.
• Remove the bolts [A] and the stopper [B].
• Take off the chain slipper [C] from the swingarm.
Drive Chain Guide, Guide Roller, Chain Slipper Wear
Halaman 235
Swingarm
Swingarm Installation
• Installation is the reverse of removal.
○Apply plenty of grease to the inside of the needle bear-
ings, sleeves, and grease seals.
○Tighten the following:
Torque - Swingarm Pivot Shaft Nut: 108 N·m (11 kgf·m, 80
ft·lb)
Rocker Arm Pivot Nut: 59 N·m (6.0 kgf·m, 44 ft·lb)
Swingarm Bearing Removal
• Remove:
Swingarm (see Swingarm Removal)
Sleeve [A]
Needle Bearings [B]
Grease Seals [C]
Special Tool - Oil Seal & Bearing Remover: 57001-1058
Swingarm Bearing Installation
• Replace the needle bearings and grease seals with new
ones.
• Apply plenty of grease to the needle bearings and grease
seals.
• Install the needle bearings and grease seals.
Special Tool - Bearing Driver Set: 57001-1129
NOTE
○Install the needle bearings so that the manufacturer’s
marks face out.
○Install the grease seals so that the deep groove side of
the rip in-ward.
Swingarm Bearing, Sleeve Inspection
NOTICE
Do not remove the bearings for inspection.
Re-
moval may damage them.
• Inspect the needle bearings installed in the swingarm.
○The rollers in a bearing normally wear very little, and wear
is difficult to measure.
Instead of measuring, visually
inspect the bearing for abrasion, discoloration, or other
damage.
If the needle bearing, and sleeve show any things of ab-
normal wear, discoloration or damage, replace them as a
set.
Drive Chain Guide, Guide Roller, Chain Slipper
Wear
• Refer to the Drive Chain Guide, Guide Roller, Chain Slip-
per Wear in the Periodic Maintenance chapter.
SUSPENSION 12-19
Rocker Arm Removal
Halaman 236
12-20 SUSPENSION
Tie-Rod, Rocker Arm
Tie-Rod Removal
• Raise the rear wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
NOTICE
When pulling out the mounting bolts, lift the rear
wheel slightly. Forcing or tapping on a bolt could
damage the bolt, sleeve, and bearing.
• Remove the tie-rod rear mounting bolt and nut [A].
• Remove the tie-rod front mounting bolt and nut [B], and
then take out the tie-rod [C].
Tie-Rod Installation
• Apply plenty of grease to the inside of the grease seals.
• Apply plenty of 2-stroke oil to the threads of the tie-rod
front and rear mounting bolts.
• Tighten the tie-rod front and rear mounting nuts.
Torque - Tie-Rod Mounting Nuts:
59 N·m (6.0 kgf·m, 44
ft·lb)
Rocker Arm Removal
• Raise the rear wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
NOTICE
When pulling out the mounting bolts, lift the rear
wheel slightly.
Forcing or tapping on bolt could
damage the bolt, sleeve, and bearing.
• Remove the rear shock absorber lower mounting bolt [A].
• Remove the tie-rod rear mounting bolt and nut [B].
• Remove the rocker arm pivot bolt and nut [C].
• Remove the rocker arm [D].
Tie-Rod and Rocker Arm Bearing Removal
Halaman 237
Tie-Rod, Rocker Arm
Rocker Arm Installation
• Apply plenty of grease to the inside of the rocker arm,
needle bearings and grease seals outside of the sleeve.
• Apply plenty of 2-stroke oil to the threads of the tie-rod
rear mounting bolts.
• Replace the rear shock absorber mounting nut (lower),
rocker arm pivot nut, and tie-rod mounting nut with new
ones.
• Tighten:
Torque - Rear Shock Absorber Mounting Bolt (Lower): 39
N·m (4.0 kgf·m, 29 ft·lb)
Rear Shock Absorber Mounting Nut (Lower): 29
N·m (3.0 kgf·m, 21 ft·lb)
Rocker Arm Pivot Nut: 59 N·m (6.0 kgf·m, 44 ft·lb)
Tie-Rod Mounting Nut (Rear): 59 N·m (6.0 kgf·m,
44 ft·lb)
Tie-Rod and Rocker Arm Bearing Removal
• Remove:
Tie-Rod [A] (see Tie-Rod Removal)
Rocker Arm [B] (see Rocker Arm Removal)
Bushings [C]
Sleeves [D]
Grease Seals [E]
• Remove the needle bearings [F], using the bearing re-
mover.
Special Tools - Bearing Remover Head: 57001-1267
Bearing Remover Shaft: 57001-1265
Oil Seal & Bearing Remover: 57001-1058
SUSPENSION 12-21
Needle Bearing Inspection
Halaman 238
12-22 SUSPENSION
Tie-Rod, Rocker Arm
Tie-Rod and Rocker Arm Bearing Installation
• Replace the needle bearing, grease seals and oil seals
with new ones.
• Apply plenty of grease to the oil seal and needle bearings
[A].
NOTE
○Install the grease seals so that the deep groove side of
the rip out-ward.
• Install the needle bearings [A], and grease seals [B] po-
sition as shown.
○Install the needle bearings and grease seals position as
shown.
○The installation procedure is the same as the counter
side.
3 mm (0.12 in.) [C]
Rear Shock Absorber [F]
5 mm (0.20 in.) [D]
Tie-rod [G]
4.1 mm (0.164 in.) [E]
Rocker Arm [H]
Needle Bearing Inspection
If there is any doubt as to the condition of either needle
bearing, replace the bearing and sleeve as a set.
Tie-Rod and Rocker Arm Mounting Bolt Bend
Halaman 239
Uni-Trak Maintenance
Uni-Trak Linkage Inspection
• Refer to the Uni-Trak Linkage Inspection in the Periodic
Maintenance chapter.
Tie-Rod and Rocker Arm Sleeve Wear
• Pull out the sleeves [A] of the tie-rod and rocker arm.
• Measure the outside diameter of the sleeve.
If the sleeve is worn past the service limit, replace the
sleeve.
Sleeve Outside Diameter
Standard:
Tie-rod
19.979 ∼20.000 mm (0.78657 ∼0.78740 in.)
Rocker Arm:
[Large]
19.979 ∼20.000 mm (0.78657 ∼0.78740 in.)
[Middle] 17.989 ∼18.000 mm (0.70823 ∼0.70866 in.)
[Small]
15.950 ∼16.000 mm (0.62795 ∼0.62992 in.)
Service Limit:
Tie-rod
19.85 mm (0.781 in.)
Rocker Arm:
[Large]
19.85 mm (0.781 in.)
[Middle] 17.96 mm (0.707 in.)
[Small]
15.92 mm (0.627 in.)
Tie-Rod and Rocker Arm Mounting Bolt Bend
A bent bolt causes vibration, poor handling, and instabil-
ity.• To measure the bolt runout, remove the bolt, place it in V
blocks, and set a dial gauge to the bolt at a point halfway
between the blocks.
Turn [A] the bolt to measure the
runout.
The amount of dial variation is the amount of
runout.
If runout exceeds the service limit, replace the bolt.
Bolt Runout
Standard:
TIR 0.1 mm (0.004 in.) or less
Service Limit:
TIR 0.2 mm (0.008 in.)
SUSPENSION 12-23
Steering
Halaman 241
Steering
Table of Contents
Exploded View........................................................................................................................
13-2
Special Tools ..........................................................................................................................
13-4
Steering ..................................................................................................................................
13-5
Steering Inspection ...........................................................................................................
13-5
Steering Adjustment..........................................................................................................
13-5
Steering Stem, Stem Bearing Removal ............................................................................
13-5
Steering Stem, Stem Bearing Installation .........................................................................
13-6
Stem Bearing Lubrication..................................................................................................
13-8
Stem Bearing Wear, Damage ...........................................................................................
13-8
Stem Warp ........................................................................................................................
13-8
Handlebar...............................................................................................................................
13-9
Handlebar Removal ..........................................................................................................
13-9
Handlebar Installation .......................................................................................................
13-9
STEERING 13-1
13
Exploded View
Halaman 242
13-2 STEERING
Exploded View
Exploded View
Halaman 243
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Handlebar Clamp Bolts
25
2.5
18
AL
2
Steering Stem Head Nut
64
6.5
47
3
Steering Stem Nut
4.9
0.50
43 in·lb
T
4
Front Fork Clamp Bolts (Upper)
20
2.0
15
5
Front Fork Clamp Bolts (Lower)
25
2.5
18
6. Handlebar
7. Handlebar Holder
8. Steering Stem Head Bracket
9. Upper Tapered Roller Bearing
10. Frame
11. Lower Tapered Roller Bearing
12. Steering Stem
13. KLX140A8F ∼AAF/B8F ∼BAF Models
AD: Apply adhesive cement.
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease.
T: First, tighten the stem locknut with 39 N·m (4.0 kgf·m, 29 ft·lb) of torque, then loosen it and
retighten it with 4.9 N·m (0.50 kgf·m, 43 in·lb) of torque.
R: Replacement Parts
STEERING 13-3
Special Tools
Halaman 244
13-4 STEERING
Special Tools
Bearing Puller:
57001-135
Steering Stem Bearing Driver:
57001-137
Steering Stem Bearing Driver Adapter,
34.5:
57001-1074
Head Pipe Outer Race Press Shaft:
57001-1075
Steering Stem Nut Wrench:
57001-1100
Head Pipe Outer Race Driver,
46.5:
57001-1106
Head Pipe Outer Race Remover ID > 37 mm:
57001-1107
Bearing Puller:
57001-1575
Steering Stem, Stem Bearing Removal
Halaman 245
Steering
Steering Inspection
• Refer to the Steering Inspection in the Periodic Mainte-
nance chapter.
Steering Adjustment
• Refer to the Steering Adjustment in the Periodic Mainte-
nance chapter.
Steering Stem, Stem Bearing Removal
• Remove:
Front
Wheel
(see
Front
Wheel
Removal
in
the
Wheels/Tires chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)
Handlebar (see Handlebar Removal)
• Remove the number plate.
• Disconnect the ignition switch connector.
• Remove the mounting bolts [A], and take off the igni-
tion switch and choke knob bracket [B] (KLX140A8F ∼
AAF/B8F ∼BBF).
• Remove the mounting bolts [A], and take off the choke
knob bracket [B] (KLX140ABF/BBF).
• Loosen the steering stem head nut [A].
• Remove the front fork (see Front Fork Removal in the
Suspension chapter).
• Remove the head nut with the washer and the steering
stem head [B].
STEERING 13-5
Steering Stem, Stem Bearing Installation
Halaman 246
13-6 STEERING
Steering
• Pushing up on the stem base [A], and remove the steering
stem nut [B] with the steering stem nut wrench [C], then
remove the steering stem [D] and stem base.
Special Tool - Steering Stem Nut Wrench: 57001-1100
• Take off the upper stem bearing inner race (tapered roller
bearing) [A].
• Drive out the bearing outer races from the head pipe.
○Remove the outer races pressed into the head pipe, using
the head pipe outer race remover [A], and hammer the
head pipe outer race remover to drive it out.
Special Tool - Head Pipe Outer Race Remover ID > 37 mm:
57001-1107
NOTE
○If either steering stem bearing is damaged, it is recom-
mended that both the upper and lower bearing (includ-
ing outer races) should be replaced with new ones.
• Remove the lower stem bearing inner rase (tapered roller
bearing) [A] with its grease seal from the stem using bear-
ing puller.
Special Tools - Bearing Puller: 57001-1575
Bearing Puller: 57001-135
Steering Stem, Stem Bearing Installation
• Replace the bearing outer race with new ones.
○Apply grease to the outer races, and drive them into the
head pipe at the same time using the head pipe outer race
press shaft [A] and the head pipe outer race drivers.
Special Tools - Head Pipe Outer Race Press Shaft: 57001
-1075
Head Pipe Outer Race Driver,
46.5: 57001
-1106 [B]
Steering Stem, Stem Bearing Installation
Halaman 247
Steering
• Replace the lower inner races with new ones.
○Apply grease to the lower tapered roller bearing [A], and
drive it onto the stem using the steering stem bearing
driver [B] and adapter [C].
Special Tools - Steering Stem Bearing Driver: 57001-137
Steering
Stem
Bearing
Driver
Adapter,
34.5: 57001-1074
• Apply grease to the upper inner race, and install it in the
head pipe.
• Install the stem through the head pipe and upper bearing,
install the stem cap and hand-tighten the stem nut while
pushing up on the stem base.
• Install the stem head and washer, and tighten the stem
head nut lightly.
• Settle the bearing in place as follows;
○Tighten the stem nut to 39 N·m (4.0 kgf·m, 29 ft·lb) of
torque. (To tighten the steering stem nut to the specified
torque, hook the wrench [A] on the stem nut, and pull the
wrench at the hole by 22.2 kg force [B] in the direction
shown.)
Special Tool - Steering Stem Nut Wrench: 57001-1100
○Check that there is no play and the steering stem turns
smoothly without rattles. If not, the steering stem bearings
may be damaged.
○Again back out the stem nut a fraction of a turn until it
turns lightly.
○Turn the stem nut lightly clockwise until it just becomes
hard to turn. Do not overtighten, or the steering will be
too tight.
Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)
• Install the front fork (see Front Fork Installation in the Sus-
pension chapter).
NOTE
○Tighten the fork upper clamp bolts first, next the stem
head nut, last the fork lower clamp bolt.
• Tighten:
Torque - Steering Stem Head Nut: 64 N·m (6.5 kgf·m, 47
ft·lb)
Front Fork Clamp Bolts (Upper):
20 N·m (2.0
kgf·m, 15 ft·lb)
Front Fork Clamp Bolts (Lower):
25 N·m (2.5
kgf·m, 18 ft·lb)
STEERING 13-7
Stem Warp
Halaman 248
13-8 STEERING
Steering
• Install the other removed parts.
WARNING
Do not impede the handlebar turning by routing the
cables, wires and hoses improperly (see the Gen-
eral Information chapter).
• Check and Adjust:
Steering
Front Brake
Clutch Cable
Throttle Cable
Stem Bearing Lubrication
• Refer to the Stem Bearing Lubrication in the Periodic
Maintenance chapter.
Stem Bearing Wear, Damage
• Using high-flash point solvent, wash the upper and lower
tapered rollers.
• Wipe the upper and lower outer races, which are press
-fitted into the frame head pipe, clean off grease and dirt.
• Visually check the outer rase and the rollers.
Replace the bearing assembly if it show damage.
Stem Warp
• Whenever the steering stem is removed, or if the steering
cannot be adjusted for smooth action, check the steering
stem for straightness.
If the steering stem shaft is bent [A], replace the steering
stem.
Handlebar Installation
Halaman 249
Handlebar
Handlebar Removal
• Disconnect the connectors [A].
• Remove:
Engine Stop Switch (KLX140A8F ∼AAF/B8F ∼BBF) [A]
Clutch Holder [B]
Clamp [C]
• Remove:
Left Switch Housing (KLX140ABF/BBF) [A]
• Remove:
Throttle Cable and Grip [A] (see Throttle Cable Replace-
ment in the Fuel System chapter)
Engine Starter Button (KLX140A8F ∼AAF/B8F ∼BBF)
[B]
Master Cylinder [C] (see Front Master Cylinder Removal
in the Brakes chapter)
Clamp [D]
• Clear the belt [A] of the number plate.
• Remove:
Handlebar Clamp Bolts [B]
Handlebar Clamps [C]
Handlebar [D]
Handlebar Installation
• Apply adhesive to the inside of the left handlebar grip.
• Install the left handlebar grip so that the projection of grip
align to the punch mark of the handlebar.
STEERING 13-9
Handlebar Installation
Halaman 250
13-10 STEERING
Handlebar
• Install the engine stop switch [A] and the clutch lever [B]
so that their mating surfaces align to the punch marks [C]
(KLX140A8F ∼AAF/B8F ∼BBF).
• Install the left switch housing [A] (KLX140ABF/BBF).
○Fit the projection [B] into a hole [C] in the handlebar.
• Install the clutch lever [A] so that the mating surface [B]
aligns with the punch mark [C] (KLX140ABF/BBF).
• Apply grease to the throttle cable upper end and the clutch
cable upper end.
• Install the throttle cable housing firmly (see Throttle Cable
Replacement in the Fuel System chapter).
• Align the master cylinder, the engine starter button and
the throttle cable housing so that the mating surface [A]
to the punch mark [B] of the handlebar (KLX140A8F ∼
AAF/B8F ∼BBF).
Handlebar Installation
Halaman 251
Handlebar
• Align the master cylinder and throttle cable housing so
that the mating surfaces [A] to the punch marks [B] of the
handlebar (KLX140ABF/BBF).
• Install the handlebar [A], and align the handlebar punch
mark [B] to the handlebar clamp mating surface.
• Equalize the space [C] and [D].
Torque - Handlebar Clamp Bolts:
25 N·m (2.5 kgf·m, 18
ft·lb)
NOTE
○Tighten the two clamp bolts alternately two times to en-
sure even tightening torque.
• Install the other removed parts.
STEERING 13-11
Frame
Halaman 253
Frame
Table of Contents
Exploded View........................................................................................................................
14-2
Special Tool ............................................................................................................................
14-6
Frame .....................................................................................................................................
14-7
Frame Inspection ..............................................................................................................
14-7
Rear Frame Removal........................................................................................................
14-7
Rear Frame Installation.....................................................................................................
14-7
Engine Guard Removal.....................................................................................................
14-7
Seat ........................................................................................................................................
14-8
Seat Removal ...................................................................................................................
14-8
Seat Installation ................................................................................................................
14-8
Side Cover..............................................................................................................................
14-9
Side Covers Removal/Installation.....................................................................................
14-9
Fender ....................................................................................................................................
14-10
Front Fender Removal......................................................................................................
14-10
Rear Fender Removal.......................................................................................................
14-10
Rear Flap Removal...........................................................................................................
14-10
Footpegs and Brackets...........................................................................................................
14-11
Footpeg Removal/Installation ...........................................................................................
14-11
Sidestand................................................................................................................................
14-12
Sidestand Removal...........................................................................................................
14-12
Sidestand Installation........................................................................................................
14-12
FRAME 14-1
14
Exploded View
Halaman 254
14-2 FRAME
Exploded View
Exploded View
Halaman 255
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Rear Frame Mounting Bolt
34
3.5
25
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
FRAME 14-3
Exploded View
Halaman 256
14-4 FRAME
Exploded View
Exploded View
Halaman 257
Exploded View
1. Seat
2. Side Covers
3. Front Fender
4. Rear Fender
5. Rear Flap
6. Number Plate
7. CA model only
8. CA model only
FRAME 14-5
Special Tool
Halaman 258
14-6 FRAME
Special Tool
Jack:
57001-1238
Engine Guard Removal
Halaman 259
Frame
Frame Inspection
• Refer to the Frame Inspection in the Periodic Mainte-
nance chapter.
Rear Frame Removal
• Remove:
Side Covers (see Side Covers Removal/Installation)
Seat (see Seat Removal)
Muffler (see Muffler Removal in the Engine Top End
chapter)
Rear Fender (see Rear Fender Removal)
• Remove the mounting bolts [A] and the rear frame [B].
Rear Frame Installation
• Install the rear frame and tighten the mounting bolts.
Torque - Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
• Install the other removed parts.
Engine Guard Removal
• Remove the mounting bolts [A], and take off the engine
guard [B].
FRAME 14-7
Seat Installation
Halaman 260
14-8 FRAME
Seat
Seat Removal
• Remove the side covers (see Side Covers Removal/In-
stallation).
• Remove the bolt [A], nut [B] and collar on both sides.
• Take off the seat [C] backward.
Seat Installation
• Fit the hooks [A] in under the flange collar [B] and the
bracket [C].
• Replace the seat mounting nut with a new one.
• Tighten the seat mounting bolts and nuts.
• Install the side covers (see Side Covers Removal/Instal-
lation).
Side Covers Removal/Installation
Halaman 261
Side Cover
Side Covers Removal/Installation
• Remove the mounting bolt [A] and the side cover [B] on
both sides.
• Remove the screws [A] of the right side cover if necessary.
• Clear the hooks [B] and separate each other.
• Installation is the reverse of removal.
○Insert the projection [A] into the grommet [B] on the frame.
FRAME 14-9
Rear Flap Removal
Halaman 262
14-10 FRAME
Fender
Front Fender Removal
• Unscrew the bolts [A] and remove the front fender.
Rear Fender Removal
• Remove:
Side Covers (see Side Covers Removal/Installation)
Seat (see Seat Removal)
Muffler (see Muffler Removal in the Engine Top End
chapter)
• Take off the starter relay and fuse unit [A].
• Remove the mounting bolts [A] and take off the rear
fender [B].
Rear Flap Removal
• Remove the screws [A] and take off the rear flap [B].
Footpeg Removal/Installation
Halaman 263
Footpegs and Brackets
Footpeg Removal/Installation
• Remove:
Cotter pin [A]
Washer [B]
Pivot Pin [C]
Spring [D]
Footpeg [E]
• Installation is reverse of removal.
○Replace the cotter pin with a new one.
• Bend the longer side of the cotter pin.
FRAME 14-11
Sidestand Installation
Halaman 264
14-12 FRAME
Sidestand
Sidestand Removal
• Raise the rear wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
• Remove:
Spring [A]
Sidestand Bolt [B]
Sidestand Nut [C]
Sidestand [D]
Sidestand Installation
• Apply grease to the sliding area [A] of the sidestand [B].
• Replace the sidestand nut with a new one.
• Tighten the sidestand bolt [C] and nut [D].
• Hook the spring [E] so that face the long spring end up-
ward.
Electrical System
Halaman 265
Electrical System
Table of Contents
Exploded View...................................
15-2
Specifications ....................................
15-6
Special Tools and Sealant .................
15-7
Wiring Diagram..................................
15-8
Precautions........................................
15-10
Electrical Wiring.................................
15-11
Wiring Inspection .........................
15-11
Battery ...............................................
15-12
Battery Removal ..........................
15-12
Battery Installation .......................
15-12
Battery Activation.........................
15-12
Precautions..................................
15-14
Interchange..................................
15-15
Charging Condition Inspection.....
15-15
Refreshing Charge.......................
15-16
Charging System...............................
15-17
Alternator Cover Removal............
15-17
Alternator Cover Installation.........
15-17
Alternator Rotor Removal ............
15-18
Alternator Rotor Installation .........
15-18
Stator Removal ............................
15-19
Stator Installation .........................
15-19
Alternator Rotor Inspection ..........
15-19
Charging Voltage Inspection........
15-21
Regulator/Rectifier Inspection......
15-21
Starter Motor Clutch ..........................
15-25
Starter Motor Clutch Removal......
15-25
Starter Motor Clutch Installation...
15-25
Starter Motor Clutch Inspection ...
15-25
Ignition Timing ...................................
15-26
Ignition Timing Inspection ............
15-26
ELECTRICAL SYSTEM 15-1
Ignition System..................................
15-27
Crankshaft Sensor Removal........
15-27
Crankshaft Sensor Installation.....
15-27
Ignition Coil Removal/Installation.
15-27
Ignition Coil Inspection.................
15-28
Spark Plug Cleaning and
Inspection..................................
15-28
Spark Plug Gap Inspection ..........
15-29
Igniter Removal............................
15-29
Igniter Inspection..........................
15-29
Crankshaft Sensor Inspection......
15-31
Electrical Starter System ...................
15-35
Starter Motor Removal.................
15-35
Starter Motor Installation..............
15-35
Starter Motor Disassembly...........
15-35
Starter Motor Assembly ...............
15-36
Carbon Brush Inspection .............
15-36
Commutator Inspection, Cleaning
15-37
Armature Inspection.....................
15-37
Brush Lead Inspection .................
15-37
Terminal Bolt Inspection...............
15-38
Starter Relay Inspection...............
15-38
Switches and Sensors.......................
15-41
Switch Inspection.........................
15-41
LED Inspection.............................
15-41
Main Relay.........................................
15-42
Main Relay Inspection..................
15-42
Fuses.................................................
15-43
Main Fuse 10 A Removal.............
15-43
Main Fuse 10 A Inspection ..........
15-43
15
Exploded View
Halaman 266
15-2 ELECTRICAL SYSTEM
Exploded View
Exploded View
Halaman 267
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Ignition Coil Mounting Bolt
2.9
0.30
26 in·lb
2
Regulator Mounting Bolt
8.8
0.90
78 in·lb
3
Spark Plug
13
1.3
115 in·lb
4
Starter Relay Terminal Screws
2.9
0.30
26 in·lb
5. Ignition Switch (KLX140A8F ∼AAF/B8F ∼BAF)
6. Ignition Coil
7. Main Relay
8. IC Igniter
9. Battery
10. Starter Relay
11. Main Fuse 10 A
12. KLX140A8F ∼AAF/B8F ∼BAF Models
ELECTRICAL SYSTEM 15-3
Exploded View
Halaman 268
15-4 ELECTRICAL SYSTEM
Exploded View
Exploded View
Halaman 269
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Starter Motor Terminal Nut
5.2
0.53
46 in·lb
2
Starter Motor Mounting Bolts
6.9
0.70
61 in·lb
3
Starter Motor Terminal Locknut
6.9
0.70
61 in·lb
4
Starter Motor Through Bolts
4.9
0.50
43 in·lb
5
Starter Motor Clutch Bolts
12
1.2
106 in·lb
L
6
Alternator Rotor Bolt
38
3.9
28
MO
7
Stator Mounting Bolts
8.8
0.90
78 in·lb
8
Alternator Cover Plug
2.5
0.25
22 in·lb
9
Alternator Cover Center Cap
2.5
0.25
22 in·lb
10
Alternator Cover Bolts (L = 30)
8.8
0.90
78 in·lb
11
Alternator Cover Bolts (L = 45)
8.8
0.90
78 in·lb
12
Torque Limiter Cover Bolts
8.8
0.90
78 in·lb
13
Alternator Lead Clamp Screws
5.2
0.53
46 in·lb
14
Crankshaft Sensor Mounting Screws
4.2
0.43
37 in·lb
15. Starter Motor Clutch
16. Alternator Rotor
17. Stator
18. Crankshaft Sensor
19. Torque Limiter
20. KLX140A8F ∼A9F Early Models/B8F ∼B9F Early Models
21. KLX140A8F ∼A9F/B8F ∼B9F
G: Apply grease.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide oil.
R: Replacement Parts
SS: Apply silicone sealant.
ELECTRICAL SYSTEM 15-5
Specifications
Halaman 270
15-6 ELECTRICAL SYSTEM
Specifications
Item
Standard
Service Limit
Battery
Type
Sealed Battery (wet)
– – –
Model
FTX7L-BS
– – –
Capacity
12 V 6 Ah
– – –
Charging System
Crankshaft Sensor Resistance
50 ∼200 Ω(at 20°C (68°F))
– – –
Alternator Output Voltage
in the text
– – –
Stator Coil Resistance
in the text
– – –
Ignition System
Ignition Timing
BTDC 10 ±2° @1 400 r/min (rpm)
– – –
Ignition Coil:
3 Needle Arcing Distance
7 mm (0.26 in.) or more
– – –
Primary Winding Resistance
0.64 ∼0.78 Ω(at 20°C (68°F))
– – –
Secondary Winding
Resistance
11.4 ∼14.0 kΩ(at 20°C (68°F))
– – –
Primary Peak Voltage
175 V or more
– – –
Crankshaft Sensor Peak
Voltage
2 V or more
– – –
Spark Plug:
Type
NGK CR7HSA
– – –
Gap
0.6 ∼0.7 mm (0.024 ∼0.028 in.)
– – –
Electric Starter System
Starter Motor:
Brush Length
7.0 mm (0.28 in.)
3.5 mm (0.14 in.)
Commutator Diameter
22.1 mm (0.87 in.)
21.6 mm (0.85 in.)
Special Tools and Sealant
Halaman 271
Special Tools and Sealant
Inside Circlip Pliers:
57001-143
Rotor Puller, M16/M18/M20/M22 × 1.5:
57001-1216
Timing Light:
57001-1241
Spark Plug Wrench, Hex 16:
57001-1262
Flywheel Holder:
57001-1313
ELECTRICAL SYSTEM 15-7
Hand Tester:
57001-1394
Peak Voltage Adapter:
57001-1415
Needle Adapter Set:
57001-1457
Flywheel Puller, M28 × 1.0:
57001-1471
Liquid Gasket, TB1211F:
92104-0004
Wiring Diagram
Halaman 272
15-8 ELECTRICAL SYSTEM
Wiring Diagram
KLX140A8F ∼AAF/B8F ∼BAF
Wiring Diagram
Halaman 273
Wiring Diagram
KLX140ABF/BBF
ELECTRICAL SYSTEM 15-9
Precautions
Halaman 274
15-10 ELECTRICAL SYSTEM
Precautions
There are numbers of important precautions that are
musts when servicing electrical systems. Learn and ob-
serve all the rules below.
○The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
○Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item(s), they too must be repaired or replaced, or
the new replacement will soon fail again.
○Make sure all connectors in the circuit are clean and tight,
and examine wires for signs of burning, fraying, etc. Poor
wires and bad connections will affect electrical system op-
eration.
○Measure coil and winding resistance when the part is cold
(at room temperature).
○Electrical Connectors
Connectors [A]
Connectors [B]
Safety Instructions:
WARNING
The ignition system produces extremely high volt-
age. Do not touch the spark plug, ignition coil or ig-
nition coil lead while the engine is running, or you
could receive a severe electrical shock.
Wiring Inspection
Halaman 275
Electrical Wiring
Wiring Inspection
• Visually inspect the wiring for signs of burning, fraying,
etc.
If any wiring is poor, replace the damaged wiring.
• Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
• Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect the hand tester between the ends of the leads.
Special Tool - Hand Tester: 57001-1394
○Set the tester to the × 1 Ωrange, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Re-
place the lead or the wiring harness [B] if necessary.
ELECTRICAL SYSTEM 15-11
Battery Activation
Halaman 276
15-12 ELECTRICAL SYSTEM
Battery
Battery Removal
• Remove the seat (see Seat Removal in the Frame chap-
ter).
• Disconnect the negative (–) cable [A] and then positive
(+) cable [B].
NOTICE
Be sure to disconnect the negative (–) cable first.
• Remove the battery holder bolts [C] and holder [D].
• Remove the battery.
Battery Installation
• Visually inspect the surface of the battery container.
If any signs of cracking or electrolyte leakage from the
sides of the battery.
• Put the battery into the battery case.
• Connect the positive cable [A] to the (+) terminal first, and
then the negative cable [B] to the (–) terminal.
• Install the battery holder and tighten the bolts.
• Apply a little grease on the terminals to prevent corrosion.
• Cover the (+) terminal with the cap.
Battery Activation
Electrolyte Filling
• Make sure that the model name [A] of the electrolyte con-
tainer matches the model name [B] of the battery. These
names must be the same.
Battery Model Name: FTX7L-BS
NOTICE
Be sure to use the electrolyte container with the
same model name as the battery since the elec-
trolyte volume and specific gravity vary with the
battery type.
This is to prevent overfilling of the
electrolyte, shorting the battery life, and deteriora-
tion of the battery performance.
NOTICE
Do not remove the aluminum sealing sheet [A] from
the filler ports [B] until just prior to use. Be sure to
use the dedicated electrolyte container for correct
electrolyte volume.
• Place the battery on a level surface.
• Check to see that the sealing sheet has no peeling, tears,
or holes in it.
• Remove the sealing sheet.
NOTE
○The battery is vacuum sealed. If the sealing sheet has
leaked air into the battery, it may require a longer initial
charge.
Battery Activation
Halaman 277
Battery
• Remove the electrolyte container from the vinyl bag.
• Detach the strip of caps [A] from the container and set
aside, these will be used later to seal the battery.
NOTE
○Do not pierce or otherwise open the sealed cells [B] of
the electrolyte container. Do not attempt to separate
individual cells.
• Place the electrolyte container upside down with the six
sealed cells into the filler ports of the battery. Hold the
container level, push down to break the seals of all six
cells. You will see air bubbles rising into each cell as the
ports fill.
NOTE
○Do not tilt the electrolyte container
• Check the electrolyte flow.
If no air bubbles [A] are coming up from the filler ports, or
if the container cells have not emptied completely, tap the
container [B] a few times.
• Keep the container in place for 20 minutes or more. Don’t
remove the container from the battery until it’s empty, the
battery requires all the electrolyte from the container for
proper operation.
NOTICE
Removal of the container before it is completely
empty can shorten the service life of the battery. Do
not remove the electrolyte container until it is com-
pletely empty and 20 minutes have elapsed.
• Gently remove the container from the battery.
• Let the battery sit for 30 minutes prior to charging to allow
the electrolyte to permeate into the plates for optimum
performance.
NOTE
○Charging the battery immediately after filling can
shorten service life. Let the battery sit for at least 30
minutes after filling.
ELECTRICAL SYSTEM 15-13
Precautions
Halaman 278
15-14 ELECTRICAL SYSTEM
Battery
Initial Charge
• Place the strip [A] of caps loosely over the filler ports.
• Newly activated sealed batteries require an initial charge.
Standard Charge
0.7 A × 5 ∼10 hours
If using a recommended battery charger, follow the
charger’s instructions for newly activated sealed battery.
Kawasaki-recommended chargers:
Battery Mate 150–9
OptiMate PRO 4-S/PRO S/PRO 2
Yuasa MB-2040/2060
Christie C10122S
If the above chargers are not available, use equivalent
one.
NOTE
○Charging rates will vary depending on how long the
battery has been stored, temperature, and the type of
charger used.
Let battery sit 30 minutes after initial
charge, then check voltage using a voltmeter. If it is
not at least 12.6 volts, repeat charging cycle.
• After charging is completed, press down firmly with both
hands to seat the strip of caps [A] into the battery (don’t
pound or hammer). When properly installed, the strip of
the caps will be level with the top of the battery.
NOTICE
Once the strip of the caps [A] is installed onto the
battery, never remove the caps, nor add water or
electrolyte to the battery.
NOTE
○To ensure maximum battery life and customer satisfac-
tion, it is recommended the battery be load tested at
three times its amp-hour rating for 15 seconds.
Re-check voltage and if less than 12.6 volts repeat the
charging cycle and load test. If still below 12.6 volts the
battery is defective.
Precautions
1) No need of topping-up.
No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the
seal cap to add water is very dangerous. Never do that.
2) Refreshing charge.
Give a refresh charge for 5 to 10 hours with charging current shown in the specification (see
Refreshing Charge).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions indicated on the battery.
Charging Condition Inspection
Halaman 279
Battery
NOTICE
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced no-
ticeably if charged under conditions other than given above. Never remove the seal cap
during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the relief valve
releases the gas to keep the battery normal.
3) When you do not use the motorcycle for months.
Give a refresh charge before you store the motorcycle. And then store it with the negative cable
removed. However, check the battery’s state of charge at every month to be sure it meets the
minimum 12.4 V specification and charge it to 100 % state of charge.
4) Battery life.
If the battery will not start the engine even after several refresh charges, the battery has ex-
ceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no prob-
lem).
DANGER
Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri-
ous injury and burns if ignited. Keep the battery away from sparks and open flames during
charging. When using a battery charger, connect the battery to the charger before turning
on the charger. This procedure prevents sparks at the battery terminals which could ignite
any battery gases. The electrolyte contains sulfuric acid. Be careful not to have it touch
your skin or eyes. If touched, wash it off with liberal amount of water and seek medial at-
tention for more severe burns.
Interchange
A sealed battery can fully display its performance only when combined with a proper vehicle electric
system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with
a sealed battery.
Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.
Battery Date Inspection
• Remove the battery (see Battery Removal).
• Check the manufactured date stamp [A].
Day [B]
Month [C]
Year [D]
MFG Code [F]
NOTE
○Do refresh charge with the battery that passes one
month or more.
Charging Condition Inspection
○Battery charging condition can be checked by measuring
battery terminal voltage with a digital voltmeter [A].
• Remove the seat (see Seat Removal in the Frame chap-
ter).
• Disconnect the battery terminals.
NOTICE
Be sure to disconnect the negative (–) cable first.
• Measure the battery terminal voltage.
NOTE
○Measure with a digital voltmeter which can be read one
decimal place voltage.
ELECTRICAL SYSTEM 15-15
Refreshing Charge
Halaman 280
15-16 ELECTRICAL SYSTEM
Battery
If the reading is 12.6 V or more, refresh charge is not
required, however, if the read is below the 12.6 V, refresh
charge is required.
Terminal Voltage (V) [A]
Battery Charge Rate (%) [B]
Refresh charge is required [C]
Good [D]
Refreshing Charge
• Remove the battery (see Battery Removal).
• Do refresh charge by following method according to the
battery terminal voltage.
WARNING
This battery is sealed type. Charge with current and
time as stated below.
Terminal Voltage: 11.5 ∼less than 12.6 V
Standard Charge
0.7 A × 5 ∼10 h (see following chart)
Quick Charge
3 A × 1 h
NOTICE
If possible, do not quick charge. If quick charge is
done unavoidably, do standard charge later on.
Terminal Voltage: less than 11.5 V
Charging Method:
0.7 A × 20 h
NOTE
○Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 min-
utes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D].
• Determine the battery condition after refresh charge.
○Determine the condition of the battery left for 30 minutes
after completion of the charge by measuring the terminal
voltage according to the table below.
Criteria
Judgement
12.7 V or higher
Good
12.0 ∼lower than 12.6 V
Charge insufficient →Recharge
lower than 12.0 V
Unserviceable →Replace
Alternator Cover Installation
Halaman 281
Charging System
Alternator Cover Removal
• Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).
• Disconnect the alternator lead connector [A].
○Clear the lead from the clamps.
• Remove:
Torque Limiter Cover Bolts [A]
Torque Limiter Cover [B]
Drive Chain Cover Bolts [C]
Drive Chain Cover [D]
• Remove:
Neutral Switch Terminal [A]
Torque Limiter [B]
Alternator Cover Mounting Bolts [C]
Alternator Cover [D]
Alternator Cover Installation
• Replace the gasket [A] with a new one.
• Be sure to install the dowel pins [B].
• Apply silicone sealant to the area [A] to the alternator lead
grommet.
Sealant - Liquid Gasket, TB1211F: 92104-0004
• Install the alternator cover.
Torque - Alternator Cover Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
• Install the other removed parts.
ELECTRICAL SYSTEM 15-17
Alternator Rotor Installation
Halaman 282
15-18 ELECTRICAL SYSTEM
Charging System
Alternator Rotor Removal
• Remove the alternator cover (see Alternator Cover Re-
moval).
• Hold the rotor steady, with the flywheel holder [A], and
remove the rotor bolt [B].
Special Tool - Flywheel Holder: 57001-1313
• Remove the flywheel holder.
• Attach the pullers [A] onto the rotor.
• Remove the rotor from the crankshaft.
Special Tools - Flywheel Puller, M28 × 1.0: 57001-1471
Rotor Puller, M16/M18/M20/M22 × 1.5: 57001
-1216
NOTE
○Tap the rotor puller head [B] with a hammer, while hold-
ing the puller body steady.
• Remove the woodruff key from the crankshaft.
NOTICE
If the rotor is difficult to remove, turn the puller shaft
using a wrench while tapping the head of the puller
shaft with a hammer. Do not attempt to strike the
grab bar or the alternator rotor itself. Striking the
bar or the rotor can cause the bar to bend or the
magnets to lose their magnetism.
Alternator Rotor Installation
• Using high-flash point solvent, clean off any oil or dirt on
the crankshaft and rotor tapered portions [A] [B]. Dry them
with a clean cloth.
• Fit the woodruff key [C] securely in the slot on the crank-
shaft.
• Install the rotor while turning the starter clutch gear clock-
wise, and refer following procedures.
NOTE
○Confirm the rotor fit or not to the crankshaft before tight-
ening it with specified torque.
○Install the rotor and tighten it with 30 N·m (3.1 kgf·m, 22
ft·lb) of torque.
○Remove the rotor nut.
○Check the tightening torque with the rotor puller.
If the rotor is not pulled out with 10 N·m (1.0 kgf·m, 87
in·lb) of drawing torque, it is installed correctly.
If the rotor is pulled out with under 10 N·m (1.0 kgf·m, 87
in·lb) of drawing torque, clean off any oil dirt or flaw of the
crankshaft and rotor tapered portion, and dry them with
a clean cloth. Then, confirm that it is not pulled out with
above torque.
Alternator Rotor Inspection
Halaman 283
Charging System
• Apply molybdenum disulfide oil to the thread of the rotor
bolt, but do not apply to the rotor and the crankshaft ta-
pered portion.
• Holding the rotor steady, with the flywheel holder, and
tighten the rotor bolt.
Special Tool - Rotor Holder: 57001-1313
Torque - Alternator Rotor Bolt: 38 N·m (3.9 kgf·m, 28 ft·lb)
• Install the alternator cover (see Alternator Cover Installa-
tion)
Stator Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
Stator Bolts [A]
Crankshaft Sensor Screws [B]
Lead Clumps [C]
Wiring Grommet [D]
• Take off the stator [E] and the crankshaft sensor as a set.
Stator Installation
• Install the stator.
Torque - Stator Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
• Install the crankshaft sensor and the lead clamps.
○Run the crankshaft sensor leads under the sensor and
the clamp.
Torque - Crankshaft Sensor Screws: 4.2 N·m (0.43 kgf·m,
37 in·lb)
Alternator Lead Clamp Screws:
5.2 N·m (0.53
kgf·m, 46 in·lb)
• Apply silicone sealant around the circumference of the
wiring grommet.
Sealant - Liquid Gasket, TB1211F: 92104-0004
• Set the stator wiring grommet securely in the notch of the
alternator cover.
• Install the alternator cover (see Alternator Cover Installa-
tion).
Alternator Rotor Inspection
• There are three types of alternator problems: short, open
(wire burned out), or loss in rotor magnetism.
○A short or open in one of the coil wires will result in either
a low output, or no output at all.
○A loss in rotor magnetism, which may be caused by drop-
ping or hitting the rotor by leaving it near an electromag-
netic field, or just by aging, will result in low output.
ELECTRICAL SYSTEM 15-19
Alternator Rotor Inspection
Halaman 284
15-20 ELECTRICAL SYSTEM
Charging System
• Check the alternator output voltage, do the following pro-
cedures.
○Remove the fuel tank cover (see Fuel Tank Removal in
the Fuel System chapter).
○Disconnect the alternator lead connector [A].
○Connect the hand tester [A] to the connector [B] as shown
in the table 1, using the needle adapter set.
○Start the engine.
○Run it at the rpm given in the table 1.
○Note the voltage readings.
Special Tools - Hand Tester: 57001-1394
Needle Adapter Set: 57001-1457
Table 1, Alternator Output Voltage
Connections
Tester
Range
Tester (+) to
Tester (–) to
Reading
@4 000 rpm
50 V AC
White lead
Black/Red lead
48 V or more
If the output voltage shows the value in the table, the al-
ternator operates properly.
If the output voltage shows a much lower reading than that
given in the table indicates that the alternator is defective.
• To check the stator coil resistance as follows.
○Stop the engine.
○Connect the hand tester as shown in the table 2.
○Note the readings.
Table 2, Stator Coil Resistance
Connections
Tester
Range
Tester (+) to
Tester (–) to
Reading
× 1 Ω
White lead
Black/Red lead
0.2 ∼1.0 Ω
If there is more resistance than shown in the table, or no
hand tester reading (∞) the stator has an open lead and
must be replaced. Much less than this resistance means
the stator is shorted, and must be replaced.
• Using the highest resistance range of the hand tester,
measure the resistance between each leads and chas-
sis ground.
Any hand tester reading less than infinity (∞) indicates a
short, necessitating stator replacement.
If the stator coils have normal resistance, but the voltage
check showed the alternator to be defective; then the rotor
have probably weakened, and the rotor must be replaced.
Regulator/Rectifier Inspection
Halaman 285
Charging System
Charging Voltage Inspection
• Remove the seat (see Seat Removal in the Frame chap-
ter).
• Check the battery condition (see Charging Condition In-
spection).
• Warm up the engine to obtain actual alternator operating
conditions.
• Connect the hand tester [A] as shown in the table.
Special Tool - Hand Tester: 57001-1394
Charging Voltage
Connections
Tester
Range
Tester (+) to
Tester (−) to
Reading
Battery (−)
Terminal
14.4 ±0.5 V
• Start the engine, and note the voltage readings at various
engine speeds. The readings should show nearly battery
voltage when the engine speeds is low, and, as the engine
speed rises, the readings should also rise. But they must
be kept under the specified voltage.
• Stop the engine and disconnect the hand tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defective
or the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed
increases, the regulator/rectifier is defective or the alter-
nator output is insufficient for the loads. Check the al-
ternator and regulator/rectifier to determine which part is
defective.
25 V DC
Battery (+)
Terminal
Regulator/Rectifier Inspection
• Remove the fuel tank cover (see Fuel Tank Removal in
the Fuel System chapter).
• Clear the igniter and the main relay from the bracket.
• Remove the bolt [A], and disconnect the connector [B].
ELECTRICAL SYSTEM 15-21
Regulator/Rectifier Inspection
Halaman 286
15-22 ELECTRICAL SYSTEM
Charging System
KLX140A8F ∼A9F/B8F ∼B9F
• With the Kawasaki hand tester, measure the internal re-
sistance in both directions between the terminals.
Special Tool - Hand Tester: 57001-1394
If the reading is not the specified value, replace the reg-
ulator/rectifier.
Internal Resistance @20°C (68°F)
Unit: kΩ
Tester (+) Lead
Terminal
C
L
B
E
(–)*
C
–
∞
5 ∼50
∞
L
∞
–
∞
∞
B
∞
∞
–
∞
E
∞
∞
∞
–
(–)*: Tester (–) Lead
KLX140AAF ∼ABF/BAF ∼BBF
• With the Kawasaki hand tester, measure the internal re-
sistance in both directions between the terminals.
Special Tool - Hand Tester: 57001-1394
If the reading is not the specified value, replace the reg-
ulator/rectifier.
Internal Resistance @20°C (68°F)
Unit: kΩ
Tester (+) Lead
Terminal
A
B
C
(–)*
A
–
6.9 ∼70
∞
B
∞
–
∞
C
∞
∞
–
(–)*: Tester (–) Lead
NOTICE
Use only Hand Tester 57001-1394 for this test. An
ohmmeter other than the Hand Tester may show
different readings. If a megger or a meter with a
large-capacity battery is used, the regulator will be
damaged.
NOTE
○Install the regulator/rectifier [A] in parallel with the frame
down tube [B] as shown.
Regulator/Rectifier Inspection
Halaman 287
Charging System
Charging System Circuit (KLX140A8F ∼AAF/B8F ∼BAF)
1. Ignition Switch
2. Load
3. Regulator/Rectifier
4. Starter Relay
5. Main Fuse 10 A
6. Battery 12 V 6 Ah
7. Alternator
ELECTRICAL SYSTEM 15-23
Regulator/Rectifier Inspection
Halaman 288
15-24 ELECTRICAL SYSTEM
Charging System
Charging System Circuit (KLX140ABF/BBF)
1. Load
2. Regulator/Rectifier
3. Starter Relay
4. Main Fuse 10 A
5. Battery 12 V 6 Ah
6. Alternator
Starter Motor Clutch Inspection
Halaman 289
Starter Motor Clutch
Starter Motor Clutch Removal
• Remove the alternator rotor (see Alternator Rotor Re-
moval).
• Remove the starter motor clutch bolts [A] and the starter
motor clutch.
Starter Motor Clutch Installation
• Apply a non-permanent locking agent to the starter motor
clutch bolts.
Torque - Starter Motor Clutch Bolts: 12 N·m (1.2 kgf·m, 106
in·lb)
Starter Motor Clutch Inspection
• Remove:
Alternator Cover (see Alternator Cover Removal)
• Turn the starter motor clutch gear [A] by hand. The starter
motor clutch gear should turn clockwise [B] freely, but
should not turn counterclockwise [C].
If the starter motor clutch does not operate as it should or
if it makes noise, go to the next step.
• Disassemble the starter motor clutch, and visually inspect
the clutch parts.
If there is any worn or damaged part, replace it.
NOTE
○Examine the starter motor clutch gear as well. Replace
it if it worn or damaged.
ELECTRICAL SYSTEM 15-25
Ignition Timing Inspection
Halaman 290
15-26 ELECTRICAL SYSTEM
Ignition Timing
Ignition Timing Inspection
• Remove the alternator cover plug [A].
• Attach the timing light [A] to the ignition coil lead in the
manner prescribed by the manufacturer.
Special Tool - Timing Light: 57001-1241
• Start the engine and aim the timing light at the ignition
timing mark [B] on the rotor.
• Run the engine at the speeds specified and note the align-
ment of the ignition timing mark.
○Check the engine speed, using the engine revolution
tester for high accuracy.
Ignition Timing
Engine speed
[r/min (rpm)]
Head timing mark aligns with:
1 400
Line mark on camshaft sprocket
If the ignition timing is incorrect, check the crankshaft sen-
sor (see Crankshaft Sensor Inspection).
If the crankshaft sensor are normal, check the igniter (see
Igniter Inspection).
• Install the alternator cover plug.
Ignition Coil Removal/Installation
Halaman 291
Ignition System
WARNING
The ignition system produces extremely high volt-
age. Do not touch the spark plug, ignition coil or
high tension lead while the engine is running, or
you could receive a severe electrical shock.
Crankshaft Sensor Removal
• Refer to the Stator Removal.
Crankshaft Sensor Installation
• Refer to the Stator Installation.
Ignition Coil Removal/Installation
• Remove:
Fuel Tank Cover (see Fuel Tank Removal in the Fuel
System chapter)
Ignition Coil Primary Lead Connector [A]
• Pull the plug cap off the spark plug.
• Remove the mounting bolts [A] with the collars, and re-
move the ignition coil [B].
• Installation is the reverse of removal.
• Install the ignition coil, the frame ground lead and the
clamp correctly (see Cable, Wire and Hose Routing in the
Appendix chapter).
ELECTRICAL SYSTEM 15-27
Spark Plug Cleaning and Inspection
Halaman 292
15-28 ELECTRICAL SYSTEM
Ignition System
Ignition Coil Inspection
Measuring Arcing Distance
The most accurate test for determining the condition of
the ignition coil is made by measuring arcing distance using
the coil tester for the 3-needle method.
• Remove the ignition coil (see Ignition Coil Removal).
• Connect the ignition coil (with the spark plug cap left in-
stalled on the spark plug lead) [A] to the tester [B], and
measure the arcing distance.
WARNING
To avoid extremely high voltage shocks, do not
touch the coil body or leads.
If the distance reading is less than the specified value, the
ignition coil or spark plug cap is defective.
3 Needle Arcing Distance
Standard:
7 mm (0.26 in.) or more
• To determine which part is defective, measure the arcing
distance again with the spark plug cap removed from the
ignition coil lead.
If the arcing distance is subnormal as before, the trouble
is with the ignition coil itself. If the arcing distance is now
normal, the trouble is with the spark plug cap.
Measuring Coil Resistance
If the arcing tester is not available, the coil can be
checked for a broken or badly shorted winding with an
ohmmeter.
However, an ohmmeter cannot detect layer
shorts and shorts resulting from insulation breakdown
under high voltage.
• Remove the ignition coil (see Ignition Coil Removal).
• Measure the primary winding resistance [A].
○Connect an ohmmeter between the coil terminals.
○Set the meter to the × 1 Ωrange, and read the meter.
• Measure the secondary winding resistance [B].
○Unscrew the spark plug cap off the lead.
○Connect an ohmmeter between the high tension lead and
the ground lead terminal.
○Set the meter to the × 1 kΩrange, and read the meter.
Ignition Coil Winding Resistance
Primary windings:
0.64 ∼0.78 Ω
Secondary windings:
11.4 ∼14.0 kΩ
If the meter does not read as specified, replace the coil.
If the meter reads as specified, the ignition coil windings
are probably good. However, if the ignition system still
does not perform as it should after all other components
have been checked, test replace the coil with one known
to be good.
• Check the spark plug lead for visible damage.
If the spark plug lead is damaged, replace the coil.
Spark Plug Cleaning and Inspection
• Refer to the Spark Plug Cleaning and Inspection in the
Periodic Maintenance chapter.
Igniter Inspection
Halaman 293
Ignition System
Spark Plug Gap Inspection
• Refer to the Spark Plug Cleaning and Inspection in the
Periodic Maintenance chapter.
Igniter Removal
• Remove the fuel tank cover (see Fuel Tank Removal in
the Fuel System chapter).
• Remove the igniter [A], and disconnect the igniter con-
nector [B].
Igniter Inspection
NOTICE
When inspecting the IC Igniter observe the follow-
ing to avoid damage to the IC Igniter.
Do not disconnect the IC Igniter while the engine is
running.
This may damage the IC Igniter.
Ignition Coil Primary Peak Voltage Check
• Disconnect the spark plug cap from the spark plug, but do
not remove the spark plug.
• Connect the good spark plug [A] to the spark plug cap,
then touch the engine with it.
NOTE
○Measure the voltage with each lead connected cor-
rectly.
The correct value may not be obtained if
disconnected.
○Maintain the correct value of compression pressure for
the cylinder (Be sure to measure the voltage with the
spark plug install to the cylinder head).
• Connect the peak voltage adapter [B] between the termi-
nal of primary lead (black) and ground connection of the
unit with the lead of the ignition coil [C] connected.
○Set the tester to DC 250 V range.
Special Tools - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Needle Adapter Set: 57001-1457
Connection:
Adapter
Handtester
Ground [D]
←
Red Lead
→
(+)
Black Lead [E] ←
Black Lead
→
(–)
IC Igniter [F]
Needle Adapter [G]
ELECTRICAL SYSTEM 15-29
Igniter Inspection
Halaman 294
15-30 ELECTRICAL SYSTEM
Ignition System
• Shift the gear to the neutral position.
• Crank the engine by pushing the starter button several
times to measure the peak voltage of the primary ignition
coil.
Ignition Coil Primary Peak Voltage
Standard:
175 V or more
WARNING
Electrical equipment can cause serious electrical
shock. To avoid being shocked, do not touch the
metal portion of the probe when measuring voltage.
If the voltage is less than the specified value, check the
ignition coil (see Ignition Coil Inspection).
If the ignition coil is good, check the other parts (see the
flow chart in this section).
If the all parts are good, replace the igniter.
Crankshaft Sensor Peak Voltage Check
• To check the peak voltage, do the following procedures.
○Disconnect the alternator lead connector from the main
harness (see Alternator Cover Removal).
NOTE
○Measure the voltage with each lead connected cor-
rectly.
The correct value may not be obtained if
disconnected.
○Maintain the correct value of compression pressure for
the cylinder (Be sure to measure the voltage with the
spark plug installed to the cylinder head).
○Set the hand tester to DC 10 V range.
○Connect the peak voltage adapter [A] to the tester and the
terminals of the alternator lead connector [B].
Special Tools - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Connection:
Adapter
Handtester
Blue/Yellow
Lead [C]
←
Red Lead
→
(+)
Ground
←
Black Lead
→
(–)
○Crank the engine by pushing the starter button several
times with the transmission gear in neutral to measure
the peak voltage of the crankshaft sensor.
Crankshaft Sensor Peak Voltage
Standard:
2 V or more
WARNING
Electrical equipment can cause serious electrical
shock. To avoid being shocked, do not touch the
metal portion of the probe when measuring voltage.
If the voltage is less than the specified, check the crank-
shaft sensor (see Crankshaft Sensor Inspection).
If the crankshaft sensor is good, check the other parts
(see the flow chart in this section).
If the all parts are good, replace the igniter.
Crankshaft Sensor Inspection
Halaman 295
Ignition System
Crankshaft Sensor Inspection
• Remove:
Alternator Lead Connector (see Alternator Cover Re-
moval).
• Set the hand tester [A] to the × 10 Ωrange and connect
it to the Blue/Yellow lead [B] in the connector and the
ground.
Special Tool - Hand Tester: 57001-1394
If there is more resistance than the specified value, the
coil has an open lead and must be replaced.
Much
less than this resistance means the crankshaft sensor is
shorted, and must be replaced.
Crankshaft Sensor Resistance
Standard:
50 ∼200 Ω@20 °C (68 °F)
ELECTRICAL SYSTEM 15-31
Crankshaft Sensor Inspection
Halaman 296
15-32 ELECTRICAL SYSTEM
Ignition System
Crankshaft Sensor Inspection
Halaman 297
Ignition System
Ignition System Circuit (KLX140A8F ∼AAF/B8F ∼BAF)
1. Ignition Switch
2. Engine Stop Switch
3. Engine Starter Button
4. Main Fuse 10 A
5. Battery 12 V 6 Ah
6. Crankshaft Sensor
7. IC Igniter
8. Ignition Coil
9. Spark Plug
ELECTRICAL SYSTEM 15-33
Crankshaft Sensor Inspection
Halaman 298
15-34 ELECTRICAL SYSTEM
Ignition System
Ignition System Circuit (KLX140ABF/BBF)
1. Engine Stop Switch
2. Engine Starter Button
3. Main Fuse 10 A
4. Battery 12 V 6 Ah
5. Spark Plug
6. Ignition Coil
7. IC Igniter
8. Crankshaft Sensor
Starter Motor Disassembly
Halaman 299
Electrical Starter System
Starter Motor Removal
• Remove:
Exhaust Pipe (see Muffler Removal in the Engine Top
End chapter)
Starter Motor Terminal Nut [A]
Starter Motor Mounting Bolts [B]
Engine Ground [C]
• Pull out the starter motor [D] to right side.
Starter Motor Installation
NOTICE
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.
• Clean the starter motor mounting surface [A] and the
crankcase surface [B] (mating surface with starter motor
mounting).
• Replace the O-ring [A] with a new one.
• Apply grease to the O-ring.
• Install the starter motor and other removed parts.
Torque - Starter Motor Mounting Bolts: 6.9 N·m (0.70 kgf·m,
61 in·lb)
• Tighten the starter motor terminal nut while holding the
starter motor terminal locknut.
Torque - Starter Motor Terminal Nut: 5.2 N·m (0.53 kgf·m,
46 in·lb)
Starter Motor Disassembly
• Remove the starter motor (see Starter Motor Removal).
• Remove:
Starter Motor Through Bolts [A]
Both End Covers [B]
• Pull the armature out of the yoke.
• Remove the terminal locknut [A] and brush plate screws
[B] then remove the brush and the brush plate from the
end cover [C].
Brush Springs [D]
ELECTRICAL SYSTEM 15-35
Carbon Brush Inspection
Halaman 300
15-36 ELECTRICAL SYSTEM
Electrical Starter System
Starter Motor Assembly
• Replace the O-ring [A] with a new one.
• Apply a thin coat of high-temperature grease to the oil seal
and the needle bearing in the end cover [B].
• Fit the toothed washer [C] into the end cover.
Thin Washer [D]
Thick Washer [E]
• Install the brush plate [A] and brushes [B], and tighten the
terminal locknut [C].
Torque - Starter Motor Terminal Locknut:
6.9 N·m (0.70
kgf·m, 61 in·lb)
• Insert the armature [A] between the brushes.
Thin Washer [B]
Thick Washer [C]
• Align the marks [A] of the yoke and end covers.
Torque - Starter Motor Through Bolts: 4.9 N·m (0.50 kgf·m,
43 in·lb)
Carbon Brush Inspection
• Measure the length [A] of each brush.
If any one is worn down to the service limit, replace the
carbon brush set [B].
Carbon Brush Length
Standard:
7.0 mm (0.28 in.)
Service Limit:
3.5 mm (0.14 in.)
Brush Lead Inspection
Halaman 301
Electrical Starter System
Commutator Inspection, Cleaning
• Smooth the commutator surface [A] if necessary with fine
emery cloth [B], and clean out the grooves.
• Measure the outer diameter [A] of the commutator [B].
Replace the starter motor with a new one if the commu-
tator diameter is less than the service limit.
Commutator Diameter
Standard:
22.1 mm (0.87 in.)
Service Limit:
21.6 mm (0.85 in.)
Armature Inspection
• Using the × 1 Ωhand tester range, measure the resis-
tance between any two commutator segments [A].
If there is a high resistance or no reading (∞) between any
two segments, a winding is open and the starter motor
must be replaced.
• Using the × kΩhand tester range, measure the resistance
between the segments and the shaft [B].
If there is any reading at all, the armature has a short and
the starter motor must be replaced.
Special Tool - Hand Tester: 57001–1394
NOTE
○Even if the foregoing checks show the armature to be
good, if may be defective in some manner not readily
detectable with the hand tester. If all other starter motor
and starter motor circuit components check good, but
the starter motor still does not turn over or only turns
over weakly, replace the starter motor with a new one.
Brush Lead Inspection
• Using the × 1 Ωhand tester range, measure the continuity
between the following:
Terminal Bolt and Positive (+) Brush [A]
End Cover and Negative (–) Brush [B]
If there is not close to zero ohms, the brush lead has an
open. Replace the terminal bolt assembly and the brush
holder assembly.
Special Tool - Hand Tester: 57001–1394
ELECTRICAL SYSTEM 15-37
Starter Relay Inspection
Halaman 302
15-38 ELECTRICAL SYSTEM
Electrical Starter System
Terminal Bolt Inspection
• Using the highest hand tester range, measure the resis-
tance as shown.
Terminal Bolt and End Cover [A]
Terminal Bolt and Negative Brush [B]
If there is any reading, the brush holder assembly and/or
terminal bolt assembly have a short. Replace the brush
holder assembly and the terminal bolt assembly.
Special Tool - Hand Tester: 57001–1394
Starter Relay Inspection
• Remove the seat (see Seat Removal in the Frame chap-
ter).
• Disconnect the connector [A].
• Disconnect the starter motor cable [B] and battery positive
(+) cable [C] from the starter relay [D].
• Connect the hand tester [A] and 12 V battery [B] to the
starter relay [C] as shown.
If the relay does not work as specified, the relay is defec-
tive. Replace the relay.
Starter Relay Inspection
Tester range:
× 1 Ω
Standard:
When battery is connected →0 Ω
When battery is disconnected →∞Ω
Special Tool - Hand Tester: 57001–1394
• Install the cables and other removed parts.
Torque - Starter Relay Terminal Screws:
2.9 N·m (0.30
kgf·m, 26 in·lb)
Starter Relay Inspection
Halaman 303
Electrical Starter System
Electrical Starter System Circuit (KLX140A8F ∼AAF/B8F ∼BAF)
1. Ignition Switch
2. Engine Stop Switch
3. Engine Starter Button
4. Main Relay
5. Starter Motor
6. Main Fuse 10 A
7. Starter Relay
8. Battery 12 V 6 Ah
9. Starter Lockout Switch
10. Neutral Switch
ELECTRICAL SYSTEM 15-39
Starter Relay Inspection
Halaman 304
15-40 ELECTRICAL SYSTEM
Electrical Starter System
Electrical Starter System Circuit (KLX140ABF/BBF)
1. Engine Stop Switch
2. Engine Starter Button
3. Main Relay
4. Starter Motor
5. Main Fuse 10 A
6. Starter Relay
7. Battery 12 V 6 Ah
8. Neutral Switch
9. Starter Lockout Switch
LED Inspection
Halaman 305
Switches and Sensors
Switch Inspection
• Using the hand tester, check to see that only the con-
nections shown in the table have continuity (about zero
ohms).
Special Tool - Hand Tester: 57001-1394
○For the ignition switch (KLX140A8F ∼AAF/B8F ∼BAF)
and the left switch housing (KLX140ABF/BBF), refer to
the tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace it
with a new one.
KLX140A8F ∼AAF/B8F ∼BAF
KLX140A8F ∼AAF/B8F ∼BAF
LED Inspection
KLX140A8F ∼AAF/B8F ∼BAF
• Turn the ignition switch ON.
If the LED on the ignition switch do not light, check the
following parts:
Battery (see Charging Condition Inspection)
Main Fuse 10 A (see Main Fuse 10 A Inspection)
Main Harness (see Wiring Inspection)
If the all parts are good, replace the ignition switch.
KLX140ABF/BBF
• Push the engine stop switch to RUN position.
If the LED on the ignition switch do not light, check the
following parts:
Battery (see Charging Condition Inspection)
Main Fuse 10 A (see Main Fuse 10 A Inspection)
Main Harness (see Wiring Inspection)
If the all parts are good, replace the left switch housing.
ELECTRICAL SYSTEM 15-41
Main Relay Inspection
Halaman 306
15-42 ELECTRICAL SYSTEM
Main Relay
Main Relay Inspection
• Remove the fuel tank cover (see Fuel Tank Removal in
the Fuel System chapter).
• Remove the main relay [A] from the bracket.
○Remove the boot and connector.
• Check conductivity of the following numbered terminals
by connecting the hand tester and one 12 V battery to the
main relay as shown.
If the tester does not read as specified, replace the main
relay.
Main Relay Inspection (with the battery disconnected)
Tester Connection
Tester Reading (Ω)
3-5
∞
1-2
Not ∞*
*: The actual reading varies with the hand tester used.
Main Relay Inspection (with the battery connected)
Battery Connection
(+)
(–)
Tester Connection
Tester Reading
(Ω)
1-2
3-5
0
(+): Apply positive lead.
(–): Apply negative lead.
Main Fuse 10 A Inspection
Halaman 307
Fuses
Main Fuse 10 A Removal
• Remove the seat (see Seat Removal in the Frame chap-
ter).
• Disconnect the starter relay connector [A].
• Remove the main fuse [B] from the starter relay.
Main Fuse 10 A Inspection
• Remove the fuse (see Main Fuse 10 A Removal) and in-
spect the fuse element.
If the fuse element is blown, replace the fuse.
Housing [A]
Fuse Element [B]
Terminal [C]
Blown Element [D]
NOTICE
When replacing a fuse, be sure the new fuse
matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring ad components.
ELECTRICAL SYSTEM 15-43
Appendix
Halaman 309
Appendix
Table of Contents
Cable, Wire, and Hose Routing..............................................................................................
16-2
Troubleshooting Guide ...........................................................................................................
16-20
APPENDIX 16-1
16
Cable, Wire, and Hose Routing
Halaman 310
16-2 APPENDIX
Cable, Wire, and Hose Routing
KLX140A8F ∼AAF/B8F ∼BAF
Cable, Wire, and Hose Routing
Halaman 311
Cable, Wire, and Hose Routing
1. Throttle Cable
2. Clamps
3. Starter Button Lead
4. Choke Cable
5. Ignition Switch
6. Engine Stop Switch Lead
7. Starter Lockout Switch Lead
8. Run the clutch cable to the front of the engine stop switch lead and starter lockout switch lead.
9. Clutch Cable
10. View from Upside
APPENDIX 16-3
Cable, Wire, and Hose Routing
Halaman 312
16-4 APPENDIX
Cable, Wire, and Hose Routing
KLX140ABF/BBF
Cable, Wire, and Hose Routing
Halaman 313
Cable, Wire, and Hose Routing
1. Throttle Cable
2. Choke Cable
3. Clamp
4. Left Switch Housing Lead
5. Starter Lockout Switch Lead
6. Clamp
7. Run the clutch cable to the front side of the left switch housing lead and starter lockout switch
lead.
8. Clutch Cable
APPENDIX 16-5
Cable, Wire, and Hose Routing
Halaman 314
16-6 APPENDIX
Cable, Wire, and Hose Routing
Cable, Wire, and Hose Routing
Halaman 315
Cable, Wire, and Hose Routing
1. Choke Cable (Run the choke cable to the right side of the motorcycle.)
2. Throttle Cable (Run the throttle cable to the right side of the motorcycle.)
3. Main Harness
4. Ignition Coil Primary Lead Connector
5. Clamp (Fix the ignition coil primary lead and frame ground lead.)
6. Clutch Cable
7. Clamp
8. Frame Ground Lead
9. View from A
APPENDIX 16-7
Cable, Wire, and Hose Routing
Halaman 316
16-8 APPENDIX
Cable, Wire, and Hose Routing
Cable, Wire, and Hose Routing
Halaman 317
Cable, Wire, and Hose Routing
1. Engine Stop Switch Connector (2-pins Connector, Natural)
2. Starter Lockout Switch Connector (2-pins Connector, Green)
3. Starter Button Connector (2-pins Connector, Black)
4. Ignition Switch Connector (4-pins Connector, Green)
5. Clamp
6. Regulator/Rectifier
7. Main Relay Connector (Black)
8. Regulator/Rectifier Connector (Green)
9. Install the regulator/rectifier so that the regulator/rectifier and down tube become parallel.
10. Igniter Connectors
11. Alternator Lead Connector (Run the alternator lead to the left side of the motorcycle.)
12. Battery Negative (–) Lead Connector
13. To Battery Negative (–) Terminal
14. Left Switch Housing Lead
15. KLX140ABF/BBF Models
APPENDIX 16-9
Cable, Wire, and Hose Routing
Halaman 318
16-10 APPENDIX
Cable, Wire, and Hose Routing
Cable, Wire, and Hose Routing
Halaman 319
Cable, Wire, and Hose Routing
1. Do not pinch the alternator lead between frame and fuel tank.
2. Starter Motor
3. Install the engine ground lead so that the engine ground lead and starter motor become parallel.
4. Bend the clamps of the frame to fix the main harness and alternator lead.
5. Bend the clamp of the frame to fix the main harness and engine ground lead.
6. Bend the clamp of the frame to fix the starter motor cable.
7. Starter Relay
8. Clamps
9. View from A
10. View from B
11. About 25°
12. Front
APPENDIX 16-11
Cable, Wire, and Hose Routing
Halaman 320
16-12 APPENDIX
Cable, Wire, and Hose Routing
Cable, Wire, and Hose Routing
Halaman 321
Cable, Wire, and Hose Routing
1. Alternator Lead
2. Run the neutral switch lead along the alternator cover as shown in the figure.
3. Neutral Switch
APPENDIX 16-13
Cable, Wire, and Hose Routing
Halaman 322
16-14 APPENDIX
Cable, Wire, and Hose Routing
Cable, Wire, and Hose Routing
Halaman 323
Cable, Wire, and Hose Routing
1. Clamp
2. Front Brake Hose
3. Front Brake Disc
4. Front Brake Caliper
5. Clamp
6. Front Brake Master Cylinder
7. View from A-A
8. Install the front brake hose so that it touch the front brake caliper.
9. View from B
10. Rear Brake Hose
11. Rear Brake Master Cylinder
12. Clamps
13. Rear Brake Caliper
14. Rear Brake Disc
APPENDIX 16-15
Cable, Wire, and Hose Routing
Halaman 324
16-16 APPENDIX
Cable, Wire, and Hose Routing
Cable, Wire, and Hose Routing
Halaman 325
Cable, Wire, and Hose Routing
1. Breather Hose (Run the breather hose to the inside of the frame.)
2. Carburetor
3. Clamp
4. Air Vent Hoses (Run the air vent hoses between the middle engine bracket and engine ground
lead.)
5. Overflow Hose (Run the overflow hose between middle engine bracket and engine ground lead.)
APPENDIX 16-17
Cable, Wire, and Hose Routing
Halaman 326
16-18 APPENDIX
Cable, Wire, and Hose Routing
Cable, Wire, and Hose Routing
Halaman 327
Cable, Wire, and Hose Routing
1. Breather Hose
2. Run the breather hose to the left side of the carburetor.
3. Carburetor
4. Air Cleaner Housing
APPENDIX 16-19
Troubleshooting Guide
Halaman 328
16-20 APPENDIX
Troubleshooting Guide
This is not an exhaustive list, giving every
possible cause for each problem listed.
it is
meant simply as a rough guide to assist the
troubleshooting for some of the more common
difficulties.
Engine Doesn’t Start, Starting
Difficulty:
Starter motor not rotating:
Starter lockout switch trouble
Starter motor trouble
Battery voltage low
Starter relay not contacting or operating
Starter button not contacting
Wiring open or shorted
Engine stop switch trouble
Fuse blown
Starter motor rotating but engine doesn’t
turn over:
Starter clutch trouble
Engine won’t turn over:
Valve seizure
Valve lifter seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end, big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Starter idle gear seizure
No fuel flow:
No fuel in tank
Fuel tank cap air vent obstructed
Fuel tap clogged
Fuel tap turned off
Fuel line clogged
Carburetor float valve clogged
Engine flooded:
Fuel level in carburetor float bowl too high
Float valve worn or jammed with foreign
matter
Starting technique faulty (When flooded,
crank the engine with the throttle fully
opened to allow more air to reach the
engine.)
Fuel/air mixture incorrect:
Idle adjusting screw maladjusted
Pilot jet or air passage clogged
Air cleaner clogged, poorly sealed or miss-
ing
Starter jet clogged
No spark; spark weak:
Spark plug dirty, broken or gap maladjusted
Spark plug cap or high tension wiring trou-
ble
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect heat value
Faulty IC igniter
Crankshaft sensor trouble
Ignition coil trouble
Engine stop switch shorted
Neutral switch trouble
Wiring shorted or open
Rotor damaged
Compression Low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent, de-
formed, worn or carbon accumulation on
the seating surface)
Poor Running at Low Speed:
Spark weak:
Battery voltage low
Spark plug dirty, broken or gap maladjusted
Spark plug cap or high tension wiring trou-
ble
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect heat value
Faulty IC igniter
Crankshaft sensor trouble
Rotor damaged
Ignition coil trouble
Wiring connector not in good contact
Fuel/air mixture incorrect:
Pilot screw maladjusted
Pilot jet or air passage clogged
Needle Jet or air passage clogged
Air cleaner clogged, poorly sealed or miss-
ing
Choke valve closed
Fuel level in carburetor float bowl too high
or too low
Fuel tank cap air vent obstructed
Fuel tap clogged
Carburetor holder loose
Air cleaner duct loose
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Troubleshooting Guide
Halaman 329
Troubleshooting Guide
Piston ring bad (worn, weak, broken or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent, de-
formed, worn or carbon accumulation on
the seating surface)
Other:
Faulty IC igniter
Engine oil level to high
Engine oil viscosity too high
Brake dragging
Drive train trouble
Engine overheating
Clutch slipping
Poor Running or No Power at High
Speed:
Firing incorrect:
Spark plug dirty, broken or gap maladjusted
Spark plug cap or high tension wiring trou-
ble
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect heat value
Faulty IC igniter
Crankshaft sensor trouble
Rotor damaged
Ignition coil trouble
Wiring connector not in good contact
Fuel/air mixture incorrect:
Choke valve closed
Main jet clogged or wrong size
Jet needle or needle jet worn
Air jet clogged
Fuel level in carburetor float bowl too high
or too low
Needle Jet or air passage clogged
Air cleaner clogged, poorly sealed or miss-
ing
Air cleaner duct loose
Water or foreign matter in fuel
Carburetor holder loose
Fuel tank cap air vent obstructed
Fuel tap clogged
Fuel line clogged
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken or
sticking)
Piston ring/groove clearance excessive
APPENDIX 16-21
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent, de-
formed, worn or carbon accumulation on
the seating surface.)
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect heat valve
Faulty IC igniter
Crankshaft Sensor trouble
Other:
Throttle valve won’t fully open
Brake dragging
Air cleaner clogged
Water or foreign matter in fuel
Clutch slipping
Overheating
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Crankshaft bearing worn or damaged
Engine Overheating:
Firing incorrect:
Spark plug dirty, broken or maladjusted
Spark plug incorrect
Faulty IC igniter
Fuel/air mixture incorrect:
Main jet clogged or wrong size
Fuel level in carburetor float bowl too low
Carburetor holder loose
Air cleaner clogged, poorly sealed or miss-
ing
Air cleaner duct loose
Choke valve closed
Compression high:
Carbon built up in combustion chamber
Engine load faulty:
Clutch slipping
Engine oil level too high
Engine oil viscosity too high
Brake dragging
Drive train trouble
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Clutch Operation Faulty:
Clutch slipping:
No clutch lever play
Clutch cable maladjusted
Clutch inner cable sticking
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Troubleshooting Guide
Halaman 330
16-22 APPENDIX
Troubleshooting Guide
Clutch release function trouble
Clutch hub or housing unevenly worn
Clutch not disengaging properly:
Clutch lever play excessive
Clutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing seized
Clutch release function trouble
Clutch hub nut loose
Clutch plate warped or rough
Clutch hub spline damaged
Gear Shifting Faulty:
Doesn’t go into gear; shift pedal doesn’t
return:
Clutch not disengaging
Shift fork bent, worn, or seized
Shift return spring pin loose
Shift return spring weak or broken
Shift shaft lever broken
Pawl guide plate broken
Shift pawl broken
Shift pawl spring tension lose
Gear seized
Gear set lever operation trouble
Shift drum broken
Jumps out of gear:
Shift fork ear worn, bent
Gear groove worn
Gear dogs and/or dog holes worn
Shift drum groove worn
Gear set lever spring weak or broken
Shift fork guide pin worn
Drive shaft, output shaft and/or gear splines
worn
Overshifts:
Gear set lever spring weak or broken
Pawl guide plate worn
Abnormal Engine Noise:
Knocking:
Faulty IC igniter
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect heat value
Overheating
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearing or cam face worn
Valve lifter worn
Other noise:
Connecting rod big end and/or small end
clearance excessive
Piston ring worn, broken or stuck
Piston seizure, damaged
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head con-
nection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Camshaft chain tensioner trouble
Camshaft chain, sprocket, chain guide worn
Primary gear worn or damaged
Alternator rotor loose
Abnormal Drive Train Noise:
Clutch noise:
Clutch housing finger and friction plate tang
worn
Clutch housing gear worn
Metal chips jammed in clutch housing gear
teeth
Transmission noise:
Bearings worn
Transmission gears worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient, low viscosity
Drive chain noise:
Drive chain maladjusted
Drive chain worn
Rear and/or engine sprocket worn
Drive chain lubrication insufficient
Rear wheel misaligned
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Front fork air pressure high
Rear shock absorber noise:
Shock absorber trouble
Spring weak or broken
Disc brake noise:
Pad surface glazed
Disc warped
Caliper trouble
Pad installed incorrectly
Master cylinder damaged
Other noise:
Bracket,
nut,
bolt,
etc.,
not
properly
mounted or tightened
Troubleshooting Guide
Halaman 331
Troubleshooting Guide
Abnormal Exhaust Color:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high
Black smoke:
Air cleaner element clogged
Main jet too large or fallen off
Choke valve closed
Fuel level in carburetor float bowl too high
Brown smoke:
Main jet too small
Fuel level in carburetor float bowl too low
Air cleaner duct loose
Air cleaner poorly sealed or missing
Handling and/or Stability
Unsatisfactory:
Handlebar hard to turn:
Cable, hose, wire routing incorrect
Steering stem nut too tight
Steering stem bearing damaged
Steering stem bearing lubrication inade-
quate
Steering stem bent
Tire air pressure too low
Handlebar shakes or excessively vibrates:
Tire worn
Swingarm pivot bearings worn
Rim warped or not balanced
Spokes loose
Wheel bearing worn
Handlebar holder bolt loose
Steering stem head nut loose
Front, rear axle runout excessive
Handlebar pulls to one side:
Frame bent
Rear wheel misalignment
Swingarm bent or twisted
Swingarm pivot shaft bent
Steering maladjusted
APPENDIX 16-23
Steering stem bent
Front fork bent
Right and left front fork oil level uneven
Suspension operation trouble:
(Too hard)
Tire air pressure too high
Front fork oil excessive
Front fork oil viscosity too high
Rear shock absorber adjustment too hard
Front fork bent
Front fork air pressure too high
(Too soft)
Front fork oil insufficient or leaking
Front fork oil viscosity too low
Rear shock absorber adjusted too soft
Front fork, rear shock absorber spring weak
Rear shock absorber oil or gas leaking
Tire air pressure too low
Brake Doesn’t Hold:
Air in brake system
Pad, disc worn
Brake fluid leakage
Contaminated pad
Brake fluid deteriorated
Brake master cylinder cups damaged
Master cylinder scratched inside
Disc warped
Battery Trouble:
Battery discharged:
Charge insufficient
Battery faulty (too low terminal voltage)
Battery lead making poor contact
Load excessive (e.g., bulb of excessive
wattage)
Alternator trouble
Wiring faulty
Regulator/rectifier trouble
Battery overcharged:
Alternator trouble
Regulator/rectifier trouble
Battery faulty
Troubleshooting Guide
Halaman 332
MODEL APPLICATION
Year
Model
Beginning Frame No.
2008
KLX140A8F
JKBLXPA1□8DA00036
2008
KLX140B8F
JKBLXPB1□8DA00040
2009
KLX140A9F
JKBLXPA1□9DA03214
2009
KLX140B9F
JKBLXPB1□9DA04790
2010
KLX140AAF
JKBLXPA1□ADA05349
2010
KLX140BAF
JKBLXPB1□ADA08383
2011
KLX140ABF
JKBLXPA1□BDA05509
2011
KLX140BBF
JKBLXPB1□BDA09083
□:This digit in the frame number changes from one machine to another.
