Kawasaki KLX140 / KLX140L

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Kawasaki KLX140 & KLX140L

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# KAWASAKI

KLX140
KLX140L

(Image of a Kawasaki dirt bike)

## Motorcycle Service Manual

Page 1

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
j

Electrical System
15
j

Appendix
16
j

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.

Page 2

Kawasaki

KLX140
KLX140L

Motorcycle
Service Manual

Page 3

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.

Page 4

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.

Page 5

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.

Page 6

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.

Page 7

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.

Page 8

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]

Page 9

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.

Page 10

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

Page 11

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.

Page 12

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

Page 13

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.

Page 14

GENERAL INFORMATION 1-7

### Model Identification

#### KLX140A8F Left Side View

GB038364 P

#### KLX140A8F Right Side View

GB038365 P

| Frame Number                                     | Engine Number                                    |
| :----------------------------------------------- | :----------------------------------------------- |
| ![Frame Number](image_frame_number_crop.jpeg)    | ![Engine Number](image_engine_number_crop.jpeg)  |
| GB038363 P                                       | GB038362 P                                       |

Page 15

1-8 GENERAL INFORMATION

Model Identification

KLX140B8F Left Side View

KLX140B8F Right Side View

Page 16

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

Page 17

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.)
←

Page 18

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

Page 19

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

Page 20

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

Page 21

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

Page 22

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

Page 23

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

Page 24

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

Page 25

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

Page 26

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

Page 27

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
– – –

Page 28

PERIODIC MAINTENANCE 2-9

# Specifications

| Item                                    | Standard                                            | Service Limit              |
| :-------------------------------------- | :-------------------------------------------------- | :------------------------- |
| **Final Drive**                         |                                                     |                            |
| &nbsp;&nbsp;&nbsp;Drive Chain Slack     | 35 ~ 41 mm (1.4 ~ 1.6 in.)                          | ---                        |
| &nbsp;&nbsp;&nbsp;Drive Chain 20 Link Length | 254.0 ~ 254.6 mm (10.00 ~ 10.02 in.)                | 260 mm (10.2 in.)          |
| &nbsp;&nbsp;&nbsp;Rear Sprocket Warp    | 0.4 mm (0.016 in.) or less                          | 0.5 mm (0.020 in.)         |
| **Brakes**                              |                                                     |                            |
| &nbsp;&nbsp;&nbsp;Brake Lever Free Play | (to suit rider)                                     | ---                        |
| &nbsp;&nbsp;&nbsp;Brake Fluid:          |                                                     |                            |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;Type: | DOT3 or DOT4                                        | ---                        |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;Front/Rear |                                                     |                            |
| &nbsp;&nbsp;&nbsp;Brake pad lining thickness: |                                                     |                            |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;Front | 4.5 mm (0.18 in.)                                   | 1 mm (0.04 in.)            |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;Rear  | 3.7 mm (0.15 in.)                                   | 1 mm (0.04 in.)            |
| **Suspension**                          |                                                     |                            |
| &nbsp;&nbsp;&nbsp;Fork Oil:             |                                                     |                            |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;Oil Viscosity | SHOWA SS-8 or equivalent                            | ---                        |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;Oil Quantity: |                                                     |                            |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;KLX140A | 296 ±2.5 mL (10.01 ±0.085 US oz)                    | ---                        |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;KLX140B | 290 ±2.5 mL (9.80 ±0.085 US oz)                     | ---                        |
| **Electrical System**                   |                                                     |                            |
| &nbsp;&nbsp;&nbsp;Spark Plug Gap        | 0.6 ~ 0.7 mm (0.02 ~ 0.03 in.)                      | ---                        |

TIR: Total Indicator Readings

Page 29

# 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)

Page 30

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

Page 31

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.

Page 32

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

Page 33

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.

Page 34

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

Page 35

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]

Page 36

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

Page 37

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.

Page 38

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

Page 39

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

Page 40

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

Page 41

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.)

Page 42

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

Page 43

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.

Page 44

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

Page 45

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.

Page 46

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

Page 47

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.

Page 48

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

Page 49

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

Page 50

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

Page 51

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.

Page 52

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

Page 53

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].

Page 54

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

Page 55

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.

Page 56

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

Page 57

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).

Page 58

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

Page 59

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

Page 60

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

Page 61

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

Page 62

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

Page 63

## 3-2 FUEL SYSTEM
### Exploded View

GC023778WS C

Page 64

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

Page 65

3-4 FUEL SYSTEM
Exploded View

GC02376BW5 C

Page 66

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.

Page 67

## 3-6 FUEL SYSTEM
Exploded View

GC023339BW5 C

Page 68

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.

Page 69

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

Page 70

Special Tool

Fuel Level Gauge:
57001-1017

FUEL SYSTEM 3-9

Page 71

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).

Page 72

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

Page 73

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.

Page 74

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

Page 75

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.

Page 76

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

Page 77

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].

Page 78

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

Page 79

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.

Page 80

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

Page 81

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.

Page 82

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

Page 83

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.

Page 84

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

Page 85

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.

Page 86

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

Page 87

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

Page 88

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

Page 89

# 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

Page 90

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.

Page 91

# 4-6 ENGINE TOP END
## Specifications

| Item | Standard | Service Limit |
| :--- | :--- | :--- |
| **Camshafts** | | |
| Cam Height: | | |
| &nbsp;&nbsp;&nbsp;&nbsp;Exhaust | 36.138 ~ 36.252 mm (1.4228 ~ 1.4272 in.) | 36.04 mm (1.419 in.) |
| &nbsp;&nbsp;&nbsp;&nbsp;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: | | |
| &nbsp;&nbsp;&nbsp;&nbsp;Exhaust | 0.11 ~ 0.15 mm (0.004 ~ 0.006 in.) | --- |
| &nbsp;&nbsp;&nbsp;&nbsp;Intake | 0.04 ~ 0.08 mm (0.002 ~ 0.003 in.) | --- |
| Valve Head Thickness: | | |
| &nbsp;&nbsp;&nbsp;&nbsp;Exhaust | 1.15 ~ 1.45 mm (0.045 ~ 0.057 in.) | 0.5 mm (0.02 in.) |
| &nbsp;&nbsp;&nbsp;&nbsp;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: | | |
| &nbsp;&nbsp;&nbsp;&nbsp;Exhaust | 4.958 ~ 4.973 mm (0.1952 ~ 0.1958 in.) | 4.93 mm (0.194 in.) |
| &nbsp;&nbsp;&nbsp;&nbsp;Intake | 4.975 ~ 4.990 mm (0.1959 ~ 0.1965 in.) | 4.95 mm (0.195 in.) |
| Valve Guide Inside Diameter | | |
| &nbsp;&nbsp;&nbsp;&nbsp;Exhaust | 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in.) | 5.08 mm (0.200 in.) |
| &nbsp;&nbsp;&nbsp;&nbsp;Intake | 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in.) | 5.08 mm (0.200 in.) |
| Valve/Valve Guide Clearance | | |
| (Wobble Method): | | |
| &nbsp;&nbsp;&nbsp;&nbsp;Exhaust | 0.07 ~ 0.13 mm (0.003 ~ 0.005 in.) | 0.31 mm (0.012 in.) |
| &nbsp;&nbsp;&nbsp;&nbsp;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: | | |
| &nbsp;&nbsp;&nbsp;&nbsp;Outside Diameter: | | |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;Exhaust | 22.9 ~ 23.1 mm (0.90 ~ 0.91 in.) | --- |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;Intake | 26.4 ~ 26.6 mm (1.04 ~ 1.05 in.) | --- |
| &nbsp;&nbsp;&nbsp;&nbsp;Width: | | |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;Exhaust | 0.8 ~ 1.2 mm (0.03 ~ 0.05 in.) | --- |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;Intake | 0.8 ~ 1.2 mm (0.03 ~ 0.05 in.) | --- |
| Valve Spring Free Length: | | |
| &nbsp;&nbsp;&nbsp;&nbsp;Exhaust | 36.43 mm (1.434 in.) | 34.5 mm (1.36 in.) |
| &nbsp;&nbsp;&nbsp;&nbsp;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.) | --- |

Page 92

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

Page 93

# 4-8 ENGINE TOP END
## Specifications

---

**Cam Height**

![Cam Height Diagram with label A indicating height](GE110122S1 C)

Cam Height [A]

---

**Camshaft Runout**

![Camshaft Runout Diagram with a dial gauge](GE110617S1 C)

---

**Valve Head Thickness**

![Valve Head Thickness Diagram with labels A, B, C](GE15004BS1 C)

Valve Stem Diameter [A]
Valve Head Thickness [B]
45° [C]

---

**Valve Stem Bend**

![Valve Stem Bend Diagram with a dial gauge and supports, label A](GE150112S1 C)

Dial Gauge [A]

Page 94

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

Page 95

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

Page 96

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

Page 97

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)

Service Manual Kawasaki KLX140 / KLX140L

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