Manual de Taller KAWASAKI KLX140L MANUAL TALLER 2012

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KLX140

KLX140L

Motorcycle

Service Manual

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.

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

KLX140

KLX140L

Motorcycle

Service Manual

transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,

without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki

Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible

care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation

to make such changes to products manufactured previously. See your Motorcycle dealer for the latest

information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time

of publication. Illustrations and photographs in this publication are intended for reference use only and may

not depict actual model component parts.

LIST OF ABBREVIATIONS

ampere(s)

pound(s)

ABDC after bottom dead cente

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 rea

ding

ft foot, feet

volt(s)

gram(s)

watt(s)

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.

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.

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.

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.

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.

Indicates a conditional step or what action to

take based on the results of the test or inspec-

tion in the procedural step or sub-step it fol-

lows.

In most chapters an exploded view illustration

of the system components follows the Table of

Contents. In these illustrations you will find the

instructions indicating which parts require spec-

ified tightening torque, oil, grease or a locking

agent during assembly.

GENERAL INFORMATION 1-1

General Information

Table of Contents

Before Servicing ..................................................................................................................... 1-2

Model Identification................................................................................................................. 1-7

General Specifications............................................................................................................ 1-9

Unit Conversion Table ............................................................................................................ 1-12

1-2 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.

GENERAL INFORMATION 1-3

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.

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 performance.

Remove old gaskets and clean the sealing surfaces thor-

oughly so that no gasket material or other material remains.

Install new gaskets and replace the 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 exces-

sively. Excessive application can clog oil passages and

cause serious damage.

GENERAL INFORMATION 1-5

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.

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.

GENERAL INFORMATION 1-7

Model Identification

KLX140A8 Left Side View

KLX140A8 Right Side View

Frame Number Engine Number

1-8 GENERAL INFORMATION

Model Identification

KLX140B8 Left Side View

KLX140B8 Right Side View

GENERAL INFORMATION 1-9

General Specifications

Items KLX140A8 ∼ AC KLX140B8 ∼ BC

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:

KLX140A8/B8 88 kg (194 lb) 90 kg (198 lb)

Curb Mass:

KLX140A9 ∼/B9 ∼ 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 1.1L(1.2USqt)

←

1-10 GENERAL INFORMATION

General Specifications

Items KLX140A8 ∼ AC KLX140B8 ∼ BC

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 Rat

10.286 @Top gear 11.298 @Top gear

Frame

Type Tube double cradle ←

Steering Angle 41° to either side ←

Caster (rake angle) 27° ←

Trail 85 mm (3.3 in.) 96 mm (3.8 in.)

Front Tire:

Size 70/100-17 40M 70/100-19 42M

Make/Type IRC, IX05H, Tube ←

Rear Tire:

Size 90/100-14 49M 90/100-16 52M

Make/Type IRC, IX05H, Tube

←

Rim Size:

Front 17 × 1.40 19 × 1.40

Rear 14 × 1.60 16 × 1.85

Front Suspension:

Type Telescopic fork ←

Wheel Travel 180 mm (7.09 in.) ←

Rear Suspension:

Type Swingarm (Uni-trak) ←

Wheel travel 180 mm (7.09 in.) ←

Brake Type:

Front and Rear Single disc ←

Effective Disc Diameter:

Front (effect. dia.) 192 mm (7.56 in.) ←

Rear (effect. dia.) 150 mm (5.91 in.) ←

GENERAL INFORMATION 1-11

General Specifications

Items KLX140A8 ∼ AC KLX140B8 ∼ BC

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.

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 = kg

N × 0.2248 = lb

kg × 9.807 = N

kg × 2.205 = lb

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 = cmHg

kgf/cm² × 98.07 = kPa

kgf/cm² × 14.22 = psi

cmHg × 1.333 = kPa

Units of Speed:

km/h

× 0.6214 = mph

Units of Power:

kW × 1.360 = PS

kW × 1.341 = HP

× 0.7355 = kW

PS × 0.9863 = HP

Units of Temperature:

PERIODIC MAINTENANCE 2-1

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

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

Sidestand 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

2-2 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)

See

Page

Spark plug - clean, gap †

• •

2-40

Clutch and friction plate - inspect †

• • •

2-18

Clutch cable - adjust †

• • •

2-17

Valve clearance - inspect †

• •

2-15

Air cleaner element - clean †

• • •

2-12

Throttlegripplay-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

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

• • •

–

Sidestand - 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 - inspe

• • •

2-20

†: Replace, add, adjust, clean or torque if necessary.

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY

Initial Every

hours (month (s))

5 50 100

OPERATION (1) (6) (12)

See

Page

Engine oil

• • •

2-18

Oil filter

• • •

2-19

Brake hose Every 4 years 2-32

Fuel hose Every 5 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

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 78 in·lb

Oil Seal Retaining Plate Bolts 9.8 1.0 87 in·lb L

PERIODIC MAINTENANCE 2-5

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

10 1 89 in·lb

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 Bol

ts (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 T

Handlebar Lower Holder Nut (KLX140AC ∼/BC ∼) 34 3.5 25 R

Frame

Rear Frame Mounting Bolts 34 3.5 25

Side Stand Pivot Bolt (KLX140AC ∼/BC ∼) 29 3.0 21

Side Stand Pivot Nut (KLX140AC ∼/BC ∼) 44 4.5 32 R

Electrical System

Alternator Cover Bolts (L30)

8.8 0.90 78 in·lb

Alternator Cov

er 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

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

Torque

Fastener

N·m kgf·m ft·lb

Remarks

Stator Mounting Bolts 8.8 0.90 78 in·lb

Torque Limiter Cover Bolts 8.8 0.90 78 in·lb

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

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 –––

PERIODIC MAINTENANCE 2-9

Specifications

Item Standard Service Limit

Final Drive

Drive Chain Slack 35 ∼ 41 mm (1.4 ∼ 1.6 in.)

–––

Drive Chain 20 Link Length 254.0 ∼ 254.6 mm (10.00 ∼ 10.02 in.) 260 mm (10.2 in.)

Rear Sprocket Warp 0.4 mm (0.016 in.) or less 0.5 mm (0.020 in.)

Brakes

Brake Lever Free Play (to suit rider) –––

Brake Fluid:

Type:

Front/Rear DOT3 or DOT4 –––

Brake pad lining thickness:

Front 4.5 mm (0.18 in.) 1 mm (0.04 in.)

Rear 3.7 mm (0.15 in.) 1 mm (0.04 in.)

Suspension

Fork Oil:

Oil Viscosity SHOWA SS-8 or equivalent –––

Oil Quantity:

KLX140A 296 ±2.5 mL (10.01 ±0.085 US oz)

KLX140B 290 ±2.5 mL (9.80 ±0.085 US oz) –––

Electrical System

Spark Plug Gap 0.6 ∼ 0.7 mm (0.2 ∼ 0.3 in.)

–––

TIR: Total Indicator Readings

2-10 PERIODIC MAINTENANCE

Special Tools

Inside Circlip Pliers:

57001-143

Steering Stem Nut Wrench:

57001-1100

Valve Adjusting Screw Holder:

57001-1217

Jack:

57001-1238

Spark Plug Wrench, Hex 16:

57001-1262

Fork Oil Level Gauge:

57001-1290

PERIODIC MAINTENANCE 2-11

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.

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.

PERIODIC MAINTENANCE 2-13

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.

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.

PERIODIC MAINTENANCE 2-15

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)

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]

PERIODIC MAINTENANCE 2-17

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.

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.

PERIODIC MAINTENANCE 2-19

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).

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.

80kPa(0.8kgf/cm²,

11 psi)

↑

When the track is pebbly or hard,

increasethetirepressuretoprevent

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 t

read.

•

Visually inspect the tire for cracks and cuts, replacing the

tire in case of bad damage. Swelling or high spots indi-

cate int

ernal 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

PERIODIC MAINTENANCE 2-21

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.)

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.)

PERIODIC MAINTENANCE 2-23

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.

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

theinsideofeachroller.

•

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.

PERIODIC MAINTENANCE 2-25

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 standar

d length, adjust the push rod

in the master cylinder as follows.

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.

PERIODIC MAINTENANCE 2-27

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

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.

PERIODIC MAINTENANCE 2-29

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].

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

PERIODIC MAINTENANCE 2-31

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)

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.

PERIODIC MAINTENANCE 2-33

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.

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].

PERIODIC MAINTENANCE 2-35

Periodic Maintenance Procedures

•

Remove:

TopPlug[A]withO-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±2mm(4.13±0.08in.)

○

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.

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.

PERIODIC MAINTENANCE 2-37

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)

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•

Remove the bolts [A], and take off the ignition switch [B]

with choke knob (KLX140A8 ∼ AA/B8 ∼ BA).

•

Remove the bolts [A], and take off the choke knob bracket

[B] (KLX140AB ∼/BB ∼).

•

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).

PERIODIC MAINTENANCE 2-39

Periodic Maintenance Procedures

Stem Bearing Lubrication

•

Removethesteeringstem(seeSteeringStem,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.

Sidestand Inspection

•

See if the sidestand [A] moves smoothly and retracts fully.

If not, clean and grease the pivot [B] and sliding portion

[C] (see Sidestand Installation in the Frame chapter).

•

Check the sidestand spring [D] for damage.

If necessary, replace the spring.

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

PERIODIC MAINTENANCE 2-41

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).

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

Sidestand Bolt

FUEL SYSTEM 3-1

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

3-2 FUEL SYSTEM

Exploded View

FUEL SYSTEM 3-3

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

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

3-4 FUEL SYSTEM

Exploded View

FUEL SYSTEM 3-5

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

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.

3-6 FUEL SYSTEM

Exploded View

FUEL SYSTEM 3-7

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

Fuel Tank Cover Screws

5.0 0.51 44 in·lb

AD: Apply adhesive cement

R: Replacement Parts.

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

FUEL SYSTEM 3-9

Special Tool

Fuel Level Gauge:

57001-1017

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).

FUEL SYSTEM 3-11

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.

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.

FUEL SYSTEM 3-13

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.

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.

FUEL SYSTEM 3-15

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.

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].

FUEL SYSTEM 3-17

Carburetor

•

Remove the retainer place [A] and the jet needle [B] with

theclip[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]

Screw [A]

Cover [B]

O-ring [C]

Spring [D]

Diaphragm [E]

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.

FUEL SYSTEM 3-19

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.

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 body so that

the large bore side [B] facing up as shown.

•

Carefully screw in the needle jet holder [C]. It will seat

against the needle jet, pushing the end of the jet into the

carburetor bore.

•

Install the baffle [D], main jet [E] and pilot jet [F] to the

carburetor.

NOTICE

Be careful not to overtighten the needle jet holder,

main jet or pilot jet. The jets or the carburetor body

could be damaged requiring replacement.

FUEL SYSTEM 3-21

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 m

ay also need to replace

the element and seal the housing and intake tract.

3-22 FUEL SYSTEM

Air Cleaner

Element Installation

•

When installing the element, coat the lip of the element

with a thick layer of all purpose grease [A] to assure a

complete seal against the air cleaner element base. Also,

coat the base where the lip of the element fits.

•

Apply grease to all connections and screw holes in the air

cleaner housing and intake tract.

•

Take out the cloth from the carburetor securely.

•

Install the element [A].

•

Tighten the wing bolt [B].

•

Install the seat (see Seat Installation in the Frame chap-

ter).

Element Cleaning and Inspection

•

Refer to the Air Cleaner Element Cleaning and Inspection

in the Periodic Maintenance chapter.

FUEL SYSTEM 3-23

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].

3-24 FUEL SYSTEM

Fuel Tank

Fuel Tank Installation

•

Inspect the rubber dampers [A] on the frame.

If the dampers are damaged or deteriorated, replace them

with new ones.

•

Connect the fuel hose to the fuel tap securely.

•

Set the fuel tank on the frame.

•

Install the rubber band, the fuel tank bolt and other re-

moved parts.

Torque - Fuel Tank Cover Screws: 5.0 N·m (0.51 kgf·m, 44

in·lb)

•

Insert the fuel tank breather hose into the steering stem.

Fuel Tap Removal

•

Remove the fuel tank (see Fuel Tank Removal).

•

Drain the fuel.

•

Remove the mounting bolts [A] and take off the fuel tap

[B].

Fuel Tap Installation

•

Replace the O-ring [A] with a new one.

•

Insert the filter part into the tank, and tighten the bolts [B].

Fuel Tank, Filter and Tap Cleaning

•

Refer to the Fuel Tank, Filter and Tap Cleaning in the

Periodic Maintenance chapter.

Fuel Tap and Filter Inspection

•

Refer to the Fuel Tap and Filter Inspection in the Periodic

Maintenance chapter.

ENGINE TOP END 4-1

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

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

4-2 ENGINE TOP END

Exploded View

ENGINE TOP END 4-3

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

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

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

14. KLX140AC ∼, KLX140BC ∼

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

4-4 ENGINE TOP END

Exploded View

ENGINE TOP END 4-5

Exploded View

Torque

No. Fastener

N·m kgf·m ft·lb

Remarks

1 Exhaust Pipe Cover Bolts 8.8 0.90 78 in·lb L

2 Exhaust Pipe Holder Nuts 14.7 1.5 11

3 MufflerEndCoverBolts 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. KLX140A8 ∼ A9

10. KLX140AA ∼/BA ∼

R: Replacement parts.

L: Apply a non-permanent locking agent.

4-6 ENGINE TOP END

Specifications

Item Standard Service Limit

Camshafts

Cam Height:

Exhaust 36.138 ∼ 36.252 mm (1.4228 ∼ 1.4272 in.) 36.04 mm (1.419 in.)

Intake 36.397 ∼ 36.511 mm (1.4329 ∼ 1.4374 in.) 36.30 mm (1.429 in.)

Rocker Arm Inside Diameter 12.000 ∼ 12.018 mm (0.4724 ∼ 0.4731 in.) 12.05 mm (0.474 in.)

Rocker Shaft Diameter 11.983 ∼ 11.994 mm (0.4718 ∼ 0.4722 in.) 11.96 mm (0.471 in.)

Cylinder Head

Cylinder Compression

(Usable range) 824 ∼ 1 275 kPa (8.40 ∼

13.0 kgf/cm², 119 ∼ 184.9 psi)

–––

Cylinder Head Warp

–––

0.05 mm (0.002 in.)

Valves

Valve Clearance:

Exhaust

0.11 ∼ 0.15 mm (0.004 ∼ 0.006 in.)

–––

Intake 0.04 ∼ 0.08 mm (0.002 ∼ 0.003 in.) –––

Valve Head Thickness:

Exhaust

1.15 ∼ 1.45 mm (0.045 ∼ 0.057 in.) 0.5 mm (0.02 in.)

Intake 0.60 ∼ 0.90 mm (0.024 ∼ 0.035 in.) 0.4 mm (0.02 in.)

Valve Stem Bend TIR 0.01 mm (0.0004 in.) or less

TIR 0.05 mm

(0.002 in.)

Valve Stem Diameter:

Exhaust 4.958 ∼ 4.973 mm (0.1952 ∼ 0.1958 in.) 4.93 mm (0.194 in.)

Intake

4.975 ∼ 4.990 mm (0.1959 ∼ 0.1965 in.) 4.95 mm (0.195 in.)

Valve Guide Inside Diameter

Exhaust 5.000 ∼ 5.012 mm (0.1969 ∼ 0.1973 in.) 5.08 mm (0.200 in.)

Intake 5.000 ∼ 5.012 mm (0.1969 ∼ 0.1973 in.) 5.08 mm (0.200 in.)

Valve/Valve Guide Clearance

(Wobble Method):

Exhaust

0.07 ∼ 0.13 mm (0.003 ∼ 0.005 in.) 0.31 mm (0.012 in.)

Intake 0.02 ∼ 0.09 mm (0.001 ∼ 0.004 in.) 0.26 mm (0.010 in.)

Valve Seat Cutting Angle 45°,32°,60° –––

Valve Seat Surface:

Outside Diameter:

Exhaust 22.9 ∼ 23.1 mm (0.90 ∼ 0.91 in.) –––

Intake

26.4 ∼ 26.6 mm (1.04 ∼ 1.05 in.)

–––

Width:

Exhaust 0.8 ∼ 1.2 mm (0.03 ∼ 0.05 in.) –––

Intake

0.8 ∼ 1.2 mm (0.03 ∼ 0.05 in.)

–––

Valve Spring Free Length:

Exhaust 36.43 mm (1.434 in.) 34.5 mm (1.36 in.)

Intake 36.43 mm (1.434 in.) 34.5 mm (1.36 in.)

Cylinders, Pistons

Cylinder Inside Diameter 58.000 ∼ 58.012 mm (2.2835 ∼ 2.2839 in.) 58.08 mm (2.287 in.)

Piston Diameter

57.970 ∼ 57.982 mm (2.2823 ∼ 2.2828 in.) 57.82 mm (2.276 in.)

Piston/Cylinder Clearance 0.024 ∼ 0.036 mm (0.0009 ∼ 0.0014 in.) –––

ENGINE TOP END 4-7

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 (KLX140A8 ∼ A9/B8 ∼ B9) 0.30 ∼ 0.45 mm

(0.012 ∼ 0.018 in.)

0.8 mm (0.03 in.)

(KLX140AA ∼/BA ∼)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.)

4-8 ENGINE TOP END

Specifications

Cam Height

Cam Height [A]

Camshaft Runout

Valve Head Thickness

Valve Stem Diameter [A]

Valve Head Thickness [B]

45° [C]

Valve Stem Bend

Dial Gauge [A]

ENGINE TOP END 4-9

Special Tools

Compression Gauge, 20 kgf/cm²:

57001-221

Valve Spring Compressor Assembly:

57001-241

Valve Seat Cutter, 45° - 24.5:

57001-1113

Valve Seat Cutter, 32° - 25:

57001-1118

Valve Seat Cutter, 32° - 28:

57001-1119

Valve Seat Cutter Holder Bar:

57001-1128

Valve Spring Compressor Adapter, 22:

57001-1202

Valve Guide Arbor, 5:

57001-1203

Valve Guide Reamer, 5:

57001-1204

Valve Seat Cutter, 45° - 22:

57001-1205

4-10 ENGINE TOP END

Special Tools

Valve Seat Cutter Holder, 5:

57001-1208

SparkPlugWrench,Hex16:

57001-1262

Compression Gauge Adapter, M10 × 1.0:

57001-1317

Valve Seat Cutter, 60° - 25:

57001-1328

Valve Seat Cutter, 60° - 27:

57001-1409

Filler Cap Driver:

57001-1454

Piston Pin Puller Assembly:

57001-910

ENGINE TOP END 4-11

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 standard tip 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.)

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)

ENGINE TOP END 4-13

Camshaft

Camshaft Removal

•

Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

chapter)

Camshaft Chain Cover [A]

Valve Adjusting Caps [B]

•

Remove the plug [A] and the cap [B] on the alternator

cover.

Special Tool - Filler Cap Driver: 57001-1454

•

Turn the crankshaft bolt counterclockwise [C] so that the

“T” mark on the alternator rotor watching the plug hole [D].

•

Check the mark [A] on the sprocket aligns with the pro-

jection [B] on the cylinder head. Be sure to position the

piston TDC at the end of the compression stroke by turn-

ing the crankshaft. (Align the mark when the intake valve

again comes up after it went down once.)

•

Holding the crankshaft bolt with a wrench, loosen the

camshaft sprocket bolt (left-hand thread) [C].

•

Remove:

Camshaft Chain Tensioner (see Camshaft Chain Ten-

sioner Removal)

Camshaft Sprocket [A]

NOTE

○

Does not lose the pin [B], when the camshaft sprocket

removed.

○

Hold the camshaft chain with suitable tool so that the

chain does not drop into the engine.

•

Remove the screws [A], and rocker shaft holder [B].

4-14 ENGINE TOP END

Camshaft

•

Remove the rocker shaft [A] and the rocker arm [B] on

both sides.

○

Set the rocker arms to each shaft so that they can be

installed later in the same position.

•

Pull out the camshaft [C].

NOTICE

The crankshaft may be turned while the camshaft is

removed.

Always pull the chain taut while turning the crank-

shaft. This avoids kinking the chain on the lower

(crankshaft) sprocket. A kinked chain could dam-

age both the chain and the sprocket.

Camshaft Installation

•

Blow through the oil passage [B] with compressed air [A].

•

Apply engine oil to all cam parts, journal and bearing.

○

If the camshaft is replaced with a new one, apply a thin

coat of molybdenum disulfide grease to the new cam part

surfaces and journal.

•

Install the camshaft [A] so that the roller groove [B] of it

come to upside.

•

Apply molybdenum disulfide oil to the rocker shaft surface

[A] and cam portion of the rocker arm [B], and then install

them at the original position.

○

Install the rocker shafts so that the small diameter side

face rocker shaft holder [C].

•

Apply a non-permanent locking agent to the rocker shaft

holder plate screws.

•

Install the rocker shaft holder.

Torque - Rocker Shaft Holder Plate Screws: 5.2 N·m (0.53

kgf·m, 46 in·lb)

ENGINE TOP END 4-15

Camshaft

•

Engage the camshaft sprocket [A] with the chain [B].

Then, align the "Top" mark [C] on the sprocket with the

projection [D] on the cylinder head after aligning the

notch of the magneto cover with “T” mark on the magneto

rotor watching the bolt hole of the cover.

NOTE

○

Pull the tension side (exhaust side) of the chain up to

remove slack.

•

Apply a non-permanent locking agent to the camshaft

sprocket bolt [E] and tighten it (left-hand thread).

Torque - Camshaft Sprocket Bolt: 24 N·m (2.4 kgf·m, 17.5

ft·lb)

•

Install the camshaft chain tensioner (see Camshaft Chain

Tensioner Installation).

•

Check the valve clearance (see Valve Clearance adjust-

ment).

Torque - Camshaft Chain Cover Bolts: 8.8 N·m (0.90 kgf·m,

78 in·lb)

Camshaft Chain Removal

•

Remove:

Camshaft Sprocket (see Camshaft Removal, but except

the valve adjusting caps)

Alternator Cover and Alternator Rotor (see Alternator

Rotor Removal in the Electrical System chapter)

•

Remove the camshaft chain plate [A].

•

Remove the camshaft chain [B].

Camshaft Chain Installation

•

Insert the camshaft chain from the cylinder head, and en-

gage the chain with the engine sprocket.

•

Install the camshaft chain plate.

Torque - Camshaft Chain plate Screw: 5.2 N·m (0.53 kgf·m,

46 in·lb)

•

Install the alternator rotor (see Alternator Rotor Installa-

tion in the Electrical System chapter).

•

Align the projection [A] on the crankcase with the "T" mark

[B] on the rotor.

4-16 ENGINE TOP END

Camshaft

•

Engage the camshaft sprocket [A] to the chain [B]. Then

align the mark [C] on the sprocket with the projection [D]

on the cylinder head.

NOTE

○

Pull the tension side (exhaust side) of the chain up to

remove slack.

•

Apply a non-permanent locking agent to the camshaft

sprocket bolt [E] and tighten it (left-hand thread).

Torque - Camshaft Sprocket Bolt: 24 N·m (2.4 kgf·m, 17.5

ft·lb)

•

Install:

Camshaft Chain Tensioner (see Camshaft Chain Ten-

sioner Installation)

Alternator Cover (see Electrical System chapter)

•

Replace the camshaft chain cover O-ring with a new one,

and apply grease to the O-ring.

•

Install the camshaft chain cover.

Torque - Camshaft Chain Cover Bolts: 8.8 N·m (0.90 kgf·m,

78in·lb)

ENGINE TOP END 4-17

Cylinder Head

Cylinder Compression Measurement

NOTE

○

Use the battery which is fully charged

•

Start the engine.

•

Thoroughly warm up the engine so that the engine oil be-

tween the piston and cylinder wall will help seal compres-

sion as it does during normal running.

•

Stop the engine.

•

Remove the spark plug cap [A] and the spark plug [B] with

the spark plug wrench [C].

Special Tool - Spark Plug Wrench, Hex 16: 57001-1262

Owner’s Tool - Spark Plug Wrench: 92110-1206

•

Attach the compression gauge [A] and the adapter [B]

firmly into the spark plug hole.

Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221

Compression Gauge Adapter, M10 × 1.0:

57001-1317

•

With the throttle fully open, turn the engine with the starter

motor until the compression gauge stops rising; the com-

pression is the highest reading obtainable.

Cylinder Compression

Usable Range:

824

∼ 1 275 kPa (8.40 ∼ 13.0 kgf/cm²,

119

∼ 184.9 psi)

•

Install the spark plug.

Torque - Spark Plug: 13 N·m (1.3 kgf·m, 115 in·lb)

•

Pull the spark plug cap lightly to make sure the installation

of the spark plug cap.

The following table should be consulted if the obtainable compression reading is not within the us-

able range.

Problem Diagnosis Remedy (Action)

Carbon accumulation on piston and in

cylinder head (combustion chamber) is

suspected due to damaged valve stem

or piston oil rings.

Remove the carbon deposits and replace

damaged parts if necessary.

The cylinder

compression is

higher than the

usable range

Incorrect cylinder head gasket

thickness.

Replace the gasket with a standard one.

Exhaust gas leakage around cylinder

head.

Replace the damaged gasket and check

cylinder head warp.

Incorrect seating surface of valve. Repair seating surface if possible.

Valve clearance is too narrow. Adjust the valve clearance.

Piston/cylinder clearance is too wide. Replace the piston and/or cylinder.

The cylinder

compression is

lower than the

usable range

Piston seizure. Inspect the cylinder and piston; repair or

replace them if necessary.

Bad condition of piston ring and/or

piston ring grooves.

Replace the piston and/or the piston

rings.

4-18 ENGINE TOP END

Cylinder Head

Cylinder Head Removal

•

Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

chapter)

Carburetor (see Carburetor Removal in the Fuel System

chapter)

Exhaust Pipe (see Muffler Removal)

Spark Plug Cap [A]

•

Remove:

Camshaft Chain Cover Bolts [A]

Camshaft Chain Cover [B]

Camshaft Sprocket (see Camshaft Removal)

•

Remove:

6 mm Cylinder Head Bolts [A]

8 mm Cylinder Head Bolts [B]

Front [C]

•

Remove the cylinder head [A].

NOTE

○

If necessary, tap lightly with a plastic hammer [B] as

shown.

Cylinder Head Installation

•

Install the dowel pins [A].

•

Install the new gasket [B].

•

Apply a thin coat of grease to the new O-rings [C] [D].

•

Install the O-rings onto the oil pipe as shown.

O-ring 9.8 × 1.9 [C]

O-ring 9.8 × 2.4 [D]

Oil Pipe (for KLX140A9 ∼ AB/B9 ∼ BB) [E]

Oil Pipe (for KLX140AC ∼/BC ∼)[F]

ENGINE TOP END 4-19

Cylinder Head

•

Install the washers [A] with its rounded side facing up-

ward.

•

Apply engine oil to both sides of the washers and molyb-

denum disulfide grease to the threads of the 8 mm cylin-

der head bolts [B].

•

Tighten the 8 mm bolts following the tightening sequence

as shown. Tighten them first to the torque of 15 N·m

(1.5 kgf·m, 11 ft·lb), and then tighten them to the speci-

fied torque.

Torque - 8 mm Cylinder Head Bolts: 22 N·m (2.2 kgf·m, 16

ft·lb)

•

Tighten the 6 mm bolts [5 ∼ 6].

Front [A]

Torque - 6 mm Cylinder Head Bolts: 15 N·m (1.5 kgf·m, 11

ft·lb)

•

Install:

Camshaft Sprocket and Camshaft Chain Cover (see

Camshaft Installation)

Camshaft Chain Tensioner (see Camshaft Chain Ten-

sioner Installation)

•

Install the other removed parts.

Cylinder Head Cleaning

•

Remove:

Cylinder Head (see Cylinder Head Removal)

Valves (see Valve Removal)

•

Scrape the carbon out of the combustion chamber and

exhaust port with a scraper or a suitable tool.

•

Clean the cylinder head with high-flash point solvent.

•

Blow out any particles which may obstruct the oil passage

[A] in the cylinder head using compressed air.

Front [B]

•

Install the valves (see Valve Installation).

Cylinder Head Warp Inspection

•

Clean the cylinder head (see Cylinder Head Cleaning).

•

Lay a straightedge [A] across the lower surface of the

cylinder head at the positions shown.

•

Use a thickness gauge [A] to measure the space between

the straightedge [B] and the head.

Cylinder Head Warp

Standard:

–––

Service Limit: 0.05 mm (0.02 in.)

If the cylinder head is warped more than the service limit,

replace it.

If the cylinder head is warped less than the service limit,

repair the head by rubbing the lower surface on emery

paper secured to a surface plate (first No. 200, then No.

400).

4-20 ENGINE TOP END

Valves

Valve Clearance Inspection

•

Refer to the Valve Clearance Inspection in the Periodic

Maintenance chapter.

Valve Clearance Adjustment

•

Refer to the Valve Clearance Adjustment in the Periodic

Maintenance chapter.

Valve Removal

•

Remove the cylinder head (see Cylinder Head Removal).

•

Remove the rocker shafts and rocker arms (see Camshaft

Removal).

NOTE

○

Mark and record the rocker shafts, rocker arms, and

valves locations so that they can be installed in their

original positions to keep the valve clearance un-

changed.

•

Using the valve spring compressor assembly, remove the

valves.

Special Tools - Valve Spring Compressor Assembly: 57001

-241 [A]

Valve Spring Compressor Adapter, 22:

57001-1202 [B]

Valve Installation

•

Replace the oil seal [A] with a new one.

•

Apply engine oil to the oil seal lips.

•

Apply a thin coat of molybdenum disulfide grease to the

valve stem [B] before valve installation.

•

Check the following:

Valve moves smoothly up and down in the guide.

Valve seats properly in the valve seat.

•

Install the spring [C] so that the rought coil end (blue paint

side) faces the spring retainer [D] (upwards).

•

Put the spring retainer on the springs, and fit the split

keepers [E] between the retainer and the stem while com-

pressing the valve spring.

Spring Seat [F]

Special Tool - Valve Spring Compressor Assembly: 57001

-241

Valve Spring Compressor Adapter,

22:

57001-1202

ENGINE TOP END 4-21

Valves

Valve Guide Removal

•

Remove:

Valve(seeValveRemoval)

Oil Seal

Spring Seat

•

Heat the area around the valve guide to 120 ∼ 150°C (248

∼ 302°F).

NOTICE

Do not heat the cylinder head with a torch. This will

warp the cylinder head. Soak the cylinder head and

heat the oil.

•

Hammer lightly on the valve guide arbor [A] to remove the

guide from the top of the head.

Special Tools - Valve Guide Arbor,

5: 57001-1203

Valve Guide Installation

•

Apply thin coat of oil to the valve guide outer surface.

•

Heat the area around the valve guide hole to about 120 ∼

150 °C (248 ∼ 302 °F).

NOTICE

Do not heat the cylinder head with a torch. This will

warp the cylinder head. Soak the cylinder head and

heat the oil.

•

Drive the valve guide from the top of the head using the

valve guide arbor.

Special Tool - Valve Guide Arbor,

5: 57001-1203

•

Ream the valve guide with valve guide reamer [A] even if

the old guide is reused.

Special Tool - Valve Guide Reamer,

5: 57001-1204

4-22 ENGINE TOP END

Valves

Valve/Guide Clearance Measurement (Wobble

Method)

○

If a small bore gauge is not available, inspect the valve

guide wear by measuring the valve/valve guide clearance

with the wobble method as indicated below.

•

Insert a new valve [A] into the guide [B] and set a dial

gauge against the stem perpendicular to it as close as

possible to the cylinder head mating surface.

•

Move the stem back and forth [C] to measure the valve

wobble.

•

Repeat the measurement in a direction at 90° angle to the

first measurement.

If the reading exceeds the service limit, replace the guide.

NOTE

○

The reading is greater than the actual valve/valve guide

clearance because the measurment is taken outside of

the guide.

Valve/Valve Guide Clearance (Wobble Method)

Standard:

Exhaust 0.07

∼ 0.13 mm (0.003 ∼ 0.005 in.)

Intake 0.02

∼ 0.09 mm (0.001 ∼ 0.004 in.)

Service Limit:

Exhaust 0.31 mm (0.012 in.)

Intake 0.26 mm (0.010 in.)

Valve Seat Inspection

•

Remove the valve (see Valve Removal).

•

Check the valve seating surface [A] between the valve [B]

and valve seat [C].

○

Measure the outside diameter [D] of the seating pattern

on the valve seat.

If the outside diameter is too large or too small, repair the

seat (see Valve Seat Repair).

Valve Seating Surface Outside Diameter

Standard:

Exhaust

22.9

∼ 23.1 mm (0.90 ∼ 0.91 in.)

Intake

26.4 ~ 26.6 mm (1.04

∼ 1.05 in.)

•

Check the seating surface width of the valve seat.

○

Measure the seat width [E] of the portion where there is

no build-up carbon (white portion) of the valve seat with a

vernier caliper.

Good [F]

If the width is too wide [G], too narrow [H] or uneven [J],

repair the seat (see Valve Seat Repair).

Valve Seating Surface Width

Standard:

Intake, Exhaust

0.8

∼ 1.2 mm (0.03 ∼ 0.05 in.)

ENGINE TOP END 4-23

Valves

Valve Seat Repair

•

For the instructions on how to use the valve seat cutter

[A], follow the operation manual provided by the to man-

ufacturer.

Special Tools - Valve Seat Cutter Holder,

5: 57001-1208

[B]

Valve Seat Cutter Holder Bar: 57001-1128

[C]

Exhaust:

Valve Seat Cutter, 45° -

22:

57001-1205

Valve Seat Cutter, 32° -

25:

57001-1118

Valve Seat Cutter, 60° -

25:

57001-1328

Intake :

Valve Seat Cutter, 45° -

24.5:

57001-1113

Valve Seat Cutter, 32° -

28:

57001-1119

Valve Seat Cutter, 60° -

27:

57001-1409

If the tool manufacturer’s instructions are not available,

operate in accordance with the following procedure.

Seat Cutter Operation Care

1. This valve seat cutter is developed to grind the valve for

repair. Therefore the cutter must not be used for other

purposes than seat repair.

2. Do not drop or shock the valve seat cutter, or the dia-

mond particles may fall off.

3. Do not fail to apply engine oil to the valve seat cutter

before grinding the seat surface. Also wash off ground

particles sticking to the cutter with washing oil.

NOTE

○

Do not use a wire brush to remove the metal particles

from the cutter. It will take off the diamond particles.

4. Setting the valve seat cutter holder in position, operate

the cutter in one hand. Do not apply too much force to

the diamond portion.

NOTE

○

Prior to grinding, apply engine oil to the cutter and dur-

ing the operation, wash off any ground particles sticking

to the cutter with washing oil.

5. After use, wash it with washing oil and apply thin coat of

engine oil before storing.

4-24 ENGINE TOP END

Valves

Marks Stamped on the Cutter

The marks stamped on the back of the cutter [A] represent

the following.

60° ........................... Cutter angle [B]

37.5ϕ ....................... Outer diameter of cutter [C]

Repair Operating Procedures

•

Clean the seat area carefully.

•

Coat the seat with machinist’s dye.

•

Fit a 45° cutter into the holder and slide it into the valve

guide.

•

Press down lightly on the handle and turn it right or left.

Grind the seating surface only until it is smooth.

NOTICE

Do not grind the seat too much. Overgrinding will

reduce valve clearance by sinking the valve into the

head. If the valve sinks too far into the head, it will

be impossible to adjust the clearance, and the cylin-

der head must be replaced.

Widened Width [A] of engagement by machining with

45° cutter

Ground Volume [B] by 32° cutter

32° [C]

Correct Width [D]

Ground Volume [E] by 60° cutter

60° [F]

•

Measure the outside diameter of the seating surface with

a vernier caliper.

If the outside diameter of the seating surface is too small,

repeat the 45° grind until the diameter is within the spec-

ified range.

Original Seating Surface [B]

○

Remove all pittings of flaws from 45° ground surface.

○

Alter grinding with 45° cutter, apply thin coat of machin-

ist’s dye to 45° [A] seating surface. This makes seating

surface distinct and 32° and 60° grinding operation eas-

ier.

○

When the valve guide is replaced, be sure to grind with

45° cutter for centering and good contact.

ENGINE TOP END 4-25

Valves

If the outside diameter [A] of the seating surface is too

large, make the 32° grind described below.

If the outside diameter of the seating surface is within the

specified range, measure the seat width as described be-

low.

•

Grind the seat at a 32° angle [B] until the seat O.D. is

within the specified range.

○

To make the 32° grind, fit a 32° cutter into the holder, and

slide it into the valve guide.

○

Turn the holder one turn at a time while pressing down

very lightly. Check the seat after each turn.

NOTICE

The 32° cutter removes material very quickly.

Check the seat outside diameter frequently to pre-

vent overgrinding.

○

After making the 32° grind, return to the seat O.D. mea-

surement step above.

•

To measure the seat width, use a vernier caliper to mea-

sure the width of the 45° angle portion of the seat at sev-

eral places around the seat.

If the seat width is too narrow, repeat the 45° grind until

the seat is slightly too wide, and then return to the seat

O.D. measurement step above.

If the seat width is too wide, make the 60° [A] grind de-

scribed below.

If the seat width is within the specified range, lap the valve

to the seat as described below.

•

Grind the seat at a 60° angle until the seat width is within

the specified range.

○

To make the 60° grind, fit a 60° cutter into the holder, and

slide it into the valve guide.

○

Turn the holder, while pressing down lightly.

○

After making the 60° grind, return to the seat width mea-

surement step above.

Correct Width [B]

•

Lap the valve to the seat, once the seat width and O.D.

are within the ranges specified above.

○

Put a little coarse grinding compound on the face of the

valve in a number of places around the valve head.

○

Spin the valve against the seat until the grinding com-

pound produces a smooth, matched surface on both the

seat and the valve.

○

Repeat the process with a fine grinding compound.

Rapper [A]

Valve [C]

Valve Seat [B]

4-26 ENGINE TOP END

Valves

•

The seating area should be marked about in the middle

of the valve face.

If the seat area is not in the right place on the valve, check

to be sure the valve is the correct part. If it is, it may have

been refused too much; replace it.

•

Be sure to remove all grinding compound before assem-

bly.

•

When the engine is assembled, be sure to adjust the valve

clearance (see Valve Clearance Adjustment).

ENGINE TOP END 4-27

Valves

4-28 ENGINE TOP END

Cylinder, Piston

Cylinder Removal

•

Remove:

Cylinder Head (see Cylinder Head Removal)

Front Camshaft Chain Guide [A]

•

Tap the cylinder [A] lightly with a plastic mallet to separate

from the crankcase.

•

Remove the cylinder base gasket [B].

Piston Removal

•

Remove the cylinder (see Cylinder Removal).

•

Place a clean cloth [A] under the piston and remove the

piston pin snap ring [B].

NOTICE

Do not reuse snap rings, as removal weakens and

deforms them. They could fall out and score the

cylinder wall.

•

Remove the piston pin.

Special Tool - Piston Pin Puller Assembly: 57001-910 [A]

Adapter [B]

•

Remove the piston.

•

Carefully spread the piston ring opening with your thumbs

and then push up on the opposite side [A] of the ring to

remove it.

•

Remove the oil ring in the same procedure.

ENGINE TOP END 4-29

Cylinder, Piston

Cylinder and Piston Installation

NOTE

○

If a new piston or cylinder is used, check piston to cylin-

der clearance (see Piston/Cylinder Clearance), and use

new piston ring.

•

Apply engine oil to the inner surface of the connecting rod

small end.

•

The "EX↑" mark on the piston head must point toward the

front of the engine.

•

Fit a new piston pin snap ring into the side of the piston

so that the ring opening [A] does not coincide with the slit

[B] of the piston pin hole.

○

When installing the piston pin snap ring, compress it only

enough to install it and no more.

NOTICE

Do not reuse snap rings, as removal weakens and

deforms them. They could fall out and score the

cylinder wall.

NOTE

○

The oil ring rails have no "top" or "bottom".

•

Install the oil ring expander [A] in the bottom piston ring

groove so the ends [B] butt together.

•

Install the oil ring steel rails, one above the expander and

one below it.

○

Spread the rail with your thumbs, but only enough to fit

the rail over the piston.

○

Release the rail into the bottom piston ring groove.

•

Do not mix up the top ring and second ring.

•

Install the top ring [A] so that the "R" mark [B] faces up.

•

Install the second ring [C] so that the "RN" mark [D] faces

up.

•

Install:

Dowel Pins [A]

New Cylinder Base Gasket [B]

4-30 ENGINE TOP END

Cylinder, Piston

•

The piston ring openings must be positioned as shown in

the figure. The openings of the oil ring steel rails must be

about 30 ∼ 90° of angle from the opening of the top ring.

Top Ring [A]

Second Ring [B]

Oil Ring Steel Rails [C]

Oil Ring Expander [D]

•

Apply grease to the O-rings (12.8 × 1.9) [A], and install it

as shown.

NOTE

○

To prevent misidentification as oil leak, wipe up the ex-

cessive grease.

•

Install the oil pipe [B] to the cylinder [C] from the bottom

side.

•

Apply molybdenum disulside oil to the cylinder bore [D]

and the piston sliding surfaces.

•

Install the cylinder.

○

Insert the pisiton to the cylinder bore while compressing

the pisiton rings.

•

Install the other removed parts.

Cylinder Wear

•

Since there is a difference in cylinder wear in different di-

rections, take a side-to-side and a front-to-back measure-

ment at each of the three locations (total of six measure-

ments) shown in the figure.

10 mm (0.4 in.) [A]

40 mm (1.6 in.) [B]

20 mm (0.8 in.) [C]

If any of the cylinder inside diameter measurements ex-

ceeds the service limit, replace the cylinder.

Cylinder Inside Diameter

Standard: 58.000

∼ 58.012 mm (2.2835 ∼ 2.2839

in.), and less than 0.01 mm (0.0004

in.) difference between any two

measurements.

Service Limit: 58.08 mm (2.287 in.) , or 0.05 mm

(0.002 in.) difference between any two

measurements.

ENGINE TOP END 4-31

Cylinder, Piston

Piston Wear

•

Measure the outside diameter [A] of each piston 5 mm

(0.2 in.) [B] up from the bottom of the piston at a right

angle to the direction of the piston pin.

If the measurement is smaller than service limit, replace

the piston.

Piston Diameter

Standard: 57.970

∼ 57.982 mm (2.2823 ∼ 2.2828 in.)

Service Limit: 57.82 mm (2.276 in.)

Piston/Cylinder Clearance

•

Subtract the piston diameter from the cylinder inside di-

ameter to get the piston/cylinder clearance.

Piston/Cylinder Clearance

Standard: 0.024

∼ 0.036 mm (0.0009 ∼ 0.0014 in.)

If the piston/cylinder clearance is less than the specified

range, use a smaller piston or increase the cylinder inside

diameter by honing.

f the piston/cylinder clearance is greater than specified

range, use a larger piston.

If only a piston is replaced, the clearance may exceed the

standard sl

ightly. But it must not be less than the minimum

in order to avoid piston seizure.

Boring, Honing Performance

When boring and honing a cylinder, note the following.

○

There are two sizes of oversize pistons available. Over-

size pistons require oversize rings.

Oversize Pistons and Rings

0.50 mm (0.0197 in.) Oversize

1.0 mm (0.0393 in.) Oversize

○

Before boring a cylinder, first measure the exact diame-

ter of the service data section, oversize piston, and then,

according to the standard clearance in the determine the

rebore diameter. However, if the amount of boring neces-

sary would make the inside diameter greater than 1.0 mm

(0.04 in.) oversize, the cylinder block must be replaced.

○

Cylinder inside diameter must not vary more than 0.01

mm (0.0004 in.) at any point.

○

Be wary of measurements taken immediately after boring

since the heat affects cylinder diameter.

○

In the case of a rebored cylinder and oversize piston, the

service limit for the cylinder is the diameter that the cylin-

der was bored to plus 0.10 mm (0.004 in.) and the service

limit for the piston is the oversize piston original diameter

minus 0.20 mm (0.008 in.). If the exact figure for the re-

bored diameter is unknown, it can be roughly determined

by measuring the diameter at the base of the cylinder.

4-32 ENGINE TOP END

Cylinder, Piston

Piston Ring, Piston Ring Groove Wear

•

Check for uneven groove wear by inspecting the ring seat-

ing.

The rings should fit perfectly parallel to groove surfaces.

If not, replace the piston and all the piston rings.

•

With the piston rings in their grooves, make several mea-

surements with a thickness gauge [A] to determine piston

ring/groove clearance.

Piston Ring/Ring Groove Clearance

Standard:

Top

0.04 ~ 0.08 mm (0.002 ~ 0.003 in.)

Second 0.03 ~ 0.07 mm (0.001 ~ 0.003 in.)

Service Limit:

Top

0.16 mm (0.0063 in.)

Second 0.15 mm (0.0059 in.)

If the piston ring groove clearance is greater than the ser-

vice limit, measure the ring thickness and groove width as

follows to decide whether to replace the rings, the piston

or both.

Piston Ring Groove Width

•

Measure the groove width at several points around the

piston with a vernier caliper.

Piston Ring Groove Width

Standard:

Top

0.81 ~ 0.83 mm (0.032 ~ 0.033 in.)

Second 0.80 ~ 0.82 mm (0.031 ~ 0.032 in.)

Service Limit:

Top

0.91 mm (0.036 in.)

Second 0.90 mm (0.035 in.)

If any of the groove widths exceeds the service limit, re-

place the piston.

Piston Ring Thickness

•

Measure the thickness at several points around the rings

with a micrometer.

Piston Ring Thickness (Top, Second)

Standard: 0.75 ~ 0.77 mm (0.0295 ~ 0.0303 in.)

Service Limit: 0.68 mm (0.027 in.)

If any of the measurements is less than the service limit

on either of the rings, replace the rings as a set.

NOTE

○

When using new rings in a used piston, check for un-

even groove wear. The rings should fit perfectly parallel

to the groove sides. If not, replace the piston.

ENGINE TOP END 4-33

Cylinder, Piston

Piston Ring End Gap

•

Place the piston ring [A] inside the cylinder, using the pis-

ton to locate the ring squarely in place. Plase the piston

ring close to the bottom of the cylinder, where cylinder

wear is minimal.

•

Measure the gap [B] between the ends of the ring with a

thickness gauge.

Piston Ring End Gap

Standard:

Top

0.15 ~ 0.30 mm (0.006 ~ 0.012 in.)

Second (KLX140A8

∼ A9/B8 ∼ B9) 0.30 ∼ 0.45

mm (0.012

∼ 0.018 in.)

(KLX140AA

∼/BA ∼)0.20∼ 0.35 mm

(0.008

∼ 0.014 in.)

Oil 0.20 ~ 0.70 mm (0.008 ~ 0.028 in.)

Service Limit:

Top

0.6 mm (0.02 in.)

Second (KLX140A8

∼ A9/B8 ∼ B9) 0.8 mm (0.03

in.)

(KLX140AA ∼/BA ∼) 0.7 mm (0.028 in.)

Oil 1.0 mm (0.04 in.)

If the ring end gap exceeds the service limit, replace the

ring.

4-34 ENGINE TOP END

Carburetor Holder

Carburetor Holder Removal

•

Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

chapter)

Carburetor Holder Bolts [A]

•

Loosen the clamp screw [B], and pull out the carburetor

holder [C].

Carburetor Holder Installation

•

Replace the O-ring [A] with a new one.

•

Apply grease to the new O-ring, and install the carburetor

holder [B].

•

Apply a non-permanent locking agent to the carburetor

holder bolts [C].

Torque - Carburetor Holder Bolts: 8.8 N·m (0.90 kgf·m, 78

in·lb)

ENGINE TOP END 4-35

Muffler

Muffler Removal

WARNING

The muffler can become extremely hot during nor-

mal operation and cause severe burns. Do not re-

move the muffler while it is hot.

•

Remove:

Right Side Cover (see Side Covers Removal in the

Frame chapter)

Muffler Mounting Bolts [A]

•

Loosen the muffler clamp bolt [B], and pull out the muffler

[C] backward.

•

Remove the exhaust pipe holder nuts [A], and remove the

exhaust pipe [B].

Muffler Installation

•

Replace the exhaust pipe gasket and the muffler gasket

with new ones.

Torque - Exhaust Pipe Holder Nuts: 14.7 N·m (1.5 kgf·m, 11

ft·lb)

Muffler Joint Clamp Bolt: 17 N·m (1.7 kgf·m, 13

ft·lb)

Muffler Mounting Bolt: 14.7 N·m (1.5 kgf·m, 11

ft·lb)

•

Thoroughly warm up the engine, wait until the engine

cools down, and then retighten all the bolts and nuts.

Spark Arrester Cleaning

•

Refer to the Spark Arrester Cleaning in the Periodic Main-

tenance chapter.

CLUTCH 5-1

Clutch

Table of Contents

Exploded View........................................................................................................................ 5-2

Specifications ......................................................................................................................... 5-4

Special Tool ............................................................................................................................ 5-5

Clutch Lever and Cable.......................................................................................................... 5-6

Clutch Lever Free Play Inspection.................................................................................... 5-6

Clutch Lever Free Play Adjustment .................................................................................. 5-6

Clutch Cable Removal ...................................................................................................... 5-6

Clutch Cable Lubrication and Inspection .......................................................................... 5-6

Clutch Cover........................................................................................................................... 5-7

Clutch Cover Removal ...................................................................................................... 5-7

Clutch Cover Installation ................................................................................................... 5-7

Clutch ..................................................................................................................................... 5-8

Clutch Removal................................................................................................................. 5-8

Clutch Hub Disassembly................................................................................................... 5-8

Clutch Hub Assembly........................................................................................................ 5-9

Clutch Installation..............................................................................................................5-9

Friction and Steel Plate Damage, Wear............................................................................ 5-10

Friction and Steel Plate Warp ........................................................................................... 5-10

Clutch Spring Free Length Measurement ......................................................................... 5-10

Clutch Housing Finger Damage........................................................................................ 5-10

Clutch Hub Spline Damage............................................................................................... 5-11

5-2 CLUTCH

Exploded View

CLUTCH 5-3

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

Clutch Hub Bolt

65 6.6 48 L

2 Clutch Spring Bolts 8.8 0.90 78 in·lb

3 Clutch Cover Bolts 8.8 0.90 78 in·lb

4 Oil Seal Retaining Plate Bolts 9.8 1.0 87 in·lb L

EO: Apply engine oil.

CL: Apply cable lubricant.

G: Apply grease.

HG: Apply high-temperature grease.

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil.

L: Apply a non-permanent locking agent.

R: Replacement Parts

5-4 CLUTCH

Specifications

Item Standard Service Limit

Clutch Lever

Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––

Clutch

Friction plate thickness

(small inside diameter) 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 2.6 mm (0.10 in.)

(large inside diameter) 3.50 ∼ 3.60 mm (0.138 ∼ 0.142 in.) 3.2 mm (0.13 in.)

Friction and steel plate warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.01 in.)

Clutch spring free length 40.2 mm (1.58 in.) 38.4 mm (1.51 in.)

CLUTCH 5-5

Special Tool

Clutch Holder:

57001-1554

5-6 CLUTCH

Clutch Lever and Cable

Due to friction plate wear and clutch cable stretch over

a long period of use, the clutch must be adjusted in accor-

dance with the Periodic Maintenance Chart.

WARNING

The engine and exhaust system get extremely hot

during normal operation and can cause serious

burns. Never touch the engine or exhaust chamber

during clutch adjustment.

Clutch Lever Free Play Inspection

•

Refer to the Clutch Lever Free Play Inspection in the Pe-

riodic Maintenance chapter.

Clutch Lever Free Play Adjustment

•

Refer to the Clutch Lever Free Play Adjustment in the

Periodic Maintenance chapter.

Clutch Cable Removal

•

Tuck the rubber boot [A].

•

Loosen the locknut [B] and screw in the adjuster [C].

•

Align the slots [D] in the clutch lever, locknut, and adjuster

and then free the cable from the lever.

•

Free the clutch inner cable tip from the clutch release

lever after opening the tab of the clutch cable holder.

•

Pull the clutch cable out of the frame.

Clutch Cable Lubrication and Inspection

•

Whenever the cable is removed, or in accordance with

the Periodic Maintenance Chart, lubricate the clutch ca-

ble (see General Lubrication in the Periodic Maintenance

chapter).

•

Apply a thin coat of grease to the cable ends.

•

Use the pressure cable lubber to lubricate the cable.

○

With the cable disconnected at both ends, the cable

should move freely in the cable housing.

CLUTCH 5-7

Clutch Cover

Clutch Cover Removal

•

Drain the engine oil (see Engine Oil Change in the Peri-

odic Maintenance chapter).

•

Remove:

Exhaust Pipe Cover

Brake Pedal Pivot Bolt [A]

•

Remove the clutch cover bolts [A].

•

Clear the clutch cable [B] from the clutch release lever [C].

•

Remove the other bolts [A] and the clutch cover [B].

NOTE

○

Do not remove the clutch release lever and shaft as-

sembly unless it is absolutely necessary. If removed,

the oil seal replacement may be required. Apply grease

to the oil seal lips.

Clutch Cover Installation

•

Replace the gasket [A] with a new one.

•

Install the dowel pins [B] and the bearing [C].

•

Apply molybdenum disulfide grease to the clutch pusher

[A].

•

Inspect the oil seal [B].

If the oil seal is damaged, replace it with a new one.

○

Apply a non-permanent locking agent to the oil seal re-

taining plate bolts [C].

Torque - Oil Seal Retaining Plate Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

•

Install the clutch cover and clutch cable.

Torque - Clutch Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Install other removed parts.

•

Pour in the specified engine oil (see Engine Oil Change

in the Periodic Maintenance chapter).

•

Inspect and adjust the clutch lever free play.

5-8 CLUTCH

Clutch

Clutch Removal

•

Remove the clutch cover (see Clutch Cover Removal).

NOTE

○

If the primary gear and oil pump gear are to be re-

moved, loosen the primary gear nut before clutch re-

moval (see Primary Gear and Oil Pump Gear Removal

in the Crankshaft/Transmission chapter).

•

Remove the bearing [A]

•

Remove the clutch hub bolt [B] with the clutch holder [C].

Special Tool - Clutch Holder: 57001-1554

•

Remove:

Clutch Hub Assembly [A]

Spacer [B]

Clutch Housing [C]

Collar [D]

Spacer [E]

Clutch Hub Disassembly

•

Remove:

Clutch Spring Bolts [A]

Clutch Spring Plate [B]

Clutch Springs [C]

Clutch Holder [D]

Steel Plates [E]

Friction Plates [F]

NOTE

○

The outside friction plate is different from other friction

plates. However, it is impossible to identify it on exter-

nals.

○

Mark the outside friction plate so that it can be rein-

stalled in its original position.

CLUTCH 5-9

Clutch

Clutch Hub Assembly

•

Clutch hub installation is the reverse of disassembly.

•

Install the spring seat [A], and then the spring [B] with the

concave side facing to the clutch hub.

•

When installing the friction plates and steel plates, first in-

stall the friction plate [C] whose inside diameter is larger

than the others and then install a steel plate [D] and alter-

nating them.

○

Install the marked friction plate at disassembled to the

outside.

○

When replace the friction plates with new ones, mark the

outside friction plate so that the two kinds of friction plates

do not mix up at opening the package.

NOTE

○

Set the large inside diameter friction plate to move 1/2

pitch according to the clutch housing.

•

Install the clutch spring plate and then tighten the clutch

spring bolts with specified torque.

Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

NOTICE

If new dry friction plates and steel plates are in-

stalled, apply engine oil to the surfaces of each

plate to avoid clutch plate seizure.

Clutch Installation

•

Apply molybdenum disulfide oil to the input shaft and col-

lar.

•

Install:

Spacer [A]

Collar [B]

Clutch Housing [C]

Spacer [D]

Clutch Hub Assembly [E]

•

Apply a non-permanent locking agent to the clutch hub

bolt.

•

Tighten the clutch hub bolt, while holding the clutch spring

bolts with the suitable clutch holder.

Special Tool - Clutch Holder: 57001-1554

Torque - Clutch Hub Bolt: 65 N·m (6.6 kgf·m, 48 ft·lb)

•

Install the clutch cover (see Clutch Cover Installation).

5-10 CLUTCH

Clutch

Friction and Steel Plate Damage, Wear

•

Visually inspect the friction and steel plates for signs of

seizure, overheating (discoloration), or uneven wear.

•

Measure the thickness of the friction plates [A] at several

points.

If any plates show signs of damage, or if they have worn

past the service limit, replace them with new ones.

Friction Plate Thickness

Standard:

(small inside diameter)

2.92

∼ 3.08 mm

(0.115

∼ 0.121 in.)

(large inside diameter)

3.50

∼ 3.60 mm

(0.138

∼ 0.142 in.)

Service Limit:

(small inside diameter) 2.6 mm (0.10 in.)

(large inside diameter) 3.2 mm (0.13 in.)

Friction and Steel Plate Warp

•

Place friction plate or steel plate [B] on a surface plate,

and measure the gap between the surface plate [A] with

a thickness gauge [C]. The gap is the amount of friction

or steel plate warp.

If any plate is warped over the service limit, replace it with

a new one.

Friction and Steel Plate Warp

Standard: 0.15 mm (0.0059 in.) or less

Service Limit: 0.3 mm (0.01 in.)

Clutch Spring Free Length Measurement

•

Measure the free length of the clutch springs [A].

If any spring is shorter than the service limit, it must be

replaced.

Clutch Spring Free Length

Standard: 40.2 mm (1.58 in.)

Service Limit: 38.4 mm (1.51 in.)

Clutch Housing Finger Damage

•

Visually inspect the clutch housing fingers [A] where the

friction plate tangs hit them.

If they are badly worn or if there are groove cuts where the

tangs hit, replace the housing. Also, replace the friction

plates if their tangs are damaged.

CLUTCH 5-11

Clutch

Clutch Hub Spline Damage

•

Visually inspect where the teeth on the steel plates wear

against the clutch hub splines.

If there are notches worn into the clutch hub splines [A],

replace the clutch hub. Also, replace the steel plates if

their teeth are damaged.

ENGINE LUBRICATION SYSTEM 6-1

Engine Lubrication System

Table of Contents

Exploded View........................................................................................................................ 6-2

Engine Oil Flow Chart............................................................................................................. 6-4

Specifications ......................................................................................................................... 6-5

Special Tools .......................................................................................................................... 6-6

Engine Oil and Oil Filter.......................................................................................................... 6-7

Oil Level Inspection........................................................................................................... 6-7

Engine Oil Change............................................................................................................ 6-7

Oil Filter Change ............................................................................................................... 6-7

Oil Screen Removal .......................................................................................................... 6-8

Oil Screen Installation ....................................................................................................... 6-8

Oil Pump................................................................................................................................. 6-9

Oil Pump Removal ............................................................................................................ 6-9

Oil Pump Installation ......................................................................................................... 6-9

Oil Pump Inspection.......................................................................................................... 6-9

Oil Pressure............................................................................................................................ 6-10

Oil Pressure Measurement ............................................................................................... 6-10

6-2 ENGINE LUBRICATION SYSTEM

Exploded View

ENGINE LUBRICATION SYSTEM 6-3

Exploded View

Torque

No. Fastener

N·m kgf·m ft·lb

Remarks

1 Engine Oil Drain Plug 18 1.8 13

2 Clutch Cover Bolts 8.8 0.90 78 in·lb

Oil Filter Cover Bolts

8.8 0.90 78 in·lb

4 Oil Pump Mounting Screws (L = 18) 5.2 0.53 46 in·lb

5 Oil Pump Mounting Screws (L = 30) 5.2 0.53 46 in·lb

6 Oil Seal Retaining Plate Bolts 9.8 1.0 87 in·lb L

G: Apply grease.

EO: Apply engine oil.

R: Replacement Parts

6-4 ENGINE LUBRICATION SYSTEM

Engine Oil Flow Chart

1. Oil Screen

2. Oil Pump

3. Oil Pipe

4. Oil Filter

5. Crankshaft

6. Crankshaft Oil Seal

7. Camshaft

8. Camshaft Chain Tunnel

9. Clutch Cover

10. Engine Breather Hose

ENGINE LUBRICATION SYSTEM 6-5

Specifications

Item Standard

Engine Oil

Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

Viscosity SAE 10W-40

Capacity 0.93 L (0.98 US qt) (when filter is not removed)

0.95 L (1.00 US qt) (when filter is removed)

1.10 L (1.16 US qt) (when engine is completely dry)

Level Between upper and lower level lines

Oil Pressure Measurement

Oil pressure 29 ∼ 59 kPa (0.3 ∼ 0.6 kgf/cm², 4.3 ∼ 8.5 psi) at 4 000 r/min (rpm)

Oil Temperature 90°C (194°F)

6-6 ENGINE LUBRICATION SYSTEM

Special Tools

Oil Pressure Gauge, 5 kgf/cm²:

57001-125

Oil Pressure Gauge Adapter, M10 × 1.25:

57001-1182

Oil Pressure Cap:

57001-1555

ENGINE LUBRICATION SYSTEM 6-7

Engine Oil and Oil Filter

WARNING

Vehicle operation with insufficient, deteriorated,

or contaminated engine oil will cause accelerated

wear and may result in engine seizure, accident,

and injury. Check the oil level before each use and

change the oil and filter according to the periodic

maintenance chart.

Oil Level Inspection

•

Situate the motorcycle so that it is vertical.

•

Remove the oil filler gauge [A], wipe its gauge dry, and

tighten it into the filler opening.

•

Unscrew the oil filler gauge and check that the engine oil

level is between the upper [A] and lower [B] levels in the

gauge.

•

Replace the O-ring [C] with a new one.

NOTE

○

If the motorcycle has just been used, wait several min-

utes for all the oil to drain down.

○

If the oil has just been changed, start the engine and

run it for several minutes at idle speed. This fills the oil

filter with oil. Stop the engine, then wait several minutes

until the oil settles.

NOTICE

Racing the engine before the oil reaches every part

can cause engine seizure.

If the oil level is too high, remove the excess oil, using a

syringe or other suitable device.

If the oil level is too low, add the correct amount of oil.

Use the same type and make of oil that is already in the

engine.

NOTE

○

If the engine oil type and make are unknown, use any

brand of the specified oil to top off the level rather than

running the engine with the oil level low. Then at your

earliest convenience, change the oil completely.

Engine Oil Change

•

Refer to the Engine Oil Change in the Periodic Mainte-

nance chapter.

Oil Filter Change

•

Refer to the Oil Filter Change in the Periodic Maintenance

chapter.

6-8 ENGINE LUBRICATION SYSTEM

Engine Oil and Oil Filter

Oil Screen Removal

•

Drain the engine oil (see Engine Oil Change in the Peri-

odic Maintenance chapter).

•

Remove:

Clutch Cover (see Clutch Cover Removal in the Clutch

chapter)

Oil Screen [A]

Oil Screen Installation

•

Clean the oil screen [A] with high-flash point solvent and

remove any particles stuck to it.

○

Clean thoroughly whenever the oil screen is removed.

WARNING

Gasoline and low-flash point solvents can be

flammable and/or explosive and cause severe

burns. Clean the screen in a well-ventilated area,

and take care that there are no sparks or flame

anywhere near the working area; this includes any

appliance with a pilot light. Do not use gasoline or

a low-flash point solvent to clean the screen.

NOTE

○

While cleaning the screen, check for any metal particles

that might indicate internal engine damage.

•

Inspect the screen carefully for net tearing or other dam-

ages.

If the screen is damaged, replace it with a new one.

•

Apply engine oil to the rubber portion on the oil screen [A].

•

Insert the oil screen to the crankcase.

○

Upturn the “UP” mark [B], and turn the narrow side [C] to

interior.

•

Install the clutch cover (see Clutch Cover Installation in

the Clutch chapter).

ENGINE LUBRICATION SYSTEM 6-9

Oil Pump

Oil Pump Removal

•

Drain the engine oil (see Engine Oil Change in the Peri-

odic Maintenance chapter).

•

Remove:

Clutch Cover (see Clutch Cover Removal in the Clutch

chapter)

Clutch (see Clutch Removal in the Clutch chapter)

Primary Gear (see Primary Gear Removal in the Crank-

shaft/Transmission chapter)

•

Remove the mounting screws [A] and remove the oil

pump assembly [B].

○

Turn the pump gear so that the pump mounting screws

can be removed through the pump gear holes.

Oil Pump Installation

•

Replace the O-rings [A] with new ones.

•

Install the dowel pin [B].

•

Install the oil pump assembly [A].

○

The lower bolt is longer than the other ones.

Torque - Oil Pump Mounting Screws: 5.2 N·m (0.53 kgf·m,

46 in·lb)

•

Install the other removed parts.

Oil Pump Inspection

•

Visually inspect the oil pump body [A] and the gear [B].

If there is any damage or uneven wear, replace the oil

pump assembly.

•

Turn the gear by hand to inspect the condition of the oil

pump.

If the rotation of the pump is noisy, dose not turn smoothly

or has any rough spots, replace the oil pump assembly.

NOTICE

Do not disassemble the oil pump, because the indi-

vidual parts of pump are not supplied.

6-10 ENGINE LUBRICATION SYSTEM

Oil Pressure

Oil Pressure Measurement

•

Remove the bolts [A] and oil filter cover [B].

•

Move the spring and the O-ring of the oil filter cover to the

oil pressure cap.

Special Tools - Oil Pressure Cap: 57001-1555

•

Attach the oil pressure cap [A], the oil pressure gauge

adapter [B] and the oil pressure gauge [C].

Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125

Oil Pressure Gauge Adapter, M10 × 1.25:

57001-1182

Oil Pressure Cap: 57001-1555

•

Start the engine and warm up the engine thoroughly.

•

Run the engine at the specified speed, and read the oil

pressure value.

If the oil pressure is much lower than the standard, check

the oil pump, and crankshaft oil seal of the clutch cover.

If the value is much higher than the standard, check the

oil pump screen and the oil filter first, and oil passages for

dirt or clogging.

Oil Pressure

Standard: 29

∼ 59 kPa (0.3 ∼ 0.6 kgf/cm², 4.3 ∼ 8.5 psi)

at 4 000 r/min (rpm), Oil Temperature 90°C

(194°F)

•

Stop the engine, and remove the oil pressure cap, gauge

and adapter.

WARNING

Hot oil can cause severe burns. Beware of hot en-

gine oil that will drain through the oil passage when

the oil pressure gauge adapter is removed.

•

Replace the O-ring with a new one, and apply grease to

the O-ring.

•

Install the spring to the oil filter cover.

•

Install the oil filter cover.

○

The arrow mark on the cover is upward.

Torque - Oil Filter Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

ENGINE REMOVAL/INSTALLATION 7-1

Engine Removal/Installation

Table of Contents

Exploded View........................................................................................................................ 7-2

Special Tool ............................................................................................................................ 7-4

Engine Removal/Installation................................................................................................... 7-5

Engine Removal................................................................................................................ 7-5

Engine Installation............................................................................................................. 7-7

7-2 ENGINE REMOVAL/INSTALLATION

Exploded View

ENGINE REMOVAL/INSTALLATION 7-3

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

Upper Engine Mounting Nut (M10)

49 5.0 36 R

2 Middle Engine Mounting Nut (M10) 49 5.0 36 R

3 Front Engine Mounting Nuts (M10) 49 5.0 36 R

4 Rear Engine Mounting Nut (M10) 49 5.0 36 R

5 Engine Bracket Bolts (M8) 29 3.0 21

Engine Bracket Nuts (M8)

29 3.0 21 R

7. Upper Engine Mounting Bolt (L = 160)

8. Middle Engine Mounting Bolt (L = 105)

9. Front Engine Mounting Bolts (L = 77)

10. Rear Engine Mounting Bolt (L = 105)

7-4 ENGINE REMOVAL/INSTALLATION

Special Tool

Jack:

57001-1238

ENGINE REMOVAL/INSTALLATION 7-5

Engine Removal/Installation

Engine Removal

•

Place the jack [A] under the frame to support the motor-

cycle.

Special Tool - Jack: 57001-1238

•

Squeeze the brake lever slowly and hold it with a band

[A].

WARNING

Motorcycle may fall over unexpectedly resulting in

an accident or injury. Be sure to hold the front brake

when removing the engine.

NOTICE

Be sure to hold the front brake when removing the

engine, or the motorcycle may fall over. The engine

or the motorcycle could be damaged.

•

Drain in the engine oil (see Engine Oil Change in the Pe-

riodic Maintenance chapter).

•

Remove:

Engine Guard (see Engine Guard Removal in the Frame

chapter)

Seat (see Seat Removal in the Frame chapter)

Fuel Tank (see Fuel Tank Removal in the Fuel System

chapter)

Carburetor (see Carburetor Removal in the Fuel System

chapter)

Muffler (see Muffler Removal in the Engine Top End

chapter)

Engine Sprocket (see Engine Sprocket Removal in the

Final Drive chapter)

•

Remove the brake pedal pivot bolt [A].

•

Remove the breather tube and the spark plug cap only

the cylinder head.

7-6 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

•

Remove the bolts [A].

•

Take off the clutch cable lower end [B] from the clutch

lever [C].

•

Remove the starter motor cable [A] and the engine ground

[B].

•

Disconnect the alternator lead connector [A], and clear

the clamp.

•

Remove the bolt [A], and take off the shift change lever

[B] from the shift shaft .

•

Remove:

Upper Engine Mounting Bolt/Nut [A]

Upper Engine Bracket Bolts [B] (both sides)

Upper Engine Bracket [C] (both sides)

Middle Engine Mounting Bolt/Nut [D]

Middle Engine Bracket Bolts [E] (both sides)

Middle Engine Bracket [F] (both sides)

ENGINE REMOVAL/INSTALLATION 7-7

Engine Removal/Installation

•

Remove:

Front Engine Mounting Bolts/Nuts [A]

Front Engine Bracket Bolts/Nuts [B]

Front Engine Bracket [C] (both sides)

Rear Engine Mounting Bolt/Nut [D]

•

Remove the engine toward right.

Engine Installation

•

Replace the engine mounting nuts and bracket nuts with

new ones.

•

Install the engine body and the engine brackets, and

tighten lightly all mounting bolts and nuts temporarily.

○

Install all nuts to right side.

○

Insert the rear engine mounting bolt first.

•

Tighten the engine mounting nuts.

Torque - Engine Mounting Nuts [A]: 49 N·m (5.0 kgf·m, 36

ft·lb)

•

Tighten the engine bracket bolts and nuts.

Torque - Engine Bracket Bolts [A](both sides): 29 N·m (3.0

kgf·m, 21 ft·lb)

Engine Bracket Nuts [B]: 29 N·m (3.0 kgf·m, 21

ft·lb)

•

Install the other removed parts.

•

Run the cables, hoses and leads according to the Cable,

Wire and Hose Routing section in the Appendix chapter.

•

Fillthe engine oil (see Engine Oil Change in the Periodic

Maintenance chapter).

•

Adjust:

Throttle Cable (see Throttle Grip Free Play Adjustment

in the Periodic Maintenance chapter)

Clutch Cable (see Clutch Lever Free Play Adjustment in

the Periodic Maintenance chapter)

Drive Chain (see Drive Chain Slack Adjustment in the

Periodic Maintenance chapter)

•

Adjust the idling (see Idle Speed Adjustment in the Peri-

odic Maintenance chapter).

•

Check the operation of the clutch lever.

•

Check

the brake effectiveness.

WARNING

After servicing, it takes several applications of the

brake pedal before the brake pads contact the disc,

which could result in increased stopping distance

and cause an accident resulting in injury or death.

Do not attempt to ride the motorcycle until a firm

brake pedal is obtained by pumping the pedal until

the pads are against the disc.

CRANKSHAFT/TRANSMISSION 8-1

Crankshaft/Transmission

Table of Contents

Exploded View........................................................................................................................ 8-2

Specifications ......................................................................................................................... 8-6

Special Tools and Sealants .................................................................................................... 8-7

Crankcase .............................................................................................................................. 8-8

Crankcase Disassembly ................................................................................................... 8-8

Crankcase Assembly ........................................................................................................ 8-9

Crankshaft .............................................................................................................................. 8-13

Crankshaft Removal ......................................................................................................... 8-13

Crankshaft Installation ...................................................................................................... 8-13

Crankshaft Disassembly ................................................................................................... 8-13

Connecting Rod Big End Seizures.................................................................................... 8-13

Connecting Rod Big End Radial Clearance ...................................................................... 8-13

Connecting Rod Big End Side Clearance ......................................................................... 8-13

Crankshaft Runout............................................................................................................ 8-13

Primary Gear .......................................................................................................................... 8-15

Primary Gear and Oil Pump Gear Removal...................................................................... 8-15

Primary Gear and Oil Pump Gear Installation................................................................... 8-15

External Shift Mechanism....................................................................................................... 8-16

Shift Pedal Ball Joint Installation....................................................................................... 8-16

External Shift Mechanism Removal .................................................................................. 8-16

External Shift Mechanism Inspection................................................................................ 8-16

Transmission .......................................................................................................................... 8-17

Transmission Shaft Removal ............................................................................................ 8-17

Transmission Shaft Installation ......................................................................................... 8-17

Transmission Disassembly ............................................................................................... 8-17

Transmission Assembly .................................................................................................... 8-17

Shift Fork Bending ............................................................................................................ 8-19

Shift Fork/Gear Groove Wear ........................................................................................... 8-20

Shift Fork Guide Pin/Drum Groove Wear.......................................................................... 8-20

Gear Dog and Gear Dog Hole Damage............................................................................ 8-20

Ball Bearing, and Oil Seal....................................................................................................... 8-21

Ball Bearing Replacement ................................................................................................ 8-21

Ball Bearing Wear ............................................................................................................. 8-21

Oil Seal Inspection ............................................................................................................ 8-21

8-2 CRANKSHAFT/TRANSMISSION

Exploded View

CRANKSHAFT/TRANSMISSION 8-3

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

Primary Gear Nut

98 10 72

Lh, MO

2 Crankcase Bolts (L = 50) 8.8 0.90 78 in·lb

3 Crankcase Bolts (L = 60) 8.8 0.90 78 in·lb

4 Bearing Retaining Screws 5.2 0.53 46 in·lb L

5 Engine Oil Drain Plug 18 1.8 13

Neutral Switch

15 1.5 11

7. KLX140AA ∼/BA ∼

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

M: Apply molybdenum disulfide grease.

R: Replacement parts.

8-4 CRANKSHAFT/TRANSMISSION

Exploded View

CRANKSHAFT/TRANSMISSION 8-5

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

Shift Drum Cam Bolt

12 1.2 106 in·lb L

2 Gear Set Lever Mounting Nut 9.8 1.0 87 in·lb

3 Shift Return Spring Pin (Bolt) 29 3.0 21 L

4 Shift Pedal Ball Joint Clamp Bolt 12 1.2 106 in·lb

5 Shift Linkage Rod Locknut 9.8 1.0 87 in·lb

EO: Apply engine oil.

L: Apply a non-permanent locking agent.

R: Replacement parts.

8-6 CRANKSHAFT/TRANSMISSION

Specifications

Item Standard Service Limit

Crankshaft, Connecting Rods

Connecting Rod Big End:

Radial Clearance 0.005 ∼ 0.017 mm (0.0002 ∼ 0.0007 in.) 0.07 mm (0.003 in.)

Side Clearance 0.1 ∼ 0.2 mm (0.004 ∼ 0.008 in.) 0.4 mm (0.016 in.)

Crankshaft Runout TIR 0.03 mm (0.001 in.) or less TIR 0.08 mm (0.003 in.)

Transmission

Shift Fork Ear Thickness 4.9 ∼ 5.0 mm (0.19 ∼ 0.20 in.) 4.8 mm (0.19 in.)

Gear Shift Fork Groove Width 5.05 ∼ 5.15 mm (0.199 ∼ 0.203 in.) 5.25 mm (0.207 in.)

Shift Fork Guide Pin Diameter 5.9 ∼ 6.0 mm (0.23 ∼ 0.24 in.) 5.8 mm (0.23 in.)

Shift Drum Groove Width 6.05 ∼ 6.20 mm (0.238 ∼ 0.244 in.) 6.3 mm (0.25 in.)

CRANKSHAFT/TRANSMISSION 8-7

Special Tools and Sealants

Outside Circlip Pliers:

57001-144

Bearing Driver Set:

57001-1129

Crankshaft Jig:

57001-1174

Gear Holder:

57001-1602

Liquid Gasket, TB1105B:

92104-002

Liquid Gasket, TB1216:

92104-1063

Liquid Gasket, TB1215:

92104-1065

8-8 CRANKSHAFT/TRANSMISSION

Crankcase

Crankcase Disassembly

•

Remove the engine (see Engine Removal in the Engine

Removal/Installation chapter)

•

Set the engine on a clean surface and hold the engine

steady while parts are being removed.

•

Remove:

Camshaft Chain (see Camshaft Chain Removal in the

Engine Top End chapter)

Cylinder Head (see Cylinder Head Removal in the En-

gine Top End chapter)

Cylinder (see Cylinder Removal in the Engine Top End

chapter)

Piston (see Piston Removal in the Engine Top End chap-

ter)

Alternator (see Alternator Removal in the Electrical Sys-

tem chapter)

Starter Motor (see Starter Motor Removal in the Electri-

cal System chapter)

Clutch (see Clutch Removal in the Clutch chapter)

Oil Pump Gear and Primary Gear (see Primary Gear

Removal in the Clutch chapter)

Oil Pump (see Oil Pump Removal in the Engine Lubri-

cation chapter)

External Shift Mechanism (see External Shift Mecha-

nism Removal)

Gear Set Lever [A]

Shift Drum Cam [B]

•

Remove the output shaft sleeve [A] and O-ring [B].

•

Remove all the crankcase bolts [A] on both sides.

CRANKSHAFT/TRANSMISSION 8-9

Crankcase

•

Insert a suitable tool to the pry points [A], and split the

crankcase.

•

Remove the left crankcase half.

•

Disassemble the transmission system from the right

crankcase half (see Transmission Disassembly).

•

Support the left crankcase half [A] with a suitable retainer.

•

Remove the crankshaft [B] from the left crankcase half

using a press.

NOTICE

Do not remove the ball bearings and the oil seals

unless it is necessary. If they are removed, replace

them with new ones.

Crankcase Assembly

NOTICE

Right and left crankcase halves are machined at the

factory in the assembled state, so if replaced, they

must be replaced as a set.

•

Chip off the old gasket from the mating surfaces of the

crankcase halves and clean them off with high-flash point

solvent.

•

Using compressed air, blow out the oil passages in the

crankcase halves.

WARNING

Gasoline and low-flash point solvents can be

flammable and/or explosive and cause severe

burns. Clean the engine parts in a well-ventilated

area, and take care that there is no spark or flame

anywhere near the working areas. Do not use

gasoline or low-flash point solvents to clean parts.

8-10 CRANKSHAFT/TRANSMISSION

Crankcase

•

Support the crankcase bearing boss with a suitable re-

tainer [A].

•

Using a press and the bearing driver set [C], install a new

bearing [B] until it bottoms out.

Special Tool - Bearing Driver Set: 57001-1129

•

Apply a non-permanent locking agent to the bearing re-

taining screws.

•

Tighten the input shaft and the shift drum bearing retain-

ing screws securely in the right crankcase half.

Torque - Bearing Retaining screws: 5.2 N·m (0.53 kgf·m, 46

in·lb)

NOTICE

Support the crankcase bearing boss when the bear-

ings are pressed, or the crankcase could be dam-

aged.

•

Press the output shaft bearing [B] in the left crankcase

half [A].

Special Tool - Bearing Driver Set: 57001-1129

•

Put in the output shaft oil seal [C], being careful of the

proper direction as shown.

•

Using compressed air [A], blow out the oil passage in the

right crankshaft [B].

•

Positioning the connecting rod [A] big end at BDC, put in

the crankshaft jig [B] between the crankshaft flywheels.

•

Press the crankshaft [C] in the right crankcase half [D].

Special Tool - Crankshaft Jig: 57001-1174

•

Assemble the transmission system (see Transmission

Assembly).

CRANKSHAFT/TRANSMISSION 8-11

Crankcase

•

Apply liquid gasket to the mating surface [A] of the left

crankcase half.

NOTE

○

Don’t apply liquid gasket to this area [B].

Sealant - Liquid Gasket, TB1105B: 92104-002

Liquid Gasket, TB1216: 92104-1063

Liquid Gasket, TB1215: 92104-1065

•

Using a suitable tool on the left crankcase to press around

the hole for the crankshaft, fit the crankcase halves to-

gether with a press on the tool.

•

Remove the crankshaft jig.

•

Install the crankcase bolts [A] in the left and right

crankcase half and tighten them, starting with the nearest

ones to the crankshaft, then farther ones.

Torque - Crankcase Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Check to see that the crankshaft, drive shaft, and output

shaft all turn freely (in the neutral position).

If the crankshaft will not turn, probably the crankshaft is

not centered; tap the mount portion [A] of the crankcase

with a plastic hammer to reposition it.

•

Apply a non-permanent locking agent to the shift drum

cam bolt [A] and tighten it.

Torque - Shift Drum Cam Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)

•

Install the gear set lever and tighten the nut [B].

Torque - Gear Set Lever Mounting Nut: 9.8 N·m (1.0 kgf·m,

87 in·lb)

•

Install the external shift mechanism (see External Shift

Mechanism Installation).

•

Check to see that gears shift smoothly from 1st to 5th

gear, and 5th to 1st while spinning the output shaft.

•

Set the shift drum in the neutral position.

8-12 CRANKSHAFT/TRANSMISSION

Crankcase

•

Replace the O-ring [B] on the output shaft with a new one.

•

Apply grease to the inside of the output shaft collar [A].

CRANKSHAFT/TRANSMISSION 8-13

Crankshaft

Crankshaft Removal

•

Refer to the Crankcase Disassembly in this chapter.

Crankshaft Installation

•

Refer to the Crankcase Assembly in this chapter.

Crankshaft Disassembly

If the crankshaft is damaged, replace it as a set. Not for

sale to each part of the crankshaft.

Connecting Rod Big End Seizures

•

In case of seizure, replace the crankshaft assembly.

Connecting Rod Big End Radial Clearance

•

Support the crankshaft on both sides, and place a dial

gauge [A] against the connecting rod big end.

•

Push [B] the connecting rod first towards the gauge and

then in the opposite direction. The difference between

two gauge readings is the radial clearance.

Connecting Rod Big End Radial Clearance

Standard:

0.005 mm

∼ 0.017 mm

(0.0002 ∼ 0.0007 in.)

Service Limit: 0.07 mm (0.003 in.)

If the radial clearance exceeds the service limit, replace

the crankshaft assembly.

Connecting Rod Big End Side Clearance

•

Measure connecting rod big end side clearance [A].

Connecting Rod Big End Side Clearance

Standard: 0.1 ∼ 0.2 mm (0.004 ∼ 0.008 in.)

Service Limit: 0.4 mm (0.02 in.)

If the clearance exceeds the service limit, replace the

crankshaft assembly.

Crankshaft Runout

•

Supporting the crankshaft on both sides, place a dial

gauge as shown and turn the crankshaft slowly. The

maximum difference in gauge reading is the crankshaft

runout.

9 mm (0.35 in.) [A]

Crankshaft Runout

Standard: TIR 0.03 mm (0.001 in.) or less

Service Limit: TIR 0.1 mm (0.003 in.)

If the runout at either point exceeds the service limit, re-

place the crankshaft assembly with a new one or align the

crankshaft so that the runout falls within the service limit.

8-14 CRANKSHAFT/TRANSMISSION

Crankshaft

•

First correct the horizontal misalignment by striking the

projecting crank half [A] with a plastic, soft lead, or brass

hammer as shown.

•

Recheck the runout with a dial gauge and repeat the

process until the runout falls within the service limit.

•

Next, correct the vertical misalignment by either driving a

wedge [A] in between the crank halves or by squeezing

them in a vice, depending on the nature of the misalign-

ment.

NOTICE

Do not hammer the crank half at the point [B].

CRANKSHAFT/TRANSMISSION 8-15

Primary Gear

Primary Gear and Oil Pump Gear Removal

•

Remove the clutch cover (see Clutch Cover Removal in

the Clutch chapter).

•

Hold the primary gear with the gear holder [A].

Special Tool - Gear Holder: 57001-1602

•

Loosen the primary gear nut [B] (Left hand thread).

•

Remove:

Clutch (see Clutch Removal in the Clutch chapter)

Primary Gear Nut

Primary Gear [C]

Oil Pump Assembly (see Oil Pump Removal in the En-

gine Lubrication System)

Oil Pump Drive Gear

Woodruff Key

Primary Gear and Oil Pump Gear Installation

•

Set the woodruff key [A] securely in the slot.

•

Apply molybdenum disulfide oil to the seating surface of

primary gear nut.

•

Install:

Oil Pump Drive Gear [B]

Oil Pump Assembly (see Oil Pump Installation in the En-

gine Lubrication chapter)

Primary Gear [C]

○

On the KLX140AC ∼/BC ∼ models, install the primary gear

with its grooved side [D] facing outward.

•

Install the conical spring washer [E] with its concaved side

toward the gear.

•

Install the clutch (see Clutch Installation in the Clutch

chapter).

•

Temporarily tighten the primary gear nut [F].

•

Hold the primary gear with the gear holder [A].

Special Tool - Gear Holder: 57001-1602

•

Tighten the primary gear nut [B].

Torque - Primary Gear Nut: 98 N·m (10 kgf·m, 72 ft·lb)

•

Install the clutch cover (see Clutch Cover Installation in

the Clutch chapter).

8-16 CRANKSHAFT/TRANSMISSION

External Shift Mechanism

Shift Pedal Ball Joint Installation

•

Install the shift pedal ball joint [A].

○

Align the punch marks [B].

○

Align the shift pedal and the footpeg upper surface to the

same level.

•

Install the rubber boot [A] of the shift pedal ball joint over

the rib [B].

•

Be sure the sealing lip of the rubber boot fits into the

groove of the ball joint.

External Shift Mechanism Removal

•

Drain the engine oil (see Engine Oil Change in the Peri-

odic Maintenance chapter).

•

Remove:

Clutch Cover (see Clutch Cover Removal in the Clutch

chapter)

Clutch (see Clutch Removal in the Clutch chapter)

Shift Pedal (see Shift Pedal Removal)

•

Turn the shift drum and position the neutral groove [A] as

shown.

•

Remove the shift shaft [B] while pushing backward [C] the

shift mechanism arm [D].

External Shift Mechanism Inspection

•

Examine the shift shaft [A] for any damage.

If the shaft is bent, straighten or replace it.

If the splines [B] are damaged, replace the shaft.

If the springs [C] [D] are damaged in any way, replace

them.

If the shift pawl [E] is damaged in any way, replace the

shift shaft assembly.

•

Check the return spring pin [A] is not loose.

If it is loose, unscrew it to apply a non-permanent locking

agent to the threads, and tighten it.

Torque - Shift Shaft Return Spring Pin: 29 N·m (3.0 kgf·m,

22 ft·lb)

•

Check the gear set lever [B], and their springs [C] for

breaks or distortion.

If the lever or springs are damaged in any way, replace

them.

•

Visually inspect the shift drum cam [D].

If the cam is badly worn or if it shows any damage, replace

it.

CRANKSHAFT/TRANSMISSION 8-17

Transmission

Transmission Shaft Removal

•

Split the crankcase (see Crankcase Disassembly)

•

Pull out the shift rod [A] allowing the shift fork guide pins

to free from the shift drum [B].

•

Remove the shift forks [C].

•

Remove the shift drum.

•

Pull out the drive shaft [D] and output shaft [E] together

with their gears meshed.

Transmission Shaft Installation

•

Apply engine oil to the sliding portions of every gear and

bearing.

•

Install the drive shaft [A], output shaft [D], and shift drum

[C] in the right crankcase with their gears [B] meshed.

•

Apply a small amount of engine oil to the shift fork fingers

and fit each shift fork into the groove of the proper gear.

•

The shift forks can be identified by their shape or mark.

Install them noting the direction shown.

○

Install each shift forks with its mark facing the engine left

side.

Marks:

0051 (Drive Shaft)

NR (Right Output Shaft)

NL (Left Output Shaft)

•

Fit each shift fork guide pin into the corresponding groove

in the shift drum.

•

Apply a little engine oil to the shift rods and slide them into

the shift forks.

•

Assemble the crankcase (see Crankcase Assembly).

Transmission Disassembly

•

Remove the transmission shafts (see Transmission Shaft

Removal).

•

Remove the circlips, washers and gears.

Special Tool - Outside Circlip Pliers: 57001-144

Transmission Assembly

•

Replace any circlips with new ones.

•

Install the circlips [A] so that the opening [B] is aligned

with a spline groove [C].

NOTE

○

Take care not to damage the circlips. First, expand the

circlip opening, and fit onto the shaft. Next, push the

circlip into the suitable place with the gear.

•

Check that each gear spins or slides freely on the trans-

mission shafts without binding after assembly.

•

Be sure that all parts are put back in the correct sequence

and all circlips and washers are properly in place.

8-18 CRANKSHAFT/TRANSMISSION

Transmission

KLX140A8 ∼ A9/B8 ∼ B9

1. Drive gear-1st

2. Drive gear-2nd

3. Drive gear-3rd

4. Drive gear-4th

5. Drive gear-Top

6. Output gear-1st

7. Output gear-2nd

8. Output gear-3rd

9. Output gear-4th

10. Output gear-Top

11. Spacer

12. Circlip

13. Washer

14. Shim

CRANKSHAFT/TRANSMISSION 8-19

Transmission

KLX140AA ∼/BA ∼

1. Drive gear-1st

2. Bushing

3. Drive gear-4th

4. Spacer

5. Snap Ring

6. Drive gear-3rd

7. Bushing

8. Drive gear-Top

9. Drive gear-2nd

10. Spacer

11. Output Shaft

12. Bushing

13. Output gear-1st

14. Shim

15. Output gear-4th

16. Spacer

17. Output gear-Top

18. Output gear-2nd

19. Bushing

Shift Fork Bending

•

Visually inspect the shift forks, and replace any fork that is

bent. A bent fork could cause difficulty in shifting, or allow

the transmission to jump out of gear when under power.

90° [A]

8-20 CRANKSHAFT/TRANSMISSION

Transmission

Shift Fork/Gear Groove Wear

•

Measure the thickness of the shift fork ears [A], and mea-

sure the width [B] of the gear grooves.

Shift Fork Ear Thickness

Standard: 4.9

∼ 5.0 mm (0.19 ∼ 0.20 in.)

Service Limit: 4.8 mm (0.19 in.)

Gear Groove Width

Standard: 5.05 ∼ 5.15 mm (0.199 ∼ 0.203 in.)

Service Limit: 5.25 mm (0.207 in.)

If the thickness of a shift fork ear is less than the service

limit, the shift fork must be replaced.

If the gear groove is worn exceeding the service limit, the

gear must be replaced.

Shift Fork Guide Pin/Drum Groove Wear

•

Measure the diameter of each shift fork guide pin [A], and

measure the width of each shift drum groove [B].

Shift Fork Guide Pin Diameter

Standard: 5.9

∼ 6.0 mm (0.23 ∼ 0.24 in.)

Service Limit: 5.8 mm (0.23 in.)

Shift Drum Groove Width

Standard: 6.05

∼ 6.20 mm (0.238 ∼ 0.244 in.)

Service Limit: 6.3 mm (0.25 in.)

If the guide pin on any shift fork is less than the service

limit, the fork must be replaced.

If any shift drum groove is worn exceeding the service

limit, the drum must be replaced.

Gear Dog and Gear Dog Hole Damage

•

Visually inspect the gear dogs [A] and gear dog holes [B].

Replace any damaged gears or gears with excessively

worn dogs or dog holes.

•

Visually inspect the gear teeth [C] on the transmission

gears.

Replace lightly damaged gear teeth with an oilstone. The

gear must be replaced if the teeth are badly damaged.

When gear is repaired or replaced, the driving gear should

also be inspected and repaired or replaced if necessary.

CRANKSHAFT/TRANSMISSION 8-21

Ball Bearing, and Oil Seal

Ball Bearing Replacement

NOTICE

Do not remove the ball bearings unless it is neces-

sary. Removal may damaged them.

•

Remove the ball bearing and/or needle bearing outer race

withapressorpuller.

NOTE

○

In the absence of the above mentioned tools, satisfac-

tory results may be obtained by heating the case to ap-

proximately 93°C (200°F) max, and tapping the bearing

in or out.

NOTICE

Do not heat the case with a torch. This will warp the

case. Soak the case in oil and heat the oil.

•

Install the new bearing until its outer race stops at the

bottom of the case with a press and the bearing driver set

[A].

Special Tool - Bearing Driver Set: 57001-1129

Ball Bearing Wear

NOTICE

Do not remove the bearings for inspection. Re-

moval may damage them.

•

Inspect the ball bearings.

○

Since the ball bearings are made to extremely close toler-

ances, the wear must be judged by feel rather than mea-

surement. Clean each bearing in high-flash point solvent,

dry it (do not spin the bearing while it is dry), and oil it with

engine oil to it.

○

Spin [A] the bearing by hand to check its condition.

If the bearing is noisy, does not spin smoothly, or has any

rough spots, replace it.

•

Check the needle bearing.

○

The rollers in a needle bearing normally wear very little,

and wear is difficult to measure. Instead of measuring,

inspect the bearing for abrasion, color change, or other

damage.

If there is any doubt as to the condition of a needle bear-

ing, replace it.

Oil Seal Inspection

•

Inspect the oil seals.

Replace the seal if the lips are deformed, discolored (in-

dicating that the rubber has deteriorated), hardened or

otherwise damaged.

WHEELS/TIRES 9-1

Wheels/Tires

Table of Contents

Exploded View........................................................................................................................ 9-2

Specifications ......................................................................................................................... 9-4

Special Tools .......................................................................................................................... 9-5

Wheels (Rims) ........................................................................................................................ 9-6

Front Wheel Removal ....................................................................................................... 9-6

Front Wheel Installation .................................................................................................... 9-6

Rear Wheel Removal........................................................................................................ 9-7

Rear Wheel Installation..................................................................................................... 9-7

Wheels Inspection............................................................................................................. 9-8

Spoke Tightness Inspection.............................................................................................. 9-8

Rim Runout Inspection...................................................................................................... 9-8

Axle Inspection..................................................................................................................9-8

Tires........................................................................................................................................ 9-9

Tire Removal.....................................................................................................................9-9

Tire Installation.................................................................................................................. 9-10

Air Pressure Inspection/Adjustment.................................................................................. 9-11

Hub Bearings.......................................................................................................................... 9-12

Hub Bearing Removal....................................................................................................... 9-12

Hub Bearing Installation.................................................................................................... 9-12

Hub Bearing Inspection..................................................................................................... 9-12

Hub Bearing Lubrication ................................................................................................... 9-13

9-2 WHEELS/TIRES

Exploded View

WHEELS/TIRES 9-3

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

1 Front Axle Nut 79 8.1 58 R

2 Rear Axle Nut 79 8.1 58 R

3. Spoke Nipples

4. Spokes

5. Rims

6. Front Axle

7. Rear Axle

8. Rear Sprocket

9. Front Brake Disc

10. Rear Brake Disc

HG: Apply high temperature grease.

WL: Apply soap and water solution, or rubber lubricant.

R: Replacement Parts.

9-4 WHEELS/TIRES

Specifications

Item Standard Service Limit

Wheels (Rims)

Rim Size:

Front (KLX140A) 17 × 1.40 –––

(KLX140B) 19 × 1.40 –––

Rear (KLX140A) 14 × 1.60 –––

(KLX140B) 16 × 1.85 –––

Rim Runout:

Axial

TIR 0.8 mm (0.031 in.

)orless

TIR 2.0 mm (0.08 in.)

Radial TIR 1.2 mm (0.047 in.) or less TIR 2.0 mm (0.08 in.)

Axle Runout/100 mm (3.94 in.) TIR 0.1 mm (0.004 in.) or less TIR 0.2 mm (0.008 in.)

Tires

Air Pressure (when cold):

Front and Rear

100 kPa (1.02 kgf/cm², 14.5 psi)

–––

Standard Tire:

Front:

Size (KLX140A) 70/100-17 40M –––

(KLX140B) 70/100-19 42M –––

Make

IRC

–––

Type IX05H, Tube –––

Rear:

Size (KLX140A) 90/100-14 49M –––

(KLX140B) 90/100-16 52M –––

Make IRC –––

Type IX05H, Tube –––

WHEELS/TIRES 9-5

Special Tools

Inside Circlip Pliers:

57001-143

Rim Protector:

57001-1063

Bead Breaker Assembly:

57001-1072

Bearing Driver Set:

57001-1129

Jack:

57001-1238

9-6 WHEELS/TIRES

Wheels (Rims)

Front Wheel Removal

•

Stabilize the motorcycle with the jack.

Special Tool - Jack: 57001-1238

•

Apply the rear brake to rear wheel does not turn.

•

Remove the cotter pin [A] and the front axle nut [B].

•

Raise the front wheel off the ground with the jack.

•

Pull out the axle [C], and remove the wheel.

○

Take care not to damage the front caliper.

•

Take off the cap [A] on both sides.

NOTICE

Do not lay the wheel on the ground with the disc

facing down. This can damage or warp the disc.

Place blocks under the wheel so the disc does not

touch the ground.

•

Insert a wood wedge between the disc brake pads this

prevents them from being moved out of their proper posi-

tion, should the brake lever be squeezed accidentally.

Front Wheel Installation

•

Apply high-temperature grease to the oil seal [A] on both

sides.

•

Install the cap [B] on both sides and install the wheel.

○

Take care not to damage the front caliper.

•

Replace the front axle nut with a new one.

•

Insert the axle [A] from left side, and tighten the axle nut

[B].

Torque - Front Axle Nut: 79 N·m (8.1 kgf·m, 58 ft·lb)

•

Insert a new cotter pin [C] to the front axle, and bend it to

both sides.

•

Remove the jack.

•

Check the front brake for good braking power and no

brake drag.

WARNING

After servicing, it takes several applications of the

brake lever before the brake pads contact the disc,

which could result in increased stopping distance

and cause an accident resulting in injury or death.

Do not attempt to ride the motorcycle until a firm

brake lever is obtained by pumping the lever until

the pads are against the disc.

WHEELS/TIRES 9-7

Wheels (Rims)

Rear Wheel Removal

•

Raise the rear wheel off the ground with the jack.

Special Tool - Jack: 57001-1238

•

Remove the rear caliper (see Rear Caliper Removal in

the Brakes chapter).

•

Remove the cotter pin [A] and the rear axle nut [B].

•

Remove the axle [C], and take off the chain adjuster [D]

on both sides.

•

Disengage the drive chain from the rear sprocket.

○

Hang the chain on the swingaem.

•

Remove the rear wheel.

○

Take care not to damage the rear caliper.

•

Take off the cap [A] on both sides.

NOTICE

Do not lay the wheel on the ground with the disc

facing down. This can damage or warp the disc.

Place blocks under the wheel so the disc does not

touch the ground.

•

Insert a wood wedge between the brake pads. This pre-

vents them from being moved out of their proper position,

should the brake pedal be squeezed accidentally.

Rear Wheel Installation

•

Install the brake holder onto the swingarm.

○

Fit the groove [A] of the holder and the projection [B] of

the swingarm.

9-8 WHEELS/TIRES

Wheels (Rims)

•

Apply high-temperature grease to the oil seal [A] on both

sides, and install the cap [B] on both sides.

•

Engage the drive chain with the rear sprocket, and set the

rear wheel to the motorcycle.

•

Replace the rear axle nut with a new one.

•

Insert the axle from the left side, and tighten the axle nut.

Torque - Rear Axle Nut: 79 N·m (8.1 kg·m, 58 ft·lb)

•

Insert a new cotter pin to the rear axle, and bend it along

both sides.

•

Remove the jack.

•

Install the rear caliper (see Rear Caliper Install in the

Brakes chapter).

•

Check the rear brake for good braking power and no

brake drag.

WARNING

After servicing, it takes several applications of the

brake pedal before the brake pads contact the disc,

which could result in increased stopping distance

and cause an accident resulting in injury or death.

Do not attempt to ride the motorcycle until a firm

brake pedal is obtained by pumping the pedal until

the pads are against the disc.

Wheels Inspection

•

Raise the front/rear wheel off the ground with the jack.

Special Tool - Jack: 57001-1238

•

Spin the wheel lightly, and check for roughness or binding.

If the roughness or binding is found, replace the hub bear-

ings.

•

Visually inspect the front and rear axles for damage.

If the axle is damaged or bent, replace it.

Spoke Tightness Inspection

•

Refer to the Spoke Tightness Inspection in the Periodic

Maintenance chapter.

Rim Runout Inspection

•

Refer to the Rim Runout Inspection in the Periodic Main-

tenance chapter.

Axle Inspection

•

Visually inspect the front and rear axle for damages.

If the axle is damaged or bent, replace it.

•

Place the axle in V blocks that are 100 mm (3.937 in.)

[A] apart, and set a dial gauge [B] on the axle at a point

halfway between the blocks. Turn [C] the axle to measure

the runout. The difference between the highest and low-

est dial readings is the amount of runout.

If the runout exceeds the service limit, replace the axle.

Axle Runout/100 mm (3.94 in.)

Standard: TIR 0.1 mm (0.004 in.) or less

Service Limit: TIR 0.2 mm (0.008 in.)

WHEELS/TIRES 9-9

Tires

Tire Removal

NOTICE

Do not lay the wheel on the ground with the disc

facing down. This can damage or warp the disc.

Place blocks under the wheel so the disc does not

touch the ground.

•

Remove the wheel from the motorcycle (see Wheels Re-

moval).

•

To maintain front wheel balance, mark [A] the valve stem

position on the tire with chalk so that the tire can be rein-

stalled in the same position.

•

Remove the valve cap [B].

•

Take out the valve core [A] to let out the air.

•

Remove the valve stem nut [B].

○

When handling the rim, be careful not to damage the rim

flanges.

•

Loosen the bead protector nut [A].

•

Lubricate the tire beads and rim flanges on both sides with

a soap and water solution or rubber lubricant. This helps

the tire beads slip off the rim flanges.

NOTICE

Never lubricate with mineral oil (engine oil) or gaso-

line because they will cause deterioration of the tire.

•

Break the beads away from both sides of the rim with the

bead breaker [A].

Special Tool - Bead Breaker Assembly: 57001-1072

9-10 WHEELS/TIRES

Tires

•

Step on the side of the tire opposite valve stem, pry the

tire off the rim with the tire iron [A] of the bead breaker

protecting the rim with rim protectors [B].

Special Tools - Rim Protector: 57001-1063

Bead Breaker Assembly: 57001-1072

NOTICE

Take care not to inset the tire irons so deeply that

the tube gets damaged.

•

Remove the bead protector and tube when one side of

thetireispriedoff.

•

Pry the tire off the rim.

Tire Installation

NOTE

○

The Tires should be installed so that the ID serial NO.

[A] faces to left side.

•

Inspect the rim and tire, and replace them if necessary.

•

Install the tube band and tube.

•

Apply a soap and water solution, or rubber lubricant to the

rim flange and tire beads.

•

Position the front tire on the rim so that the valve [A] is

at the tire balance mark [B] (the chalk mark made during

removal, or the white paint mark on a new tire. see Tire

Removal).

•

Insert the valve stem into the rim, and screw the nut on

loosely.

•

Fit the rim protectors and use tire irons to install the tire

bead.

NOTE

○

To prevent rim damage, be sure to place the rim protec-

tors at any place the tire irons are applied.

•

Pry one side of the tire back onto the rim. Fit the bead

protector into the tire.

•

Pry the other side of the tire onto the rim, starting at the

side opposite the valve.

○

Take care not to insert the tire irons so deeply that the

tube is damaged.

•

Install the other side of the tire bead onto the rim in the

same manner.

•

Check that the tube is not pinched between the tire and

rim.

WHEELS/TIRES 9-11

Tires

•

Tighten the bead protector nut [A] and valve stem nut [B],

and put on the valve cap [C].

•

Check and adjust the air pressure after installing.

Air Pressure Inspection/Adjustment

•

Refer to the Air Pressure Inspection/Adjustment in the Pe-

riodic Maintenance chapter.

9-12 WHEELS/TIRES

Hub Bearings

Hub Bearing Removal

•

Remove the wheel (see Wheel Removal).

NOTICE

Do not lay the wheel on the ground with the disc

facing down. This can damage or warp the disc.

Place blocks under the wheel so that the disc does

not touch the ground.

•

Remove the oil seals and the circlip.

Special Tool - Inside Circlip Pliers: 57001-143

•

Remove the hub bearing by tapping evenly around the

bearing inner race as shown.

[A] Bar

[B] Distance Collar

[C] Hub Bearing

Hub Bearing Installation

•

Before installing the wheel bearings [A], blow any dirt or

foreign particles out of the hub with compressed air to

prevent contamination of the bearings.

•

Replace the bearings with new ones.

•

Install them using the bearing driver set [B] so that the

marked or shielded sides face out.

○

Press in the bearings until they are bottomed.

Special Tool - Bearing Driver Set: 57001-1129

•

Replace the circlips and oil seals with new ones.

•

Press in the oil seals [A] so that the seal surface is flush

[B] with the end of the hole.

Special Tool - Bearing Driver set: 57001-1129 [C]

•

Apply high temperature grease to the oil seal lips.

Hub Bearing Inspection

NOTE

○

It is not necessary to remove any bearings for inspec-

tion. If any bearings are removed, they will need to be

replaced with new ones.

•

Spin [A] it by hand to check its condition.

If it is noisy, does not spin smoothly, or has any rough

spots, it must be replaced.

•

Examine the bearing seal [B] for tears or leakage.

If the seal is torn or is leaking, replace the bearing.

WHEELS/TIRES 9-13

Hub Bearings

Hub Bearing Lubrication

NOTE

○

Since the hub bearings are packed with grease and

sealed, lubrication is not required.

FINAL DRIVE 10-1

Final Drive

Table of Contents

Exploded View........................................................................................................................ 10-2

Specifications ......................................................................................................................... 10-4

Special Tool ............................................................................................................................ 10-5

Drive Chain............................................................................................................................. 10-6

Drive Chain Slack Inspection ............................................................................................ 10-6

Drive Chain Slack Adjustment .......................................................................................... 10-6

Wheel Alignment Inspection ............................................................................................. 10-6

Wheel Alignment Adjustment............................................................................................ 10-6

Drive Chain Wear Inspection ............................................................................................ 10-6

Drive Chain Lubrication..................................................................................................... 10-6

Drive Chain Removal ........................................................................................................ 10-6

Drive Chain Installation..................................................................................................... 10-7

Sprockets................................................................................................................................ 10-8

Engine Sprocket Removal ................................................................................................ 10-8

Engine Sprocket Installation ............................................................................................ 10-8

Rear Sprocket Removal.................................................................................................... 10-8

Rear Sprocket Installation................................................................................................. 10-9

Sprocket Wear Inspection................................................................................................. 10-9

Rear Sprocket Warp Inspection ........................................................................................ 10-9

10-2 FINAL DRIVE

Exploded View

FINAL DRIVE 10-3

Exploded View

Torque

No Fastener

N·m

kgf·m ft·lb

Remarks

Rear Sprocket Nuts

32 3.3 24 R

2 Drive Chain Cover Bolts 8.8 0.90 78 in·lb

3. Engine Sprocket

4. Output Shaft

5. Chain Guide

6. Chain Slipper

7. Swingarm

8. Chain Guide

9. Locknut

10. Adjusting Bolt

11. Chain Adjuster

12. Drive Chain

13. Rear Sprocket

14. Upper Chain Guide Roller

15. Lower Chain Guide Roller

16. KLX140A8 ∼ A9/B8 ∼ B9

17. KLX140A8 ∼ AB Early Model, KLX140B8 ∼ BB Early Model

G: Apply grease.

HO: Apply heavy oil.

L: Apply a non-permanent locking agent.

R: Replacement Parts

10-4 FINAL DRIVE

Specifications

Item Standard Service Limit

Drive Chain

Chain Slack 35 ∼ 41 mm (1.4 ∼ 1.6 in.) –––

Chain 20-link Length 254.0 ∼ 254.6 mm (10.00 ∼ 10.02 in.) 260 mm (10.2 in.)

Standard Chain:

Make DAIDO –––

Type DID428H –––

Length (KLX140A) 122 Links

(KLX140B) 126 Links

–––

Sprocket

Rear Sprocket Warp TIR 0.4 mm (0.016 in.) or less TIR 0.5 mm (0.020 in.)

FINAL DRIVE 10-5

Special Tool

Outside Circlip Pliers:

57001-144

10-6 FINAL DRIVE

Drive Chain

Drive Chain Slack Inspection

•

Refer to the Drive Chain Slack Inspection in the Periodic

Maintenance chapter.

Drive Chain Slack Adjustment

•

Refer to the Drive Chain Slack Adjustment in the Periodic

Maintenance chapter.

Wheel Alignment Inspection

•

Check that the rear end [A] of the chain adjuster aligns

with the same swing arm mark [B] as the other side ad-

juster.

WARNING

Misalignment of the wheel will result in abnormal

wear and may result in an unsafe riding condition.

Be sure the wheel is properly aligned.

Wheel Alignment Adjustment

•

This procedure is the same as Drive Chain Slack Adjust-

ment (see Drive Chain Slack Adjustment in the Periodic

Maintenance chapter).

Drive Chain Wear Inspection

•

Refer to the Drive Chain Wear Inspection in the Periodic

Maintenance chapter.

Drive Chain Lubrication

•

Refer to the Drive Chain Lubrication in the Periodic Main-

tenance chapter.

Drive Chain Removal

•

Remove the bolts [A] with the collar and the engine

sprocket cover [B] with the chain guide [C].

•

Remove the clip [A] from the master link using pliers, and

remove the chain from the rear sprocket.

•

Take the chain off the motorcycle.

FINAL DRIVE 10-7

Drive Chain

Drive Chain Installation

WARNING

For safety, use only the standard chain.

•

Fit the drive chain back onto the sprockets with the ends

at the rear sprocket.

•

Install the master link from the frame side.

•

Install the clip [A] so that the closed end of the "U" points

in the direction of chain rotation [B]. (The open end of the

"U" points in the reverse direction of chain rotation).

•

Adjust the drive chain slack (see Drive Chain Slack Ad-

justment in the Periodic Maintenance chapter).

•

Check the brake for good braking power, and no brake

drag.

WARNING

A rear brake that cannot be fully operated with the

pedal can cause a crash resulting in serious injury

or death. If a full brake pedal is not obtained, disas-

semble and inspect the brake parts for wear. Worn

brake parts diminish brake performance, can dam-

age brake components and lead to brake failure or

cause the brake to lock, resulting in a crash that

may cause serious injury or death.

10-8 FINAL DRIVE

Sprockets

Engine Sprocket Removal

•

Remove:

Drive Chain Cover Bolts [A] with Collar

Drive Chain Cover [B]

Drive Chain Guide [C]

•

Remove the circlip [A] and the engine sprocket [B] with

the drive chain [C].

Special Tool - Outside Circlip Pliers: 57001-144

•

Take off the sprocket from the chain.

Engine Sprocket Installation

•

Replace the O-ring with a new one, and install the collar

[A].

•

Install the engine sprocket [B] so that the marked [C] side

faces outward.

•

Replace the circlip with a new one.

•

Install the drive chain cover with the chain guide.

○

Run the neutral switch lead [A] to between [B] the ribs of

the chain guide [C].

Torque - Drive Chain Cover Bolts : 8.8 N·m (0.90 kgf·m, 78

in·lb)

Rear Sprocket Removal

•

Remove the rear wheel (see Rear wheel Removal in the

Wheels/Tires chapter).

NOTICE

Do not lay the wheel on the ground with the disc

facing down. This can damage or warp the disc.

Place blocks under the wheel so that the disc does

not touch the ground.

•

Unscrew the rear sprocket nuts [A], and remove the rear

sprocket [B].

FINAL DRIVE 10-9

Sprockets

Rear Sprocket Installation

•

Install the rear sprocket [A] so that the marked [B] side

faces outward.

•

Replace the rear sprocket nuts with new ones.

•

Install the rear sprocket nuts.

Torque - Rear Sprocket Nuts: 32 N·m (3.3 kgf·m, 24 ft·lb)

Sprocket Wear Inspection

•

Refer to the Sprocket Wear Inspection in the Periodic

Maintenance chapter.

Rear Sprocket Warp Inspection

•

Refer to the Rear Sprocket Warp Inspection in Periodic

Maintenance chapter.

BRAKES 11-1

Brakes

Table of Contents

Exploded View........................................................................................................................ 11-2

Specifications ......................................................................................................................... 11-6

Special Tool ............................................................................................................................ 11-7

Brake Lever, Brake Pedal....................................................................................................... 11-8

Brake Lever Adjustment.................................................................................................... 11-8

Brake Pedal Position Adjustment...................................................................................... 11-8

Brake Pedal Removal ....................................................................................................... 11-8

Brake Pedal Installation .................................................................................................... 11-8

Brake Fluid ............................................................................................................................. 11-9

Fluid Level Inspection ....................................................................................................... 11-9

Fluid Change.....................................................................................................................11-9

Bleeding the Brake Line.................................................................................................... 11-10

Calipers .................................................................................................................................. 11-12

Caliper Removal ............................................................................................................... 11-12

Caliper Installation ............................................................................................................ 11-12

Caliper Disassembly ......................................................................................................... 11-13

Fluid Seal Damage ........................................................................................................... 11-13

Dust Seal and Cover Damage .......................................................................................... 11-13

Piston Cylinder Damage ................................................................................................... 11-13

Caliper Holder Shaft Wear ................................................................................................ 11-13

Brake Pad Inspection........................................................................................................ 11-13

Master Cylinder ...................................................................................................................... 11-14

Front Master Cylinder Removal ........................................................................................ 11-14

Front Master Cylinder Installation ..................................................................................... 11-14

Rear Master Cylinder Removal......................................................................................... 11-14

Rear Master Cylinder Installation...................................................................................... 11-15

Front Master Cylinder Disassembly .................................................................................. 11-15

Rear Master Cylinder Disassembly................................................................................... 11-15

Master Cylinder Assembly ................................................................................................ 11-15

Master Cylinder Inspection (Visual Inspection)................................................................. 11-16

Brake Disc .............................................................................................................................. 11-17

Brake Disc Removal ........................................................................................................ 11-17

Brake Disc Installation ..................................................................................................... 11-17

Brake Disc Inspection ....................................................................................................... 11-17

Brake Hose............................................................................................................................. 11-18

Brake Hose Removal/Installation...................................................................................... 11-18

Brake Hose Inspection...................................................................................................... 11-18

11-2 BRAKES

Exploded View

BRAKES 11-3

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

Front Master Cylinder Clamp Bolts

8.8 0.90 78 in·lb

2 Brake Hose Banjo Bolts 25 2.5 18

3 Brake Pad Bolts 17 1.7 13

4 Caliper Bleed Valve 7.8 0.80 69 in·lb

5 Front Caliper Mounting Bolts 34 3.5 25

6 Brake Disc Mounting Bolts 9.8 1.0 87 in·lb L

7 Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb

8 Brake Lever Pivot Bolt 5.9 0.60 52 in·lb Si

9 Brake Reservoir Cap Screws 1.5 0.15 13 in·lb

10 Brake Lever Adjuster Locknut 5.9 0.60 52 in·lb

11. Front Brake Reservoir

12. Brake Lever

13. Brake Lever Adjuster

14. Brake Hose

15. Front Caliper

16. Brake Pad

17. Piston

18. Front Disc

B: Apply brake fluid.

L: Apply a non-permanent locking agent.

R: Replacement Parts.

S: Tighten the fasteners following the specified sequence.

Si: Apply Silicone grease.

11-4 BRAKES

Exploded View

BRAKES 11-5

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Re-

marks

1 Brake Hose Banjo Bolts 25 2.5 18

2 Rear Master Cylinder Mounting Bolts 10 1.0 89 in·lb

Rear Master Cylinder Push Rod Locknut

17 1.7 13

Caliper Bleed Valve

7.8 0.80 69 in·lb L

5 Brake Pad Bolts 17 1.7 13

Rear Caliper Mounting Bolts

25 2.5 18

7 Brake Pedal Pivot Bolt 25 2.5 18

G,L

8 Brake Disc Mounting Bolts 9.8 1.0 87 in·lb L

Brake Reservoir Cap Bolts

1.5 0.15 13 in·lb

10. Brake Hose

11. Rear Master Cylinder

12. Brake Pedal

13. Rear Caliper

14. Piston

15. Brake Pads

16. Rear Disc

B: Apply brake fluid.

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

Si: Apply Silicone grease.

11-6 BRAKES

Specifications

Item Standard Service Limit

Brake Adjustment

Lever/Pedal Free Play Adjustable (to suit rider) –––

Brake Fluid

Recommended Type:

Front/Rear DOT3 or DOT4

–––

Brake Pads

Lining thickness:

Front 4.5 mm (0.18 in.) 1 mm (0.04 in.)

Rear 3.7 mm (0.15 in.) 1 mm (0.04 in.)

Brake Discs

Thickness:

Front/Rear 2.85 ∼ 3.15 mm (0.112 ∼ 0.124 in.) 2.5 mm (0.10 in.)

Runout:

Front/Rear TIR 0.15 mm (0.0059 in.) or less TIR 0.3 mm (0.01 in.)

BRAKES 11-7

Special Tool

Jack:

57001-1238

11-8 BRAKES

Brake Lever, Brake Pedal

Brake Lever Adjustment

•

Refer to the Brake Lever and Pedal Position Adjustment

in the Periodic Maintenance chapter.

Brake Pedal Position Adjustment

•

Refer to the Brake Lever and Pedal Position Adjustment

in the Periodic Maintenance chapter.

Brake Pedal Removal

•

Remove:

Cotter Pin [A]

Joint Pin [B] with Washer

•

Remove the mounting bolt [C] and take off the brake pedal

and the return spring [D].

Brake Pedal Installation

•

Replace the O-rings [A] with a new one.

•

Apply grease to the O-rings and the shaft portion [B] of

the brake pedal pivot bolt.

•

Apply a non-permanent locking agent to the thread [C].

•

Install the brake pedal with the return spring [A] as shown.

Torque - Brake Pedal Pivot Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

Check the brake pedal position.

•

Install the joint pin, washer and a new cotter pin.

○

Bend the ends of the cotter pin along the circumference.

BRAKES 11-9

Brake Fluid

WARNING

When working with the disc brake, observe the pre-

cautions listed below.

1. Never reuse old brake fluid.

2. Do not use fluid from a container that has been left

unsealed or that has been open for a long time.

3. Do not mix two types and brands of fluid for use in

the brake. This lowers the brake fluid boiling point

and could cause the brake to be ineffective. It may

also cause the rubber brake parts to deteriorate.

4. Don’t leave the reservoir cap off for any length of

time to avoid moisture contamination of the fluid.

5. Don’t change the fluid in the rain or when a strong

wind is blowing.

6. Except for the disc pads and disc, use only disc

brake fluid, isopropyl alcohol, or ethyl alcohol for

cleaning of the brake parts. Do not use any other

fluid for cleaning these parts. Gasoline, engine oil,

or any other petroleum distillate will cause deterio-

ration of the rubber parts. Oil spilled on any part will

be difficult to wash off completely and will eventually

deteriorate the rubber used in the disc brake.

7. When handling the disc pads or disc, be careful that

no disc brake fluid or any oil gets on them. Clean

off any fluid or oil that inadvertently gets on the pads

or disc with high-flash point solvent. Do not use one

which will leave an oily residue. Replace the pads

with new ones if they cannot be cleaned satisfacto-

rily.

8. Brake fluid quickly ruins painted surfaces; any

spilled fluid should be completely wiped up imme-

diately.

9. If any of the brake line fittings or the bleed valve is

opened at any time, the AIR MUST BE BLED FROM

THE BRAKE LINE.

Fluid Level Inspection

•

Refer to the Brake Fluid Level Inspection in the Periodic

Maintenance chapter.

Fluid Change

•

Refer to the Brake Fluid Change in the Periodic Mainte-

nance chapter.

11-10 BRAKES

Brake Fluid

Bleeding the Brake Line

The brake fluid has a very low compression coefficient so

that almost all the movement of the brake lever or pedal

is transmitted directly to the caliper for braking action. Air,

however, is easily compressed. When air enters the brake

lines, brake lever or pedal movement will be partially used

in compressing the air. This will make the lever or pedal feel

spongy, and there will be a loss in braking power.

WARNING

Air in the brake lines diminish braking performance

and can cause an accident resulting in injury or

death. If the brake lever or pedal has a soft or

"spongy" feeling mushy when it is applied, there

might be air in the brake lines or the brake may be

defective. Do not operate the vehicle and service

the brake system immediately.

NOTE

○

The procedure to bleed the front brake line is as follows.

Bleeding the rear brake line is the same as for the front

brake.

•

Remove the reservoir cap [A], and check that there is

plenty of fluid in the reservoir.

•

With the reservoir cap off, slowly pump the brake lever

several times until no air bubbles can be seen rising up

through the fluid from the holes at the bottom of the reser-

voir.

○

Bleed the air completely from the master cylinder by this

operation.

•

Install the reservoir cap.

•

Attach a clear plastic hose [A] to the bleed valve [B] on the

caliper, and run the other end of the hose into a container.

BRAKES 11-11

Brake Fluid

•

Bleed the brake line and the caliper as follows:

○

Repeat this operation until no more air can be seen com-

ing out into the plastic hose.

1. Pump the brake lever until it becomes hard, and apply

the brake [C] and hold it.

2. Quickly open and close [D] the bleed valve while holding

the brake applied.

3. Release the brake [E].

NOTE

○

The fluid level must be checked often during the bleed-

ing operation and replenished with fresh brake fluid as

necessary. If the fluid in the reservoir runs almost out

any time during bleeding operation, the bleeding opera-

tion must be done over again from the beginning since

air will have entered the line.

○

Tap the brake hose lightly from the caliper to the reser-

voir for easier bleeding.

•

Remove the clear plastic hose.

•

Tighten the bleed valve, and install the rubber cap.

Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

•

Check the fluid level.

•

After bleeding is done, check the brake for good braking

power, no brake drag and no fluid leakage.

WARNING

After servicing, it takes several applications of the

brake lever or pedal before the brake pads contact

the disc, which could result in increased stopping

distance and cause an accident resulting in injury

or death. Do not attempt to ride the motorcycle until

a firm brake lever or pedal is obtained by pumping

the lever or pedal until the pads are against the disc.

11-12 BRAKES

Calipers

Caliper Removal

Front Brake:

Loosen the brake pad bolts [A] when you disassemble the

caliper.

•

Loosen the banjo bolt [B] so as not to spill brake fluid.

•

Remove the caliper mounting bolts [C].

NOTE

○

If the caliper is to be disassembled after removal and if

compressed air is not available, remove the piston us-

ing the following steps before disconnecting the brake

hose [D] from the caliper.

○

Remove the pads and springs.

○

Apply the brake to remove the piston.

•

Remove the banjo bolt and take off the brake hose [D]

from the caliper.

Rear Brake:

Loosen the brake pad bolts [A] when you disassemble the

caliper.

•

Loosen the banjo bolt [B] so as not to spill brake fluid.

•

Remove the caliper mounting bolts [C].

NOTE

○

If the caliper is to be disassembled after removal and if

compressed air is not available, remove the piston us-

ing the following steps before disconnecting the brake

hose [D] from the caliper.

○

Remove the pads and springs.

○

Apply the brake to remove the piston.

•

Unscrew the banjo bolt and remove the brake hose [D]

from the caliper.

NOTICE

Immediately wipe up any brake fluid that is spilled.

Caliper Installation

•

Tighten the brake pad bolts if it was removed.

Torque - Brake Pad Bolts: 17 N·m (1.7 kgf·m, 13 ft·lb)

•

Install the caliper and tighten the bolts.

Torque - Front Caliper Mounting Bolts: 34 N·m (3.4 kgf·m,

25 ft·lb)

Rear Caliper Mounting Bolts: 25 N·m (2.5 kgf·m,

18 ft·lb)

•

Install the brake hose lower end.

○

Replace the washers that are on each side of hose fitting

with new ones.

Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

BRAKES 11-13

Calipers

•

Bleed the brake line (see Bleeding the Brake Line).

•

Check the brake for good braking power, no brake drag

and no fluid leakage.

WARNING

After servicing, it takes several applications of the

brake lever or pedal before the brake pads contact

the disc, which could result in increased stopping

distance and cause an accident resulting in injury

or death. Do not attempt to ride the motorcycle until

a firm brake lever or pedal is obtained by pumping

the lever or pedal until the pads are against the disc.

Caliper Disassembly

•

Refer to the Caliper Piston Seal and Dust Seal Replace-

ment in the Periodic Maintenance chapter.

Fluid Seal Damage

The fluid seal around the piston maintains the proper

pad/disc clearance. If this seal is not in good condition,

pad wear will increase, and constant pad drag on the disc

will raise brake and brake fluid temperature.

•

Replace the fluid seals under any of the following condi-

tions: (a) fluid leakage around the pad; (b) brakes over-

heat; (c) there is a large difference in left and right pad

wear; (d) the seal is stuck to the piston. If the fluid seal is

replaced, replace the dust seal as well. Also, replace all

seals every other time the pads are changed.

Dust Seal and Cover Damage

•

Check that the dust seals and covers are not cracked,

worn, swollen, or otherwise damaged.

If they show any damage, replace them.

Piston Cylinder Damage

•

Visually inspect the piston and cylinder surfaces.

Replace the cylinder and piston if they are badly scored

or rusty.

Caliper Holder Shaft Wear

The caliper body must slide smoothly on the caliper holder

shafts. If the body does not slide smoothly, one pad will

wear more than the other, pad wear will increase, and con-

stant drag on the disc will raise brake and brake fluid tem-

perature.

•

Check to see if the caliper holder shafts are not badly worn

or stepped, or the rubber friction boot is not damaged.

If the shafts or rubber friction boot are damaged, replace

the shafts, rubber friction boot, and the caliper holder.

Brake Pad Inspection

•

Refer to the Brake Pad Wear Inspection in the Periodic

Maintenance chapter.

11-14 BRAKES

Master Cylinder

Front Master Cylinder Removal

•

Remove the banjo bolt [A] to disconnect the upper brake

hose [B] from the master cylinder [C].

•

When removing the brake hose, temporarily secure the

end of the brake hose to some high place to keep fluid

loss to a minimum.

•

Unscrew the clamp bolts [A], and take off the master cylin-

der [B] as an assembly with the reservoir and brake lever.

Front Master Cylinder Installation

•

The master cylinder clamp must be installed with the “UP”

mark [A] upward.

○

Align the punch mark on the handlebar and the master

cylinder mating surface.

○

Tighten the upper clamp bolt [B] first, and then the lower

clamp bolt [C]. There will be a gap at the lower part of the

clamp after tightening.

Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.90

kgf·m, 78 in·lb)

•

Replace the washers that are on each side of hose fitting

with new ones.

•

Tighten the brake hose banjo bolt.

Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

Bleed the brake line (see Bleeding the Brake Line).

•

Check the brake for good braking power, no brake drag,

and no fluid leakage.

Rear Master Cylinder Removal

•

Remove the cotter pin [A].

•

Pull off the joint pin [B] with the washer.

NOTE

○

Pull off the joint pin while pressing down the brake

pedal.

•

Unscrew the master cylinder mounting bolts [C], and re-

move the master cylinder [D].

BRAKES 11-15

Master Cylinder

•

Unscrew the brake hose banjo bolt [A].

•

When removing the brake hose, temporarily secure the

end of the brake hose to some high place to keep fluid

loss to a minimum.

Rear Master Cylinder Installation

•

Replace the cotter pin with a new one.

•

Replace the washers are on each side of hose fitting with

new ones.

•

Tighten the following:

Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

Rear Master Cylinder Mounting Bolts: 10 N·m (1.0

kgf·m, 89 in·lb)

•

Bleed the brake line (see Bleeding the Brake Line).

•

Check the brake for good braking power, no brake drag

and no fluid leakage.

•

Check the brake pedal position (see Brake Lever and

Pedal Position Adjustment in the Periodic Maintenance

chapter).

Front Master Cylinder Disassembly

•

Refer to the Brake Master Cylinder Cup and Dust Seal

Replacement in the Periodic Maintenance chapter.

Rear Master Cylinder Disassembly

•

Refer to the Brake Master Cylinder Cup and Dust Seal

Replacement in the Periodic Maintenance chapter.

Master Cylinder Assembly

•

Refer to the Brake Master Cylinder Cup and Dust Seal

Replacement in the Periodic Maintenance chapter.

11-16 BRAKES

Master Cylinder

Master Cylinder Inspection (Visual Inspection)

•

Disassemble the front and rear master cylinders.

•

Check that there are no scratches, rust or pitting on the

inner wall of each master cylinder [A] and on the outside

of each piston [B].

If a master cylinder or piston shows any damage, replace

them.

•

Inspect the primary [C] and secondary [D] cups.

If a cup is worn, damaged, softened (rotted), or swollen,

the piston assembly should be replace to renew the cups.

If fluid leakage is noted at the brake lever, the piston as-

sembly should be replaced to renew the cup.

•

Check the dust covers [E] for damage.

If they are damaged, replace them.

•

Check the piston return springs [F] for any damage.

If a spring is damaged, replace it.

•

Check that the relief [G] and supply [H] ports are not

plugged.

If the small relief port becomes plugged, the brake pads

will drag on the disc. Blow the ports clean with com-

pressed air.

[J] Front Master Cylinder

[K] Rear Master Cylinder

BRAKES 11-17

Brake Disc

Brake Disc Removal

•

Remove the wheel (see Front/Rear Wheel Removal in the

Wheels/Tires chapter).

•

Unscrew the mounting bolts [A], and take off the disc [B].

Brake Disc Installation

•

Install the disc on the wheel so that the mark [A] faces out.

•

Apply a non-permanent locking agent to the threads of

the brake disc bolts [B].

•

Tighten:

Torque - Brake Disc Mounting bolts: 9.8 N·m (1.0 kgf·m, 87

in·lb)

Brake Disc Inspection

•

Visually inspect the disc [A].

If it is scratched or damaged, replace the disc.

•

Measure the thickness of each disc at the point where it

has worn the most.

Measuring Area [B]

Replace the disc if it has worn past the service limit.

Brake Disc Thickness

Standard: 2.85 ∼ 3.15 mm (0.112 ∼ 0.124 in.)

Service Limit: 2.5 mm (0.10 in.)

•

Raise the front/rear wheel off the ground with the jack.

Special Tool - Jack: 57001-1238

•

Set up a dial gauge against the disc [A] as shown.

○

For the front disc, turn the handlebar fully to one side.

•

Measure the disc runout while rotating the wheel slowly

[B].

If the runout exceeds the service limit, replace the disc.

Brake Disc Runout

Standard: TIR 0.15 mm (0.0059 in.) or less

Service Limit: TIR 0.3 mm (0.01 in.)

11-18 BRAKES

Brake Hose

Brake Hose Removal/Installation

•

Refer to the Brake Hose Replacement in the Periodic

Maintenance chapter.

Brake Hose Inspection

•

Refer to the Brake Hose and Connection Check in the

Periodic Maintenance chapter.

SUSPENSION 12-1

Suspension

Table of Contents

Exploded View........................................................................................................................ 12-2

Specifications ......................................................................................................................... 12-6

Special Tools .......................................................................................................................... 12-7

Front Fork ............................................................................................................................... 12-8

Front Fork Oil Change ...................................................................................................... 12-8

Front Fork Removal .......................................................................................................... 12-8

Front Fork Installation ....................................................................................................... 12-9

Front Fork Disassembly (each fork leg) ............................................................................ 12-9

Front Fork Assembly......................................................................................................... 12-11

Inner Tube Inspection ....................................................................................................... 12-12

Guide Bush Inspection...................................................................................................... 12-12

Oil Seal Inspection ............................................................................................................ 12-12

Spring Tension Inspection................................................................................................. 12-12

Rear Suspension (Uni-Trak)................................................................................................... 12-13

Rear Shock Absorber: ......................................................................................................... 12-13

Rebound Damping Adjustment (KLX140B) ...................................................................... 12-13

Compression Damping Adjustment (KLX140B)................................................................ 12-13

Spring Preload Adjustment (KLX140A)............................................................................. 12-14

Spring Preload Adjustment (KLX140B)............................................................................. 12-14

Spring Tension .................................................................................................................. 12-15

Rear Shock Absorber Removal ........................................................................................ 12-15

Rear Shock Absorber Installation ..................................................................................... 12-16

Spring Replacement ......................................................................................................... 12-16

Rear Shock Absorber Scrapping ...................................................................................... 12-17

Swingarm................................................................................................................................ 12-18

Swingarm Removal........................................................................................................... 12-18

Swingarm Installation........................................................................................................ 12-19

Swingarm Bearing Removal ............................................................................................. 12-19

Swingarm Bearing Installation .......................................................................................... 12-19

Swingarm Bearing, Sleeve Inspection .............................................................................. 12-19

Drive Chain Guide, Guide Roller, Chain Slipper Wear...................................................... 12-19

Tie-Rod, Rocker Arm.............................................................................................................. 12-20

Tie-Rod Removal .............................................................................................................. 12-20

Tie-Rod Installation ........................................................................................................... 12-20

Rocker Arm Removal........................................................................................................ 12-20

Rocker Arm Installation..................................................................................................... 12-21

Tie-Rod and Rocker Arm Bearing Removal...................................................................... 12-21

Tie-Rod and Rocker Arm Bearing Installation................................................................... 12-22

Needle Bearing Inspection................................................................................................ 12-22

Uni-Trak Maintenance ............................................................................................................ 12-23

Uni-Trak Linkage Inspection ............................................................................................. 12-23

Tie-Rod and Rocker Arm Sleeve Wear............................................................................. 12-23

Tie-Rod and Rocker Arm Mounting Bolt Bend.................................................................. 12-23

12-2 SUSPENSION

Exploded View

SUSPENSION 12-3

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

Front Fork Clamp Bolt (Upper)

20 2.0 15

2 Front Fork Clamp Bolt (Lower) 25 2.5 18

3 Steering Stem Head Nut 64 6.5 47

4 Fork Top Bolt 22.5 2.3 17

5 Fork Bottom Bolt 20 2.0 15 L

6. O-ring

7. Collar

8. Spring Seat

9. Spring

10. Retaining Ring

11. Oil Seal

12. Spacer

13. Bushing

14. Cylinder

15. Piston Ring

16. Rebound Spring

17. Cylinder Base

18. Inner Tube

19. Bushing

20. Outer Tube

21. Gasket

22. Dust Seal

23. Inner Tube

24. O-ring

25. Gasket

26. Steering Stem Head

27. Steering Stem

L: Apply a non-permanent locking agent to the threads.

R: Replacement Parts

12-4 SUSPENSION

Exploded View

SUSPENSION 12-5

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

Swingarm Pivot Shaft Nut

108 11 80

2 Rocker Arm Pivot Nut 59 6.0 44 R

3 Tie-rod Mounting Nuts 59 6.0 44 R

Rear Shock Absorber Mounting Bolt (Upper)

39 4.0 29

Rear Shock Absorber Mounting Bolt (Lower)

39 4.0 29

Rear Shock Absorber Mounting Nut (Lower)

29 3.0 21 R

7. Swingarm Pivot Shaft

8. Swingarm

9. Rocker Arm

10. Tie-Rod

11. KLX140A model

12. KLX140B model

G: Apply grease.

12-6 SUSPENSION

Specifications

Item Standard Service Limit

Front Fork

Air Pressure Atmospheric pressure –––

Rebound Damping Adjustment Non-Adjustable –––

Compression Damping Adjustment

Non-Adjustable –––

Fork Oil:

Type

SHOWA SS-8 or equivalent

–––

Viscosity SAE 10W-20 –––

Capacity (KLX140A) 296 ±2.5 mL (10.01 ±0.085

US oz)

–––

(KLX140B) 290 ±2.5 mL (9.80 ±0.085

US oz)

–––

Level

(KLX140A) 95 ±2 mm (3.74 ±0.08 in.)

–––

(fully compressed, without spring) (KLX140B) 105 ±2 mm (4.13 ±0.08 in.) –––

Fork Spring Free Length 391.6 mm (15.42 in.) 384 mm (15.1 in.)

Rear Suspension (Uni-Trak):

Rear Shock Absorber

Rebound Damping A

djustment

(KLX140A) Non-Adjustable –––

(KLX140B) 10 clicks counterclockwise

(from the seated position adjuster

turned fully clockwise)

(Adjustable Range)

20 clicks

Spring Preload Adjustment (KLX140A) 2nd step

(from the seated position adjuster

turned fully clockwise)

(Adjustable Range)

5 steps

(KLX140B) 80.7 mm (3.18 in.)

(Adjusting nut lowersurface form the

mounting bolt pivot)

(Adjustable Range)

68.2 ∼ 101.2 mm

(2.685 ∼ 3.984 in.)

Spring Free Length (KLX140A) 244.3 mm (9.62 in.)

(KLX140B) 252.0 mm (10.04 in.)

239 mm (9.41 in.)

247 mm (9.72 in.)

Gas Reservoir

Compression Damping

Adjustment

(KLX140A) Non-Adjustable –––

(KLX140B) 2nd position

(Adjustable Range)

4 positions

Gas Pressure 1 000 kPa (10 kgf/cm², 145 psi) –––

Tie-Rod, Rocker Arm

Sleeve Outside Diameter:

Tie-rod 19.979 ∼ 20.000 mm

(0.78657 ∼ 0.78740 in.)

19.85 mm (0.781 in.)

Rocker Arm:

Large (to Swingarm) 19.979 ∼ 20.000 mm

(0.78657 ∼ 0.78740 in.)

19.85 mm (0.781 in.)

Middle (to Tie-rod) 17.989 ∼ 18.000 mm

(0.70823 ∼ 0.70866 in.)

17.96 mm (0.707 in.)

Small (to Shock Absorber)

15.950 ∼ 16.000 mm

(0.62795 ∼ 0.62992 in.)

15.92 mm (0.627 in.)

Rocker Arm Mounting Bolt

Runout

TIR 0.1 mm (0.004 in.) or less

TIR 0.2 mm (0.008

in.)

SUSPENSION 12-7

Special Tools

Fork Cylinder Holder Handle:

57001-183

Fork Cylinder Holder Adapter:

57001-1011

Oil Seal & Bearing Remover:

57001-1058

Bearing Driver Set:

57001-1129

Front Fork Oil Seal Driver:

57001-1219

Jack:

57001-1238

Bearing Remover Shaft, 9:

57001-1265

Bearing Remover Head, 15 × 17:

57001-1267

Hook Wrench T=3.2 R37:

57001-1522

Hook Wrench T=3.2 R35:

57001-1523

12-8 SUSPENSION

Front Fork

Front Fork Oil Change

•

Refer to the Front Fork Oil Change in the Periodic Main-

tenance chapter.

Front Fork Removal

•

Remove:

Number Plate [A]

Brake Hose Clamp (Lower) [B]

Front Wheel (see Front Wheel Removal in the

Wheels/Tires chapter)

Front Caliper (see Front Caliper Removal in the Brake

chapter)

•

Put the caliper [A] on a suitable stand [B].

•

Loosen the upper [A] and lower [B] fork clamp bolts.

•

Pull out to downward the fork leg [A] with a twisting motion

[B].

SUSPENSION 12-9

Front Fork

Front Fork Installation

•

Install the fork, and align the brim of the fork top plug [A]

to the upper surface of the upper fork clamp [B].

•

Route the cables and hose according to the Cable, Har-

ness and Hose Routing section in the Appendix chapter.

•

Install the front wheel (see Front Wheel Installation in the

Wheels/Tires chapter).

•

Tighten the fork clamp bolts.

Torque - Front Fork Clamp Bolt (Upper): 20 N·m (2.0 kgf·m,

15 ft·lb)

Front Fork Clamp Bolt (Lower): 25 N·m (2.5 kgf·m,

18 ft·lb)

•

Install the other removed parts.

•

Check the front brake operation after installation.

Front Fork Disassembly (each fork leg)

•

Loosen the front fork upper clamp bolts [A].

•

Loosen the top plug [B].

•

Remove the front fork (see Front Fork Removal).

•

Thoroughly clean the fork before disassembly.

NOTICE

Be careful not scratch the inner tube and not to

damage the dust seal.

Avoid scratching or damaging the inner tube or the

dust seal. Use a mild detergent and sponge out dirt

with plenty of water.

•

Loosen the clamp screw [A], and pull out the fork boot [B].

•

Remove:

TopPlug[A]withO-ring

Spring Collar [B]

Washer [C]

Fork Spring [D]

12-10 SUSPENSION

Front Fork

•

Prepare a drain pan [A] and drain the fork oil.

NOTE

○

Pump the fork tube several times to discharge the oil.

•

Remove the Allen bolt [A] from the bottom of the fork.

Special Tools - Fork Cylinder Holder Handle [B]: 57001-183

Fork Cylinder Holder Adapter [C]: 57001

-1011

NOTE

○

Hold the outer tube in a vise [D], stop the cylinder unit

[E] from turning by using the special tools, and unscrew

the Allen bolt.

•

Remove:

Cylinder [A]

Piston Ring [B]

Rebound Spring [C]

•

Remove the retaining ring [A].

•

Separate the inner tube [A] and the outer tube [B].

NOTE

○

From the compressed state, firmly pull down the outer

tube a few times towards the direction of elongation.

SUSPENSION 12-11

Front Fork

•

Remove the following parts from the inner tube.

Guide Bushings [A] [B]

Washer [C]

Oil Seal [D]

•

Remove the cylinder base from the outer tube.

Front Fork Assembly

•

When the fork tubes are not disassembled, hold the fork

inverted position for more than 20 minutes to allow the

fork oil to fully drain.

•

Insert the cylinder and the rebound spring into the inner

tube.

•

Install the cylinder base to the cylinder that protruded from

the inner tube.

•

Replace the following parts with new ones:

Oil Seal

Washer

Guide Bushing

•

Insert the inner tube into the outer tube.

•

Apply a non-permanent locking agent to the fork bottom

bolt and tighten it using the fork cylinder holder.

Special Tools - Fork Cylinder Holder Handle: 57001-183

Fork Cylinder Holder Adapter: 57001-1011

Torque - Fork Bottom Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb)

•

Install the oil seal [A] using the fork oil seal driver [B] until

it stops.

Tap the driver strongly.

Special Tool - Fork Oil Seal Driver: 57001-1219

•

Install:

Retaining Ring

Spring (turn the small diameter side downward)

Washer

Collar

•

Fill the fork oil (see Fork Oil Change in the Periodic Main-

tenance chapter).

•

Tighten the top plug.

Torque - Fork Top Bolt: 22.5 N·m (2.3 kgf·m, 17 ft·lb)

•

Install the fork legs (see Front Fork Installation).

12-12 SUSPENSION

Front Fork

Inner Tube Inspection

•

Visually inspect the inner tube [A], repair any damage.

•

Nick or rust damage can sometimes be repaired by using

a wet-stone to remove sharp edges or raised areas which

cause seal damage.

If the damage is not repairable, replace the inner tube.

Since damage to the inner tube damages the oil seal,

replace the oil seal whenever the inner tube is repaired

or replaced.

•

Temporarily assemble the inner [A] and outer tube [B], and

pump them back and forth manually to check for smooth

operation.

NOTICE

If the inner tube is badly bent or creased, replace

it. Excessive bending, followed by subsequent

straightening, can weaken the inner tube.

Guide Bush Inspection

•

Visually inspect the guide bushings [A], and replace them

if necessary.

Oil Seal Inspection

•

Replace the oil seal [A] with a new one whenever it has

been removed.

Spring Tension Inspection

•

Since a spring becomes shorter as it weakens, check its

free length [A] to determine its condition.

If the spring of either fork leg is shorter than the service

limit, it must be replaced. If the length of a replacement

spring and that of the remaining spring vary greatly, the

remaining spring should also be replaced in order to keep

the fork legs balanced from motorcycle stability.

Fork Spring Free Length

Standard: 391.6 mm (15.42 in.)

Service Limit: 384 mm (15.1 in.)

SUSPENSION 12-13

Rear Suspension (Uni-Trak)

Rear Shock Absorber:

The rear suspension system of this motorcycle is Uni-trak.

It consists of a rear shock absorber, swingarm, tie-rod and

rocker arm.

To suit to various riding conditions, the spring preload of

the shock absorber can be adjusted or the spring can be re-

placed with an optional one. Besides KLX140B model can

adjust the damping force without changing the oil viscosity.

Rebound Damping Adjustment (KLX140B)

•

Turn the rebound damping adjuster [A] on the rear shock

absorber lower end with the blade of a screwdriver until

youfeelaclick.

If the damper setting feels too soft or too stiff, adjust it in

accordance with the following table:

Seated position: adjuster turned fully clockwise [A].

Rebound Damping Adjustment (KLX140B)

Standard:

10 clicks [B]

Softer (Counterclockwise) [C]

Harder (Clockwise) [D]

*: Number of turns counterclockwise usable range - 20

or more.

Counterclockwise from the fully seated position.

NOTE

○

Adjustment of the rebound damping adjuster for the rear

suspension will slightly affect the compression damping

force. Always make any damping adjustments in small

steps and test their effects before using them in com-

petition.

Compression Damping Adjustment (KLX140B)

•

Turn the compression damping adjuster [A] with a flat

-head screwdriver.

If the damping feels too soft or too stiff, adjust it in accor-

dance with the following.

1st Position [B] (softest setting)

2nd Position [C]

3rd Position [D]

4th Position [E] (hardest setting)

Compression Damping Adjustment (KLX140B)

Standard:

2nd Position

NOTE

○

Adjustment of the rebound damping adjuster for the rear

suspension will slightly affect the compression damping

force. Always make any damping adjustments in small

steps and test their effects before using them in com-

petition.

12-14 SUSPENSION

Rear Suspension (Uni-Trak)

Spring Preload Adjustment (KLX140A)

•

Remove:

Seat (see Seat Removal in the Frame chapter)

Muffler Body (see Muffler Removal in the Engine Top

End chapter)

Rear Fender (see Rear Fender Removal in the Frame

chapter)

Air Cleaner Housing (see Air Cleaner Housing Re-

moval/Installation in the Fuel System chapter)

•

Raise the rear wheel off the ground with the jack.

Special Tool - Jack: 57001-1238

•

Turn the adjusting nut [A] as required using the hook

wrench [B]. Turning the adjusting nut downward marks

the spring action harder and upward softer.

Special Tool - Hook Wrench T=3.2 R37: 57001-1522

Spring Preload Adjustment (KLX140A)

Standard:

2nd step

Adjustable Range:

5steps

Spring Preload Adjustment (KLX140B)

•

Remove:

Seat (see Seat Removal in the Frame chapter)

Muffler (see Muffler Removal in the Engine Top End

chapter)

Rear Fender (see Rear Fender Removal in the Frame

chapter)

Air Cleaner Housing (see Air Cleaner Housing Re-

moval/Installation in the Fuel System chapter)

•

Raise the rear wheel off the ground with the jack.

Special Tool - Jack: 57001-1238

•

Using the hook wrenches [A], loosen the locknut [B] on

the rear shock absorber.

Special Tools - Hook Wrench T=3.2 R37: 57001-1522

Hook Wrench T=3.2 R35: 57001-1523

SUSPENSION 12-15

Rear Suspension (Uni-Trak)

•

Turn the adjusting nut [A] as required. Turning the ad-

justing nut downward marks the spring action harder and

upward softer.

Spring Preload Adjustment (KLX140B)

(Adjusting nut lower surface [A] from the mounting

bolt pivot [B])

Standard: 80.7 mm (3.18 in.)

Adjustable Range:

68.2

∼ 101.2 mm (2.685 ∼ 3.984

in.)

•

Tighten the locknut securely.

•

After adjusting, move the spring up and down to make

sure that the spring is seated.

•

Install the other removed parts.

Spring Tension

•

Since the spring becomes shorter as it weakens, check

its free length [A] to determine its condition.

If the spring of either rear shock abs

orber is shorter than

the service limit, it must be replaced. If the length of re-

placement spring and that of the remaining spring vary

greatly, the remaing spring should also be replaced in or-

der to keep the rear shock absorbers balanced of motor-

cycle stability.

Shock Absorber Spring Free Length

Standard: (KLX140A) 244.3 mm (9.62 in.)

(KLX140B) 252.0 mm (10.04 in.)

Service Limit: (KLX140A) 239 mm (9.41 in.)

(KLX140B) 247 mm (9.72 in.)

Rear Shock Absorber Removal

•

Remove:

Seat (see Seat Removal in the Frame chapter)

Muffler (see Muffler Removal in the Engine Top End

chapter)

Rear Fender (see Rear Fender Removal in the Frame

chapter)

Air Cleaner Housing (see Air Cleaner Housing Re-

moval/Installation in the Fuel System chapter)

•

Raise the rear wheel off the ground with the jack.

Special Tool - Jack: 57001-1238

12-16 SUSPENSION

Rear Suspension (Uni-Trak)

NOTICE

When pulling out the mounting bolts, lift the rear

wheel slightly. Forcing or tapping on a bolt could

damage the bolt, sleeve and bearing.

•

Remove the tie-rod rear mounting bolt and nut [A], and

turn the tie-rod [B] downward.

•

Remove the rear shock absorber lower mounting bolt [C]

and nut.

•

Remove the rear shock absorber upper mounting bolt and

take off the rear shock absorber.

Rear Shock Absorber Installation

•

Pack the rocker arm needle bearings with grease.

•

Tighten the following:

KLX140A

Torque - Rear Shock Absorber Mounting Bolt (Upper): 39

N·m (4.0 kgf·m, 29 ft·lb)

Rear Shock Absorber Mounting Nut (Lower): 29

N·m (3.0 kgf·m, 21 ft·lb)

Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25

ft·lb)

Tie-Rod Mounting Nut (Front): 59 N·m (6.0 kgf·m,

44 ft·lb)

KLX140B

Torque - Rear Shock Absorber Mounting Bolt (Upper): 39

N·m (4.0 kgf·m, 29 ft·lb)

Rear Shock Absorber Mounting Bolt (Lower): 39

N·m (4.0 kgf·m, 29 ft·lb)

Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25

ft·lb)

Tie-Rod Mounting Nut (Front): 59 N·m (6.0 kgf·m,

44 ft·lb)

•

Install the other removed parts.

Spring Replacement

In addition to the standard spring, heavy and light springs

are available. If the standard spring is improper for your

purpose, select a proper one according to the rider’s weight

or course conditions.

•

Remove the rear shock absorber (see Rear Shock Ab-

sorber Removal).

•

Clean the threaded portion on the upper of the rear shock

absorber.

•

Hold the lower of the rear shock absorber with a vise.

SUSPENSION 12-17

Rear Suspension (Uni-Trak)

•

Using the hook wrenches, loosen the locknut [A] and turn

the adjusting nut [B] all way up.

Special Tools - Hook Wrench T=3.2 R37: 57001-1522

Hook Wrench T=3.2 R35: 57001-1523

KLX140A model [C]

KLX140B model [D]

•

Remove the rear shock absorber from the vise.

•

Slide down the rubber bumper [A].

•

Remove the spring guides [B] from the shock absorber

and lift off the spring [C].

•

Exchange the spring for an optional part. Install the spring

so that closed coil large diameter end [A] faces upward.

•

Install the spring guide.

•

Adjust the spring preload (see Spring Preload Adjust-

ment).

•

Install the rear shock absorber.

•

Install the other removed parts.

Rear Shock Absorber Scrapping

WARNING

Since the rear shock absorber contains nitrogen

gas, do not incinerate the rear shock absorber with-

out first releasing the gas or it may explode.

Before a rear shock absorber is scrapped, drill a

hole at the point [A] shown to release the nitrogen

gas completely. Wear safety glasses when drilling

the hole, as the gas may blow out bits of drilled

metal when the hole opens.

12-18 SUSPENSION

Swingarm

Swingarm Removal

•

Raise the rear wheel off the ground with the jack.

Special Tool - Jack: 57001-1238

•

Remove:

Rear Wheel (see Rear Wheel Removal in the

Wheels/Tires chapter)

Rear Caliper with bracket (see Rear Caliper Removal in

the Brakes chapter)

Brake Hose Clamps [A]

•

Remove:

Chain Cover Screws [A]

Chain Cover [B]

Chain Guide Bolts [C] and Screws [D]

Chain Guide Plate [E]

Chain Guide [F]

•

Unscrew the rocker arm pivot nut [A] and pull out the

rocker arm pivot bolt [B].

NOTICE

When pulling out the mounting bolt, lift the

swingarm wheel slightly. Forcing or tapping on a

bolt could damage the bolt, sleeve, and bearing.

•

Remove the rear shock absorber (see Rear Shock Ab-

sorber Removal).

•

Remove the nut [A], and pull out the swingarm pivot shaft

[B].

•

Remove the swingarm backward.

•

Remove the bolts [A] and the stopper [B].

•

Take off the chain slipper [C] from the swingarm.

SUSPENSION 12-19

Swingarm

Swingarm Installation

•

Installation is the reverse of removal.

○

Apply plenty of grease to the inside of the needle bear-

ings, sleeves, and grease seals.

○

Tighten the following:

Torque - Swingarm Pivot Shaft Nut: 108 N·m (11 kgf·m, 80

ft·lb)

Rocker Arm Pivot Nut: 59 N·m (6.0 kgf·m, 44 ft·lb)

Swingarm Bearing Removal

•

Remove:

Swingarm (see Swingarm Removal)

Sleeve [A]

Needle Bearings [B]

Grease Seals [C]

Special Tool - Oil Seal & Bearing Remover: 57001-1058

Swingarm Bearing Installation

•

Replace the needle bearings and grease seals with new

ones.

•

Apply plenty of grease to the needle bearings and grease

seals.

•

Install the needle bearings and grease seals.

Special Tool - Bearing Driver Set: 57001-1129

NOTE

○

Install the needle bearings so that the manufacturer’s

marks face out.

○

Install the grease seals so that the deep groove side of

the rip in-ward.

Swingarm Bearing, Sleeve Inspection

NOTICE

Do not remove the bearings for inspection. Re-

moval may damage them.

•

Inspect the needle bearings installed in the swingarm.

○

The rollers in a bearing normally wear very little, and wear

is difficult to measure. Instead of measuring, visually

inspect the bearing for abrasion, discoloration, or other

damage.

If the needle bearing, and sleeve show any things of ab-

normal wear, discoloration or damage, replace them as a

set.

Drive Chain Guide, Guide Roller, Chain Slipper

Wear

•

Refer to the Drive Chain Guide, Guide Roller, Chain Slip-

per Wear in the Periodic Maintenance chapter.

12-20 SUSPENSION

Tie-Rod, Rocker Arm

Tie-Rod Removal

•

Raise the rear wheel off the ground with the jack.

Special Tool - Jack: 57001-1238

NOTICE

When pulling out the mounting bolts, lift the rear

wheel slightly. Forcing or tapping on a bolt could

damage the bolt, sleeve, and bearing.

•

Remove the tie-rod rear mounting bolt and nut [A].

•

Remove the tie-rod front mounting bolt and nut [B], and

then take out the tie-rod [C].

Tie-Rod Installation

•

Apply plenty of grease to the inside of the grease seals.

•

Apply plenty of 2-stroke oil to the threads of the tie-rod

front and rear mounting bolts.

•

Tighten the tie-rod front and rear mounting nuts.

Torque - Tie-Rod Mounting Nuts: 59 N·m (6.0 kgf·m, 44

ft·lb)

Rocker Arm Removal

•

Raise the rear wheel off the ground with the jack.

Special Tool - Jack: 57001-1238

NOTICE

When pulling out the mounting bolts, lift the rear

wheel slightly. Forcing or tapping on bolt could

damage the bolt, sleeve, and bearing.

•

Remove the rear shock absorber lower mounting bolt [A].

•

Remove the tie-rod rear mounting bolt and nut [B].

•

Remove the rocker arm pivot bolt and nut [C].

•

Remove the rocker arm [D].

SUSPENSION 12-21

Tie-Rod, Rocker Arm

Rocker Arm Installation

•

Apply plenty of grease to the inside of the rocker arm,

needle bearings and grease seals outside of the sleeve.

•

Apply plenty of 2-stroke oil to the threads of the tie-rod

rear mounting bolts.

•

Replace the rear shock absorber mounting nut (lower),

rocker arm pivot nut, and tie-rod mounting nut with new

ones.

•

Tighten:

Torque - Rear Shock Absorber Mounting Bolt (Lower): 39

N·m (4.0 kgf·m, 29 ft·lb)

Rear Shock Absorber Mounting Nut (Lower): 29

N·m (3.0 kgf·m, 21 ft·lb)

Rocker Arm Pivot Nut: 59 N·m (6.0 kgf·m, 44 ft·lb)

Tie-Rod Mounting Nut (Rear): 59 N·m (6.0 kgf·m,

44 ft·lb)

Tie-Rod and Rocker Arm Bearing Removal

•

Remove:

Tie-Rod [A] (see Tie-Rod Removal)

Rocker Arm [B] (see Rocker Arm Removal)

Bushings [C]

Sleeves [D]

Grease Seals [E]

•

Remove the needle bearings [F], using the bearing re-

mover.

Special Tools - Bearing Remover Head: 57001-1267

Bearing Remover Shaft: 57001-1265

Oil Seal & Bearing Remover: 57001-1058

12-22 SUSPENSION

Tie-Rod, Rocker Arm

Tie-Rod and Rocker Arm Bearing Installation

•

Replace the needle bearing, grease seals and oil seals

with new ones.

•

Apply plenty of grease to the oil seal and needle bearings

[A].

NOTE

○

Install the grease seals so that the deep groove side of

the rip out-ward.

•

Install the needle bearings [A], and grease seals [B] po-

sition as shown.

○

Install the needle bearings and grease seals position as

shown.

○

The installation procedure is the same as the counter

side.

3 mm (0.12 in.) [C] Rear Shock Absorber [F]

5 mm (0.20 in.) [D] Tie-rod [G]

4.1 mm (0.164 in.) [E] Rocker Arm [H]

Needle Bearing Inspection

If there is any doubt as to the condition of either needle

bearing, replace the bearing and sleeve as a set.

SUSPENSION 12-23

Uni-Trak Maintenance

Uni-Trak Linkage Inspection

•

Refer to the Uni-Trak Linkage Inspection in the Periodic

Maintenance chapter.

Tie-Rod and Rocker Arm Sleeve Wear

•

Pull out the sleeves [A] of the tie-rod and rocker arm.

•

Measure the outside diameter of the sleeve.

If the sleeve is worn past the service limit, replace the

sleeve.

Sleeve Outside Diameter

Standard:

Tie-rod

19.979

∼ 20.000 mm (0.78657 ∼ 0.78740 in.)

Rocker Arm:

[Large]

19.979

∼ 20.000 mm (0.78657 ∼ 0.78740 in.)

[Middle]

17.989

∼ 18.000 mm (0.70823 ∼ 0.70866 in.)

[Small] 15.950

∼ 16.000 mm (0.62795 ∼ 0.62992 in.)

Service Limit:

Tie-rod

19.85 mm (0.781 in.)

Rocker Arm:

[Large]

19.85 mm (0.781 in.)

[Middle]

17.96 mm (0.707 in.)

[Small] 15.92 mm (0.627 in.)

Tie-Rod and Rocker Arm Mounting Bolt Bend

A bent bolt causes vibration, poor handling, and instabil-

ity.

•

To measure the bolt runout, remove the bolt, place it in V

blocks, and set a dial gauge to the bolt at a point halfway

between the blocks. Turn [A] the bolt to measure the

runout. The amount of dial variation is the amount of

runout.

If runout exceeds the service limit, replace the bolt.

Bolt Runout

Standard: TIR 0.1 mm (0.004 in.) or less

Service Limit: TIR 0.2 mm (0.008 in.)

STEERING 13-1

Steering

Table of Contents

Exploded View........................................................................................................................ 13-2

Special Tools .......................................................................................................................... 13-4

Steering .................................................................................................................................. 13-5

Steering Inspection ........................................................................................................... 13-5

Steering Adjustment.......................................................................................................... 13-5

Steering Stem, Stem Bearing Removal ............................................................................ 13-5

Steering Stem, Stem Bearing Installation ......................................................................... 13-6

Stem Bearing Lubrication.................................................................................................. 13-8

Stem Bearing Wear, Damage ........................................................................................... 13-8

Stem Warp ........................................................................................................................ 13-8

Handlebar............................................................................................................................... 13-9

Handlebar Removal .......................................................................................................... 13-9

Handlebar Installation ....................................................................................................... 13-9

13-2 STEERING

Exploded View

STEERING 13-3

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

Handlebar Clamp Bolts

25 2.5 18 AL

2 Steering Stem Head Nut 64 6.5 47

3 Steering Stem Nut 4.9 0.50 43 in·lb T

4 Front Fork Clamp Bolts (Upper) 20 2.0 15

5 Front Fork Clamp Bolts (Lower) 25 2.5 18

6 Handlebar Lower Holder Nut 34 3.5 25 R

7. Handlebar

8. Handlebar Holder

9. Steering Stem Head Bracket

10. Upper Tapered Roller Bearing

11. Frame

12. Lower Tapered Roller Bearing

13. Steering Stem

14. KLX140A8 ∼ AA/B8 ∼ BA Models

AD: Apply adhesive cement.

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

G: Apply grease.

T: First, tighten the stem locknut with 39 N·m (4.0 kgf·m, 29 ft·lb) of torque, then loosen it and

retighten it with 4.9 N·m (0.50 kgf·m, 43 in·lb) of torque.

R: Replacement Parts

13-4 STEERING

Special Tools

Bearing Puller:

57001-135

Steering Stem Bearing Driver:

57001-137

Steering Stem Bearing Driver Adapter, 34.5:

57001-1074

Head Pipe Outer Race Press Shaft:

57001-1075

Steering Stem Nut Wrench:

57001-1100

Head Pipe Outer Race Driver, 46.5:

57001-1106

Head Pipe Outer Race Remover ID > 37 mm:

57001-1107

Bearing Puller:

57001-1575

STEERING 13-5

Steering

Steering Inspection

•

Refer to the Steering Inspection in the Periodic Mainte-

nance chapter.

Steering Adjustment

•

Refer to the Steering Adjustment in the Periodic Mainte-

nance chapter.

Steering Stem, Stem Bearing Removal

•

Remove:

Front Wheel (see Front Wheel Removal in the

Wheels/Tires chapter)

Front Fender (see Front Fender Removal in the Frame

chapter)

Handlebar (see Handlebar Removal)

•

Remove the number plate.

•

Disconnect the ignition switch connector.

•

Remove the mounting bolts [A], and take off the ignition

switch and choke knob bracket [B] (KLX140A8 ∼ AA/B8 ∼

BB).

•

Remove the mounting bolts [A], and take off the choke

knob bracket [B] (KLX140AB ∼/BB ∼).

•

Loosen the steering stem head nut [A].

•

Remove the front fork (see Front Fork Removal in the

Suspension chapter).

•

Remove the head nut with the washer and the steering

stem head [B].

13-6 STEERING

Steering

•

Pushing up on the stem base [A], and remove the steering

stem nut [B] with the steering stem nut wrench [C], then

remove the steering stem [D] and stem base.

Special Tool - Steering Stem Nut Wrench: 57001-1100

•

Take off the upper stem bearing inner race (tapered roller

bearing) [A].

•

Drive out the bearing outer races from the head pipe.

○

Remove the outer races pressed into the head pipe, using

the head pipe outer race remover [A], and hammer the

head pipe outer race remover to drive it out.

Special Tool - Head Pipe Outer Race Remover ID > 37 mm:

57001-1107

NOTE

○

If either steering stem bearing is damaged, it is recom-

mended that both the upper and lower bearing (includ-

ing outer races) should be replaced with new ones.

•

Remove the lower stem bearing inner rase (tapered roller

bearing) [A] with its grease seal from the stem using bear-

ing puller.

Special Tools - Bearing Puller: 57001-1575

Bearing Puller: 57001-135

Steering Stem, Stem Bearing Installation

•

Replace the bearing outer race with new ones.

○

Apply grease to the outer races, and drive them into the

head pipe at the same time using the head pipe outer race

press shaft [A] and the head pipe outer race drivers.

Special Tools - Head Pipe Outer Race Press Shaft: 57001

-1075

Head Pipe Outer Race Driver,

46.5: 57001

-1106 [B]

STEERING 13-7

Steering

•

Replace the lower inner races with new ones.

○

Apply grease to the lower tapered roller bearing [A], and

drive it onto the stem using the steering stem bearing

driver [B] and adapter [C].

Special Tools - Steering Stem Bearing Driver: 57001-137

Steering Stem Bearing Driver Adapter,

34.5: 57001-1074

•

Apply grease to the upper inner race, and install it in the

head pipe.

•

Install the stem through the head pipe and upper bearing,

install the stem cap and hand-tighten the stem nut while

pushing up on the stem base.

•

Install the stem head and washer, and tighten the stem

head nut lightly.

•

Settle the bearing in place as follows;

○

Tighten the stem nut to 39 N·m (4.0 kgf·m, 29 ft·lb) of

torque. (To tighten the steering stem nut to the specified

torque, hook the wrench [A] on the stem nut, and pull the

wrench at the hole by 22.2 kg force [B] in the direction

shown.)

Special Tool - Steering Stem Nut Wrench: 57001-1100

○

Check that there is no play and the steering stem turns

smoothly without rattles. If not, the steering stem bearings

may be damaged.

○

Again back out the stem nut a fraction of a turn until it

turns lightly.

○

Turn the stem nut lightly clockwise until it just becomes

hard to turn. Do not overtighten, or the steering will be

too tight.

Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)

•

Install the front fork (see Front Fork Installation in the Sus-

pension chapter).

NOTE

○

Tighten the fork upper clamp bolts first, next the stem

head nut, last the fork lower clamp bolt.

•

Tighten:

Torque - Steering Stem Head Nut: 64 N·m (6.5 kgf·m, 47

ft·lb)

Front Fork Clamp Bolts (Upper): 20 N·m (2.0

kgf·m, 15 ft·lb)

Front Fork Clamp Bolts (Lower): 25 N·m (2.5

kgf·m, 18 ft·lb)

13-8 STEERING

Steering

•

Install the other removed parts.

WARNING

Do not impede the handlebar turning by routing the

cables, wires and hoses improperly (see the Gen-

eral Information chapter).

•

Check and Adjust:

Steering

Front Brake

Clutch Cable

Throttle Cable

Stem Bearing Lubrication

•

Refer to the Stem Bearing Lubrication in the Periodic

Maintenance chapter.

Stem Bearing Wear, Damage

•

Using high-flash point solvent, wash the upper and lower

tapered rollers.

•

Wipe the upper and lower outer races, which are press

-fitted into the frame head pipe, clean off grease and dirt.

•

Visually check the outer rase and the rollers.

Replace the bearing assembly if it show damage.

Stem Warp

•

Whenever the steering stem is removed, or if the steering

cannot be adjusted for smooth action, check the steering

stem for straightness.

If the steering stem shaft is bent [A], replace the steering

stem.

STEERING 13-9

Handlebar

Handlebar Removal

•

Disconnect the connectors [A].

•

Remove:

Engine Stop Switch (KLX140A8 ∼ AA/B8 ∼ BB) [A]

Clutch Holder [B]

Clamp [C]

•

Remove:

Left Switch Housing (KLX140AB ∼/BB ∼)[A]

•

Remove:

Throttle Cable and Grip [A] (see Throttle Cable Replace-

ment in the Fuel System chapter)

Engine Starter Button (KLX140A8 ∼ AA/B8 ∼ BB) [B]

Master Cylinder [C] (see Front Master Cylinder Removal

in the Brakes chapter)

Clamp [D]

•

Clear the belt [A] of the number plate.

•

Remove:

Handlebar Clamp Bolts [B]

Handlebar Clamps [C]

Handlebar [D]

Handlebar Installation

•

Apply adhesive to the inside of the left handlebar grip.

•

Install the left handlebar grip so that the projection of grip

align to the punch mark of the handlebar.

13-10 STEERING

Handlebar

•

Install the engine stop switch [A] and the clutch lever [B]

so that their mating surfaces align to the punch marks [C]

(KLX140A8 ∼ AA/B8 ∼ BB).

•

Install the left switch housing [A] (KLX140AB ∼/BB ∼).

○

Fit the projection [B] into a hole [C] in the handlebar.

•

Install the clutch lever [A] so that the mating surface [B]

aligns with the punch mark [C] (KLX140AB ∼/BB ∼).

•

Apply grease to the throttle cable upper end and the clutch

cable upper end.

•

Install the throttle cable housing firmly (see Throttle Cable

Replacement in the Fuel System chapter).

•

Align the master cylinder, the engine starter button and

the throttle cable housing so that the mating surface [A] to

the punch mark [B] of the handlebar (KLX140A8 ∼ AA/B8

∼ BB).

STEERING 13-11

Handlebar

•

Align the master cylinder and throttle cable housing so

that the mating surfaces [A] to the punch marks [B] of the

handlebar (KLX140AB ∼/BB ∼).

•

Install the handlebar [A], and align the handlebar punch

mark [B] to the handlebar clamp mating surface.

•

Equalize the space [C] and [D].

Torque - Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

NOTE

○

Tighten the two clamp bolts alternately two times to en-

sure even tightening torque.

•

Install the other removed parts.

FRAME 14-1

Frame

Table of Contents

Exploded View........................................................................................................................ 14-2

Special Tool ............................................................................................................................ 14-6

Frame ..................................................................................................................................... 14-7

Frame Inspection .............................................................................................................. 14-7

Rear Frame Removal........................................................................................................ 14-7

Rear Frame Installation..................................................................................................... 14-7

Engine Guard Removal..................................................................................................... 14-7

Seat ........................................................................................................................................ 14-8

Seat Removal ................................................................................................................... 14-8

Seat Installation ................................................................................................................ 14-8

Side Cover.............................................................................................................................. 14-9

Side Covers Removal/Installation..................................................................................... 14-9

Fender .................................................................................................................................... 14-10

Front Fender Removal ...................................................................................................... 14-10

Rear Fender Removal....................................................................................................... 14-10

Rear Flap Removal ........................................................................................................... 14-10

Footpegs and Brackets........................................................................................................... 14-11

Footpeg Removal/Installation ........................................................................................... 14-11

Sidestand................................................................................................................................ 14-12

Sidestand Removal........................................................................................................... 14-12

Sidestand Installation........................................................................................................ 14-12

14-2 FRAME

Exploded View

FRAME 14-3

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

1 Rear Frame Mounting Bolt 34 3.5 25

2 Sidestand Pivot Bolt 29 3.0 21

Sidestand Pivot Nut

44 4.5 32 R

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

14-4 FRAME

Exploded View

FRAME 14-5

Exploded View

1. Seat

2. Side Covers

3. Front Fender

4. Rear Fender

5. Rear Flap

6. Number Plate

7. CA model only

8. CA model only

14-6 FRAME

Special Tool

Jack:

57001-1238

FRAME 14-7

Frame

Frame Inspection

•

Refer to the Frame Inspection in the Periodic Mainte-

nance chapter.

Rear Frame Removal

•

Remove:

Side Covers (see Side Covers Removal/Installation)

Seat (see Seat Removal)

Muffler (see Muffler Removal in the Engine Top End

chapter)

Rear Fender (see Rear Fender Removal)

•

Remove the mounting bolts [A] and the rear frame [B].

Rear Frame Installation

•

Install the rear frame and tighten the mounting bolts.

Torque - Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25

ft·lb)

•

Install the other removed parts.

Engine Guard Removal

•

Remove the mounting bolts [A], and take off the engine

guard [B].

14-8 FRAME

Seat

Seat Removal

•

Remove the side covers (see Side Covers Removal/In-

stallation).

•

Remove the bolt [A], nut [B] and collar on both sides.

•

Take off the seat [C] backward.

Seat Installation

•

Fit the hooks [A] in under the flange collar [B] and the

bracket [C].

•

Replace the seat mounting nut with a new one.

•

Tighten the seat mounting bolts and nuts.

•

Install the side covers (see Side Covers Removal/Instal-

lation).

FRAME 14-9

Side Cover

Side Covers Removal/Installation

•

Remove the mounting bolt [A] and the side cover [B] on

both sides.

•

Remove the screws [A] of the right side cover if necessary.

•

Clear the hooks [B] and separate each other.

•

Installation is the reverse of removal.

○

Insert the projection [A] into the grommet [B] on the frame.

14-10 FRAME

Fender

Front Fender Removal

•

Unscrew the bolts [A] and remove the front fender.

Rear Fender Removal

•

Remove:

Side Covers (see Side Covers Removal/Installation)

Seat (see Seat Removal)

Muffler (see Muffler Removal in the Engine Top End

chapter)

•

Take off the starter relay and fuse unit [A].

•

Remove the mounting bolts [A] and take off the rear

fender [B].

Rear Flap Removal

•

Remove the screws [A] and take off the rear flap [B].

FRAME 14-11

Footpegs and Brackets

Footpeg Removal/Installation

•

Remove:

Cotter pin [A]

Washer [B]

Pivot Pin [C]

Spring [D]

Footpeg [E]

•

Installation is reverse of removal.

○

Replace the cotter pin with a new one.

•

Bend the longer side of the cotter pin.

14-12 FRAME

Sidestand

Sidestand Removal

•

Raise the rear wheel off the ground with the jack.

Special Tool - Jack: 57001-1238

•

Remove:

Spring [A]

Sidestand Bolt [B]

Sidestand Nut [C]

Sidestand [D]

Sidestand Installation

•

Apply grease to the sliding area [A] of the sidestand [B].

•

Replace the sidestand pivot nut with a new one.

•

Tighten the sidestand pivot bolt [C] and nut [D].

Torque - Sidestand Pivot Bolt: 29 N·m (3.0 kgf·m, 21 ft·lb)

Sidestand Pivot Nut: 44 N·m (4.5 kgf·m, 32 ft·lb)

•

Hook the spring [E] so that face the long spring end up-

ward.

ELECTRICAL SYSTEM 15-1

Electrical System

Table of Contents

Exploded View................................... 15-2

Specifications .................................... 15-6

Special Tools and Sealant ................. 15-7

Wiring Diagram.................................. 15-8

Precautions........................................ 15-10

Electrical Wiring................................. 15-11

Wiring Inspection ......................... 15-11

Battery ............................................... 15-12

Battery Removal .......................... 15-12

Battery Installation ....................... 15-12

Battery Activation ......................... 15-12

Precautions .................................. 15-15

Interchange .................................. 15-16

Charging Condition Inspection..... 15-16

Refreshing Charge....................... 15-17

Charging System............................... 15-18

Alternator Cover Removal............ 15-18

Alternator Cover Installation......... 15-18

Alternator Rotor Removal ............ 15-19

Alternator Rotor Installation ......... 15-19

Stator Removal ............................ 15-20

Stator Installation ......................... 15-20

Alternator Rotor Inspection .......... 15-20

Charging Voltage Inspection........ 15-22

Regulator/Rectifier Inspection...... 15-22

Starter Motor Clutch .......................... 15-26

Starter Motor Clutch Removal...... 15-26

Starter Motor Clutch Installation... 15-26

Starter Motor Clutch Inspection ... 15-26

Ignition Timing ................................... 15-27

Ignition Timing Inspection ............ 15-27

Ignition System .................................. 15-28

Crankshaft Sensor Removal ........ 15-28

Crankshaft Sensor Installation ..... 15-28

Ignition Coil Removal/Installation. 15-28

Ignition Coil Inspection................. 15-29

Spark Plug Cleaning and

Inspection.................................. 15-29

Spark Plug Gap Inspection .......... 15-30

Igniter Removal............................ 15-30

Igniter Inspection.......................... 15-30

Crankshaft Sensor Inspection...... 15-32

Electrical Starter System ................... 15-36

Starter Motor Removal................. 15-36

Starter Motor Installation.............. 15-36

Starter Motor Disassembly........... 15-36

Starter Motor Assembly ............... 15-37

Carbon Brush Inspection ............. 15-37

Commutator Cleaning and

Inspection.................................. 15-38

Armature Inspection..................... 15-38

Brush Lead Inspection ................. 15-38

Terminal Bolt Inspection............... 15-39

Starter Relay Inspection............... 15-39

Switches and Sensors....................... 15-42

Switch Inspection ......................... 15-42

LED Inspection............................. 15-42

Main Relay......................................... 15-43

Main Relay Inspection.................. 15-43

Fuses................................................. 15-44

Main Fuse 10 A Removal............. 15-44

Main Fuse 10 A Inspection .......... 15-44

15-2 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 15-3

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

Ignition Coil Mounting Bolt

2.9 0.30 26 in·lb

2 Regulator Mounting Bolt 8.8 0.90 78 in·lb

Spark Plug

13 1.3 115 in·lb

Starter Relay Terminal Screws

2.9 0.30 26 in·lb

5. Ignition Switch (KLX140A8 ∼ AA/B8 ∼ BA)

6. Ignition Coil

7. Main Relay

8. IC Igniter

9. Battery

10. Starter Relay

11. Main Fuse 10 A

12. KLX140A8 ∼ AA/B8 ∼ BA Models

15-4 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 15-5

Exploded View

Torque

No. Fastener

N·m

kgf·m ft·lb

Remarks

Starter Motor Terminal Nut

5.2 0.53 46 in·lb

2 Starter Motor Mounting Bolts 6.9 0.70 61 in·lb

3 Starter Motor Terminal Locknut 6.9 0.70 61 in·lb

4 Starter Motor Through Bolts 4.9 0.50 43 in·lb

5 Starter Motor Clutch Bolts 12 1.2 106 in·lb L

6 Alternator Rotor Bolt 38 3.9 28

Stator Mounting Bolts

8.8 0.90 78 in·lb

8 Alternator Cover Plug 2.5 0.25 22 in·lb

9 Alternator Cover Center Cap 2.5 0.25 22 in·lb

10 Alternator Cover Bolts (L = 30) 8.8 0.90 78 in·lb

11 Alternator Cover Bolts (L = 45) 8.8 0.90 78 in·lb

Torque Limiter Cover Bolts

8.8 0.90 78 in·lb

Alternator Lead Clamp Screws

5.2 0.53 46 in·lb

14 Crankshaft Sensor Mounting Screws 4.2 0.43 37 in·lb

15. Starter Motor Clutch

16. Alternator Rotor

17. Stator

18. Crankshaft Sensor

19. Torque Limiter

20. KLX140A8 ∼ A9 Early Models/B8 ∼ B9 Early Models

21. KLX140A8 ∼ A9/B8 ∼ B9

G: Apply grease.

L: Apply a non-permanent locking agent.

MO: Apply molybdenum disulfide oil.

R: Replacement Parts

SS: Appl

y silicone sealant.

15-6 ELECTRICAL SYSTEM

Specifications

Item Standard Service Limit

Battery

Type Sealed Battery (wet) –––

Model FTX7L-BS –––

Capacity

12 V 6 Ah –––

Charging System

Crankshaft Sensor Resistance 50 ∼ 200 Ω at 20°C (68°F) –––

Alternator Output Voltage in the text –––

Stator Coil Resistance in the text –––

Ignition System

Ignition Timing

BTDC 10 ±2° @1 400 r/min (rpm)

–––

Ignition Coil:

3 Needle Arcing Distance 7 mm (0.26 in.) or more –––

Primary Winding Resistance 0.64 ∼ 0.78 Ω at 20°C (68°F) –––

Secondary Winding

Resistance

11.4 ∼ 14.0 kΩ at 20°C (68°F)

–––

Primary Peak Voltage 175 V or more –––

Crankshaft Sensor Peak

Voltage

2Vormore –––

Spark Plug:

Type NGK CR7HSA –––

Gap 0.6 ∼ 0.7 mm (0.024 ∼ 0.028 in.) –––

Electric Starter System

Starter Motor:

Brush Length 7.0 mm (0.28 in.) 3.5 mm (0.14 in.)

Commutator Diameter 22.1 mm (0.87 in.) 21.6 mm (0.85 in.)

ELECTRICAL SYSTEM 15-7

Special Tools and Sealant

Inside Circlip Pliers:

57001-143

Rotor Puller, M16/M18/M20/M22 × 1.5:

57001-1216

Timing Light:

57001-1241

Spark Plug Wrench, Hex 16:

57001-1262

Flywheel Holder:

57001-1313

Hand Tester:

57001-1394

Peak Voltage Adapter:

57001-1415

Needle Adapter Set:

57001-1457

Flywheel Puller, M28 × 1.0:

57001-1471

Liquid Gasket, TB1211F:

92104-0004

15-8 ELECTRICAL SYSTEM

Wiring Diagram

KLX140A8 ∼ AA/B8 ∼ BA

ELECTRICAL SYSTEM 15-9

Wiring Diagram

KLX140AB ∼/BB ∼

15-10 ELECTRICAL SYSTEM

Precautions

There are numbers of important precautions that are

musts when servicing electrical systems. Learn and ob-

serve all the rules below.

○

The electrical parts should never be struck sharply, as

with a hammer, or allowed to fall on a hard surface. Such

a shock to the parts can damage them.

○

Troubles may involve one or in some cases all items.

Never replace a defective part without determining what

CAUSED the failure. If the failure was caused by some

other item(s), they too must be repaired or replaced, or

the new replacement will soon fail again.

○

Make sure all connectors in the circuit are clean and tight,

and examine wires for signs of burning, fraying, etc. Poor

wires and bad connections will affect electrical system op-

eration.

○

Measure coil and winding resistance when the part is cold

(at room temperature).

○

Electrical Connectors

Connectors [A]

Connectors [B]

Safety Instructions:

WARNING

The ignition system produces extremely high volt-

age. Do not touch the spark plug, ignition coil or ig-

nition coil lead while the engine is running, or you

could receive a severe electrical shock.

ELECTRICAL SYSTEM 15-11

Electrical Wiring

Wiring Inspection

•

Visually inspect the wiring for signs of burning, fraying,

etc.

If any wiring is poor, replace the damaged wiring.

•

Pull each connector [A] apart and inspect it for corrosion,

dirt, and damage.

If the connector is corroded or dirty, clean it carefully. If it

is damaged, replace it.

•

Check the wiring for continuity.

○

Use the wiring diagram to find the ends of the lead which

is suspected of being a problem.

○

Connect the hand tester between the ends of the leads.

Special Tool - Hand Tester: 57001-1394

○

Set the tester to the × 1 Ω range, and read the tester.

If the tester does not read 0 Ω, the lead is defective. Re-

place the lead or the wiring harness [B] if necessary.

15-12 ELECTRICAL SYSTEM

Battery

Battery Removal

•

Remove the seat (see Seat Removal in the Frame chap-

ter).

•

Disconnect the negative (–) cable [A] and then positive

(+) cable [B].

NOTICE

Be sure to disconnect the negative (–) cable first.

•

Remove the battery holder bolts [C] and holder [D].

•

Remove the battery.

Battery Installation

•

Visually inspect the surface of the battery container.

If any signs of cracking or electrolyte leakage from the

sides of the battery.

•

Put the battery into the battery case.

•

Connect the positive cable [A] to the (+) terminal first, and

then the negative cable [B] to the (–) terminal.

•

Install the battery holder and tighten the bolts.

•

Apply a little grease on the terminals to prevent corrosion.

•

Cover the (+) terminal with the cap.

Battery Activation

Electrolyte Filling

•

Make sure that the model name [A] of the electrolyte con-

tainer matches the model name [B] of the battery. These

names must be the same.

Battery Model Name

KLX140A/B: FTX7L-BS

NOTICE

Be sure to use the electrolyte container with the

same model name as the battery since the elec-

trolyte volume and specific gravity vary with the

battery type. This is to prevent overfilling of the

electrolyte, shorting the battery life, and deteriora-

tion of the battery performance.

ELECTRICAL SYSTEM 15-13

Battery

NOTICE

Do not remove the aluminum sealing sheet [A] from

the filler ports [B] until just prior to use. Be sure to

use the dedicated electrolyte container for correct

electrolyte volume.

WARNING

The electrolyte contains sulfuric acid, which can

cause severe burns. To avoid sulfuric acid burns,

wear protective clothing and safety glasses when

handling electrolyte. If the electrolyte touches the

skin or eyes, wash the area with liberal amounts of

water and seek medical attention for more severe

burns.

•

Place the battery on a level surface.

•

Check to see that the sealing sheet has no peeling, tears,

or holes in it.

•

Remove the sealing sheet.

NOTE

○

The battery is vacuum sealed. If the sealing sheet has

leaked air into the battery, it may require a longer initial

charge.

•

Remove the electrolyte container from the vinyl bag.

•

Detach the strip of caps [A] from the container and set

aside, these will be used later to seal the battery.

NOTE

○

Do not pierce or otherwise open the sealed cells [B] of

the electrolyte container. Do not attempt to separate

individual cells.

•

Place the electrolyte container upside down with the six

sealed cells into the filler ports of the battery. Hold the

container level, push down to break the seals of all six

cells. You will see air bubbles rising into each cell as the

ports fill.

NOTE

○

Do not tilt the electrolyte container.

15-14 ELECTRICAL SYSTEM

Battery

•

Check the electrolyte flow.

If no air bubbles [A] are coming up from the filler ports, or

if the container cells have not emptied completely, tap the

container [B] a few times.

NOTE

○

Be careful not to have the battery fall down.

•

Keep the container in place. Don’t remove the container

from the battery, the battery requires all the electrolyte

from the container for proper operation.

NOTICE

Removal of the container before it is completely

empty can shorten the service life of the battery.

•

After filling, let the battery sit for 20 ∼ 60 minutes with the

electrolyte container kept in place, which is required for

the electrolyte to fully permeate into the plates.

•

Make sure that the container cells have emptied com-

pletely, and remove the container from the battery.

•

Place the strip of caps [A] loosely over the filler ports,

press down firmly with both hands to seat the strip of caps

into the battery (don’t pound or hammer). When properly

installed, the strip of caps will be level with the top of the

battery.

NOTICE

Once the strip of caps is installed onto the battery,

never remove the caps, nor add water or electrolyte

to the battery.

NOTE

○

Charging the battery immediately after filling can

shorten service life.

ELECTRICAL SYSTEM 15-15

Battery

Initial Charge

•

Newly activated sealed batteries require an initial charge.

Standard Charge:

0.7 A × 5

∼ 10 hours

If using a recommended battery charger, follow the

charger’s instructions for newly activated sealed battery.

Kawasaki-recommended chargers:

Battery Mate 150-9

OptiMate PRO 4-S/PRO S/PRO2

Yuasa MB-2040/2060

Christie C10122S

If the above chargers are not available, use equivalent

one.

•

Let battery sit 30 minutes after initial charge, then check

voltage using a voltmeter. (Voltage immediately after

charging becomes temporarily high. For accurate mea-

suring, let the battery sit for given time.)

NOTE

○

Charging rates will vary depending on how long the

battery has been stored, temperature, and the type of

charger used. If voltage is not at least 12.6 V, repeat

charging cycle.

○

To ensure maximum battery life and customer satisfac-

tion, it is recommended the battery be load tested at

three times its amp-hour rating for 15 seconds.

Re-check voltage and if less than 12.6 V repeat the

charging cycle and load test. If still below 12.6 V the

battery is defective.

Precautions

1) No need of topping-up.

No topping-up is necessary in this battery until it ends its life under normal use. F

orcibly prying off the

seal cap to add water is very dangerous. Never do that.

2) Refreshing charge.

Give a refresh charge for 5 to 10 hours with charging current shown in the specification (see

Refreshing Charge).

When a fast charge is inevitably required, do it following precisely the maximum charge current

and time conditions indicated on the battery.

NOTICE

This battery is designed to sustain no unusual deterioration if refresh-charged according

to the method specified above. However, the battery’s performance may be reduced no-

ticeably if charged under conditions other than given above. Never remove the seal cap

during refresh charge.

If by chance an excessive amount of gas is generated due to overcharging, the relief valve

releases the gas to keep the battery normal.

3) When you do not use the motorcycle for months.

Give a refresh charge before you store the motorcycle. And then store it with the negative cable

removed. However, check the battery’s state of charge at every month to be sure it meets the

minimum 12.4 V specification and charge it to 100 % state of charge.

4) Battery life.

If the battery will not start the engine even after several refresh charges, the battery has ex-

ceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no prob-

lem).

15-16 ELECTRICAL SYSTEM

Battery

DANGER

Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri-

ous injury and burns if ignited. Keep the battery away from sparks and open flames during

charging. When using a battery charger, connect the battery to the charger before turning

on the charger. This procedure prevents sparks at the battery terminals which could ignite

any battery gases. The electrolyte contains sulfuric acid. Be careful not to have it touch

your skin or eyes. If touched, wash it off with liberal amount of water and seek medial at-

tention for more severe burns.

Interchange

A sealed battery can fully display its performance only when combined with a proper vehicle electric

system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with

a sealed battery.

Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original

equipment, the sealed battery’s life will be shortened.

Battery Date Inspection

•

Remove the battery (see Battery Removal).

•

Check the manufactured date stamp [A].

Day [B]

Month [C]

Year [D]

MFG Code [F]

NOTE

○

Do refresh charge with the battery that passes one

month or more.

Charging Condition Inspection

○

Battery charging condition can be checked by measuring

battery terminal voltage with a digital voltmeter [A].

•

Remove the seat (see Seat Removal in the Frame chap-

ter).

•

Disconnect the battery terminals.

NOTICE

Be sure to disconnect the negative (–) cable first.

•

Measure the battery terminal voltage.

NOTE

○

Measure with a digital voltmeter which can be read one

decimal place voltage.

If the reading is 12.6 V or more, refresh charge is not

required, however, if the read is below the 12.6 V, refresh

charge is required.

Terminal Voltage (V) [A]

Battery Charge Rate (%) [B]

Refresh charge is required [C]

Good [D]

ELECTRICAL SYSTEM 15-17

Battery

Refreshing Charge

•

Remove the battery (see Battery Removal).

•

Do refresh charge by following method according to the

battery terminal voltage.

WARNING

This battery is sealed type. Charge with current and

time as stated below.

Terminal Voltage: 11.5 ∼ less than 12.6 V

Standard Charge 0.7 A × 5

∼ 10 h (see following chart)

Quick Charge

3A×1h

NOTICE

If possible, do not quick charge. If quick charge is

done unavoidably, do standard charge later on.

Terminal Voltage: less than 11.5 V

Charging Method:

0.7A×20h

NOTE

○

Increase the charging voltage to a maximum voltage of

25 V if the battery will not accept current initially. Charge

for no more than 5 minutes at the increased voltage then

check if the battery is drawing current. If the battery

will accept current decrease the voltage and charge by

the standard charging method described on the battery

case. If the battery will not accept current after 5 min-

utes, replace the battery.

Battery [A]

Battery Charger [B]

Standard Value [C]

Current starts to flow [D].

•

Determine the battery condition after refresh charge.

○

Determine the condition of the battery left for 30 minutes

after completion of the charge by measuring the terminal

voltage according to the table below.

Criteria

Judgement

12.7 V or higher

Good

12.0 ∼ lower than 12.6 V

Charge insufficient → Recharge

lowerthan12.0V Unserviceable → Replace

15-18 ELECTRICAL SYSTEM

Charging System

Alternator Cover Removal

•

Drain the engine oil (see Engine Oil Change in the Peri-

odic Maintenance chapter).

•

Disconnect the alternator lead connector [A].

○

Clear the lead from the clamps.

•

Remove:

Torque Limiter Cover Bolts [A]

Torque Limiter Cover [B]

Drive Chain Cover Bolts [C]

Drive Chain Cover [D]

•

Remove:

Neutral Switch Terminal [A]

Torque Limiter [B]

Alternator Cover Mounting Bolts [C]

Alternator Cover [D]

Alternator Cover Installation

•

Replace the gasket [A] with a new one.

•

Be sure to install the dowel pins [B].

•

Using a high-flash point solvent, clean off any oil or dirt

that may be on the silicone sealant coating area. Dry

them with a clean cloth.

•

Apply silicone sealant to the area [A] to the alternator lead

grommet.

Sealant - Liquid Gasket, TB1211F: 92104-0004

•

Install the alternator cover.

Torque - Alternator Cover Bolts: 8.8 N·m (0.90 kgf·m, 78

in·lb)

•

Install the other removed parts.

ELECTRICAL SYSTEM 15-19

Charging System

Alternator Rotor Removal

•

Remove the alternator cover (see Alternator Cover Re-

moval).

•

Hold the rotor steady, with the flywheel holder [A], and

remove the rotor bolt [B].

Special Tool - Flywheel Holder: 57001-1313

•

Remove the flywheel holder.

•

Attach the pullers [A] onto the rotor.

•

Remove the rotor from the crankshaft.

Special Tools - Flywheel Puller, M28 × 1.0: 57001-1471

Rotor Puller, M16/M18/M20/M22 × 1.5: 57001

-1216

NOTE

○

Tap the rotor puller head [B] with a hammer, while hold-

ing the puller body steady.

•

Remove the woodruff key from the crankshaft.

NOTICE

If the rotor is difficult to remove, turn the puller shaft

using a wrench while tapping the head of the puller

shaft with a hammer. Do not attempt to strike the

grab bar or the alternator rotor itself. Striking the

bar or the rotor can cause the bar to bend or the

magnets to lose their magnetism.

Alternator Rotor Installation

•

Using high-flash point solvent, clean off any oil or dirt on

the crankshaft and rotor tapered portions [A] [B]. Dry them

with a clean cloth.

•

Fit the woodruff key [C] securely in the slot on the crank-

shaft.

•

Install the rotor while turning the starter clutch gear clock-

wise, and refer following procedures.

NOTE

○

Confirm the rotor fit or not to the crankshaft before tight-

ening it with specified torque.

○

Install the rotor and tighten it with 30 N·m (3.1 kgf·m, 22

ft·lb) of torque.

○

Remove the rotor nut.

○

Check the tightening torque with the rotor pu

ller.

If the rotor is not pulled out with 10 N·m (1.0 kgf·m, 87

in·lb) of drawing torque, it is installed correctly.

If the r

otor is pulled out with under 10 N·m (1.0 kgf·m, 87

in·lb) of drawing torque, clean off any oil dirt or flaw of the

crankshaft and rotor tapered portion, and dry them with

a clean cloth. Then, confirm that it is not pulled out with

above torque.

15-20 ELECTRICAL SYSTEM

Charging System

•

Apply molybdenum disulfide oil to the thread of the rotor

bolt, but do not apply to the rotor and the crankshaft ta-

pered portion.

•

Holding the rotor steady, with the flywheel holder, and

tighten the rotor bolt.

Special Tool - Rotor Holder: 57001-1313

Torque - Alternator Rotor Bolt: 38 N·m (3.9 kgf·m, 28 ft·lb)

•

Install the alternator cover (see Alternator Cover Installa-

tion)

Stator Removal

•

Remove:

Alternator Cover (see Alternator Cover Removal)

Stator Bolts [A]

Crankshaft Sensor Screws [B]

Lead Clumps [C]

Wiring Grommet [D]

•

Take off the stator [E] and the crankshaft sensor as a set.

Stator Installation

•

Install the stator.

Torque - Stator Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Install the crankshaft sensor and the lead clamps.

○

Run the crankshaft sensor leads under the sensor and

the clamp.

Torque - Crankshaft Sensor Screws: 4.2 N·m (0.43 kgf·m,

37 in·lb)

Alternator Lead Clamp Screws: 5.2 N·m (0.53

kgf·m, 46 in·lb)

•

Using a high-flash point solvent, clean off any oil or dirt

that may be on the silicone sealant coating area. Dry

them with a clean cloth.

•

Apply silicone sealant around the circumference of the

wiring grommet.

Sealant - Liquid Gasket, TB1211F: 92104-0004

•

Set the stator wiring grommet securely in the notch of the

alternator cover.

•

Install the alternator cover (see Alternator Cover Installa-

tion).

Alternator Rotor Inspection

•

There are three types of alternator problems: short, open

(wire burned out), or loss in rotor magnetism.

○

A short or open in one of the coil wires will result in either

a low output, or no output at all.

○

A loss in rotor magnetism, which may be caused by drop-

ping or hitting the rotor by leaving it near an electromag-

netic field, or just by aging, will result in low output.

ELECTRICAL SYSTEM 15-21

Charging System

•

Check the alternator output voltage, do the following pro-

cedures.

○

Remove the fuel tank cover (see Fuel Tank Removal in

the Fuel System chapter).

○

Disconnect the alternator lead connector [A].

○

Connect the hand tester [A] to the connector [B] as shown

in the table 1, using the needle adapter set.

○

Start the engine.

○

Run it at the rpm given in the table 1.

○

Note the voltage readings.

Special Tools - Hand Tester: 57001-1394

Needle Adapter Set: 57001-1457

Table 1, Alternator Output Voltage

Connections

Tester

Range

Tester (+) to Tester (–) to

Reading

@4 000 rpm

50 V AC

White lead

Black/Red lead

48 V or more

If the output voltage shows the value in the table, the al-

ternator operates properly.

If the output voltage shows a much lower reading than that

given in the table indicates that the alternator is defective.

•

To check the stator coil resistance as follows.

○

Stop the engine.

○

Connect the hand tester as shown in the table 2.

○

Note the readings.

Table 2, Stator Coil Resistance

Connections

Tester

Range

Tester (+) to Tester (–) to

Reading

×1Ω

White lead

Black/Red lead 0.2 ∼ 1.0 Ω

If there is more resistance than shown in the table, or no

hand tester reading (∞) the stator has an open lead and

must be replaced. Much less than this resistance means

the stator is shorted, and must be replaced.

•

Using the highest resistance range of the hand tester,

measure the resistance between each leads and chas-

sis ground.

Any hand tester reading less than infinity (∞) indicates a

short, necessitating stator replacement.

If the stator coils have normal resistance, but the voltage

check showed the alternator to be defective; then the rotor

have probably weakened, and the rotor must be replaced.

15-22 ELECTRICAL SYSTEM

Charging System

Charging Voltage Inspection

•

Remove the seat (see Seat Removal in the Frame chap-

ter).

•

Check the battery condition (see Charging Condition In-

spection).

•

Warm up the engine to obtain actual alternator operating

conditions.

•

Connect the hand tester [A] as shown in the table.

Special Tool - Hand Tester: 57001-1394

Charging Voltage

Connections

Tester

Range

Tester (+) to Tester (−)to

Reading

25 V DC

Battery (+)

Terminal

Battery (−)

Terminal

14.4 ±0.5 V

•

Start the engine, and note the voltage readings at various

engine speeds. The readings should show nearly battery

voltage when the engine speeds is low, and, as the engine

speed rises, the readings should also rise. But they must

be kept under the specified voltage.

•

Stop the engine and disconnect the hand tester.

If the charging voltage is kept between the values given in

the table, the charging system is considered to be working

normally.

If the charging voltage is much higher than the values

specified in the table, the regulator/rectifier is defective

or the regulator/rectifier leads are loose or open.

If the charging voltage does not rise as the engine speed

increases, the regulator/rectifier is defective or the alter-

nator output is insufficient for the loads. Check the al-

ternator and regulator/rectifier to determine which part is

defective.

Regulator/Rectifier Inspection

•

Remove the fuel tank cover (see Fuel Tank Removal in

the Fuel System chapter).

•

Clear the igniter and the main relay from the bracket.

•

Remove the bolt [A], and disconnect the connector [B].

ELECTRICAL SYSTEM 15-23

Charging System

KLX140A8 ∼ A9/B8 ∼ B9

•

With the Kawasaki hand tester, measure the internal re-

sistance in both directions between the terminals.

Special Tool - Hand Tester: 57001-1394

If the reading is not the specified value, replace the reg-

ulator/rectifier.

Internal Resistance @20°C (68°F) Unit: kΩ

Tester (+) Lead

Terminal

L B E

(–)* C

– ∞

5 ∼ 50

∞

∞ – ∞ ∞

∞ ∞ – ∞

∞ ∞ ∞ –

(–)*: Tester (–) Lead

KLX140AA ∼ AB ∼/BA ∼ BB ∼

•

With the Kawasaki hand tester, measure the internal re-

sistance in both directions between the terminals.

Special Tool - Hand Tester: 57001-1394

If the reading is not the specified value, replace the reg-

ulator/rectifier.

Internal Resistance @20°C (68°F) Unit: kΩ

Tester (+) Lead

Term in al A B C

(–)* A

–

6.9 ∼ 70

∞

∞ – ∞

∞ ∞ –

(–)*: Tester (–) Lead

NOTICE

Use only Hand Tester 57001-1394 for this test. An

ohmmeter other than the Hand Tester may show

different readings. If a megger or a meter with a

large-capacity battery is used, the regulator will be

damaged.

NOTE

○

Install the regulator/rectifier [A] in parallel with the frame

down tube [B] as shown.

15-24 ELECTRICAL SYSTEM

Charging System

Charging System Circuit (KLX140A8 ∼ AA/B8 ∼ BA)

1. Ignition Switch

2. Load

3. Regulator/Rectifier

4. Starter Relay

5. Main Fuse 10 A

6. Battery 12 V 6 Ah

7. Alternator

ELECTRICAL SYSTEM 15-25

Charging System

Charging System Circuit (KLX140AB ∼/BB ∼)

1. Load

2. Regulator/Rectifier

3. Starter Relay

4. Main Fuse 10 A

5. Battery 12 V 6 Ah

6. Alternator

15-26 ELECTRICAL SYSTEM

Starter Motor Clutch

Starter Motor Clutch Removal

•

Remove the alternator rotor (see Alternator Rotor Re-

moval).

•

Remove the starter motor clutch bolts [A] and the starter

motor clutch.

Starter Motor Clutch Installation

•

Apply a non-permanent locking agent to the starter motor

clutch bolts.

Torque - Starter Motor Clutch Bolts: 12 N·m (1.2 kgf·m, 106

in·lb)

Starter Motor Clutch Inspection

•

Remove:

Alternator Cover (see Alternator Cover Removal)

•

Turn the starter motor clutch gear [A] by hand. The starter

motor clutch gear should turn clockwise [B] freely, but

should not turn counterclockwise [C].

If the starter motor clutch does not operate as it should or

if it makes noise, go to the next step.

•

Disassemble the starter motor clutch, and visually inspect

the clutch parts.

If there is any worn or damaged part, replace it.

NOTE

○

Examine the starter motor clutch gear as well. Replace

it if it worn or damaged.

ELECTRICAL SYSTEM 15-27

Ignition Timing

Ignition Timing Inspection

•

Remove the alternator cover plug [A].

•

Attach the timing light [A] to the ignition coil lead in the

manner prescribed by the manufacturer.

Special Tool - Timing Light: 57001-1241

•

Start the engine and aim the timing light at the ignition

timing mark [B] on the rotor.

•

Run the engine at the speeds specified and note the align-

ment of the ignition timing mark.

○

Check the engine speed, using the engine revolution

tester for high accuracy.

Ignition Timing

Engine speed

[r/min (rpm)]

Head timing mark aligns with:

1400

Line mark on camshaft sprocket

If the ignition timing is incorrect, check the crankshaft sen-

sor (see Crankshaft Sensor Inspection).

If the crankshaft sensor are normal, check the igniter (see

Igniter Inspection).

•

Install the alternator cover plug.

15-28 ELECTRICAL SYSTEM

Ignition System

WARNING

The ignition system produces extremely high volt-

age. Do not touch the spark plug, ignition coil or

high tension lead while the engine is running, or

you could receive a severe electrical shock.

Crankshaft Sensor Removal

•

Refer to the Stator Removal.

Crankshaft Sensor Installation

•

Refer to the Stator Installation.

Ignition Coil Removal/Installation

•

Remove:

Fuel Tank Cover (see Fuel Tank Removal in the Fuel

System chapter)

Ignition Coil Primary Lead Connector [A]

•

Pull the plug cap off the spark plug.

•

Remove the mounting bolts [A] with the collars, and re-

move the ignition coil [B].

•

Installation is the reverse of removal.

•

Install the ignition coil, the frame ground lead and the

clamp correctly (see Cable, Wire and Hose Routing in the

Appendix chapter).

ELECTRICAL SYSTEM 15-29

Ignition System

Ignition Coil Inspection

Measuring Arcing Distance

The most accurate test for determining the condition of

the ignition coil is made by measuring arcing distance using

the coil tester for the 3-needle method.

•

Remove the ignition coil (see Ignition Coil Removal).

•

Connect the ignition coil (with the spark plug cap left in-

stalled on the spark plug lead) [A] to the tester [B], and

measure the arcing distance.

WARNING

To avoid extremely high voltage shocks, do not

touch the coil body or leads.

If the distance reading is less than the specified value, the

ignition coil or spark plug cap is defective.

3 Needle Arcing Distance

Standard: 7 mm (0.26 in.) or more

•

To determine which part is defective, measure the arcing

distance again with the spark plug cap removed from the

ignition coil lead.

If the arcing distance is subnormal as before, the trouble

is with the ignition coil itself. If the arcing distance is now

normal, the trouble is with the spark plug cap.

Measuring Coil Resistance

If the arcing tester is not available, the coil can be

checked for a broken or badly shorted winding with an

ohmmeter. However, an ohmmeter cannot detect layer

shorts and shorts resulting from insulation breakdown

under high voltage.

•

Remove the ignition coil (see Ignition Coil Removal).

•

Measure the primary winding resistance [A].

○

Connect an ohmmeter between the coil terminals.

○

Set the meter to the × 1 Ω range, and read the meter.

•

Measure the secondary winding resistance [B].

○

Unscrew the spark plug cap off the lead.

○

Connect an ohmmeter between the high tension lead and

the ground lead terminal.

○

Set the meter to the × 1 kΩ range, and read the meter.

Ignition Coil Winding Resistance

Primary windings:

0.64

∼ 0.78 Ω at 20°C (68°F)

Secondary windings: 11.4

∼ 14.0 kΩ at 20°C (68°F)

If the meter does not read as specified, replace the coil.

If the meter reads as specified, the ignition coil windings

are probably good. However, if the ignition system still

does not perform as it should after all other components

have been checked, test replace the coil with one known

to be good.

•

Check the spark plug lead for visible damage.

If the spark plug lead is damaged, replace the coil.

Spark Plug Cleaning and Inspection

•

Refer to the Spark Plug Cleaning and Inspection in the

Periodic Maintenance chapter.

15-30 ELECTRICAL SYSTEM

Ignition System

Spark Plug Gap Inspection

•

Refer to the Spark Plug Cleaning and Inspection in the

Periodic Maintenance chapter.

Igniter Removal

•

Remove the fuel tank cover (see Fuel Tank Removal in

the Fuel System chapter).

•

Remove the igniter [A], and disconnect the igniter con-

nector [B].

Igniter Inspection

NOTICE

When inspecting the IC Igniter observe the follow-

ing to avoid damage to the IC Igniter.

Do not disconnect the IC Igniter while the engine is

running.

This may damage the IC Igniter.

Ignition Coil Primary Peak Voltage Check

•

Disconnect the spark plug cap from the spark plug, but do

not remove the spark plug.

•

Connect the good spark plug [A] to the spark plug cap,

then touch the engine with it.

NOTE

○

Measure the voltage with each lead connected cor-

rectly. The correct value may not be obtained if

disconnected.

○

Maintain the correct value of compression pressure for

the cylinder (Be sure to measure the voltage with the

spark plug install to the cylinder head).

•

Connect the peak voltage adapter [B] between the termi-

nal of primary lead (black) and ground connection of the

unit with the lead of the ignition coil [C] connected.

○

Set the tester to DC 250 V range.

Special Tools - Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Needle Adapter Set: 57001-1457

Connection:

Adapter Handtester

Ground [D]

←

Red Lead

→

(+)

Black Lead [E]

←

Black Lead

→

(–)

IC Igniter [F]

Needle Adapter [G]

ELECTRICAL SYSTEM 15-31

Ignition System

•

Shift the gear to the neutral position.

•

Crank the engine by pushing the starter button several

times to measure the peak voltage of the primary ignition

coil.

Ignition Coil Primary Peak Voltage

Standard:

175 V or more

WARNING

Electrical equipment can cause serious electrical

shock. To avoid being shocked, do not touch the

metal portion of the probe when measuring voltage.

If the voltage is less than the specified value, check the

ignition coil (see Ignition Coil Inspection).

If the ignition coil is good, check the other parts (see the

flow chart in this section).

If the all parts are good, replace the igniter.

Crankshaft Sensor Peak Voltage Check

•

To check the peak voltage, do the following procedures.

○

Disconnect the alternator lead connector from the main

harness (see Alternator Cover Removal).

NOTE

○

Measure the voltage with each lead connected cor-

rectly. The correct value may not be obtained if

disconnected.

○

Maintain the correct value of compression pressure for

the cylinder (Be sure to measure the voltage with the

spark plug

installed to the cylinder head).

○

Set the hand tester to DC 10 V range.

○

Connect the peak voltage adapter [A] to the tester and the

terminals of the alternator lead connector [B].

Special Tools - Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Connection:

Adapter Handtester

Blue/Yellow

Lead [C]

←

Red Lead

→

(+)

Ground

←

Black Lead

→

(–)

○

Crank the engine by pushing the starter button several

times with the transmission gear in neutral to measure

the peak voltage of the crankshaft sensor.

Crankshaft Sensor Peak Voltage

Standard:

2Vormore

WARNING

Electrical equipment can cause serious electrical

shock. To avoid being shocked, do not touch the

metal portion of the probe when measuring voltage.

If the voltage is less than the specified, check the crank-

shaft sensor (see Crankshaft Sensor Inspection).

If the crankshaft sensor is good, check the other parts

(see the flow chart in this section).

If the all parts are good, replace the igniter.

15-32 ELECTRICAL SYSTEM

Ignition System

Crankshaft Sensor Inspection

•

Remove:

Alternator Lead Connector (see Alternator Cover Re-

moval).

•

Set the hand tester [A] to the × 10 Ω range and connect

it to the Blue/Yellow lead [B] in the connector and the

ground.

Special Tool - Hand Tester: 57001-1394

If there is more resistance than the specified value, the

coil has an open lead and must be replaced. Much

less than this resistance means the crankshaft sensor is

shorted, and must be replaced.

Crankshaft Sensor Resistance

Standard: 50 ∼ 200 Ω at 20 °C (68 °F)

ELECTRICAL SYSTEM 15-33

Ignition System

15-34 ELECTRICAL SYSTEM

Ignition System

Ignition System Circuit (KLX140A8 ∼ AA/B8 ∼ BA)

1. Ignition Switch

2. Engine Stop Switch

3. Engine Starter Button

4. Main Fuse 10 A

5. Battery 12 V 6 Ah

6. Crankshaft Sensor

7. IC Igniter

8. Ignition Coil

9. Spark Plug

ELECTRICAL SYSTEM 15-35

Ignition System

Ignition System Circuit (KLX140AB ∼/BB ∼)

1. Engine Stop Switch

2. Engine Starter Button

3. Main Fuse 10 A

4. Battery 12 V 6 Ah

5. Spark Plug

6. Ignition Coil

7. IC Igniter

8. Crankshaft Sensor

15-36 ELECTRICAL SYSTEM

Electrical Starter System

Starter Motor Removal

•

Remove:

Exhaust Pipe (see Muffler Removal in the Engine Top

End chapter)

Starter Motor Terminal Nut [A]

Starter Motor Mounting Bolts [B]

Engine Ground [C]

•

Pull out the starter motor [D] to right side.

Starter Motor Installation

NOTICE

Do not tap the starter motor shaft or body. Tapping

the shaft or body could damage the motor.

•

Clean the starter motor mounting surface [A] and the

crankcase surface [B] (mating surface with starter motor

mounting).

•

Replace the O-ring [A] with a new one.

•

Apply grease to the O-ring.

•

Install the starter motor and other removed parts.

Torque - Starter Motor Mounting Bolts: 6.9 N·m (0.70 kgf·m,

61 in·lb)

•

Tighten the starter motor terminal nut while holding the

starter motor terminal locknut.

Torque - Starter Motor Terminal Nut: 5.2 N·m (0.53 kgf·m,

46 in·lb)

Starter Motor Disassembly

•

Remove the starter motor (see Starter Motor Removal).

•

Remove:

Starter Motor Through Bolts [A]

Both End Covers [B]

•

Pull the armature out of the yoke.

•

Remove the terminal locknut [A] and brush plate screws

[B] then remove the brush and the brush plate from the

end cover [C].

Brush Springs [D]

ELECTRICAL SYSTEM 15-37

Electrical Starter System

Starter Motor Assembly

•

Replace the O-ring [A] with a new one.

•

Apply a thin coat of high-temperature grease to the oil seal

and the needle bearing in the end cover [B].

•

Fit the toothed washer [C] into the end cover.

Thin Washer [D]

Thick Washer [E]

•

Install the brush plate [A] and brushes [B], and tighten the

terminal locknut [C].

Torque - Starter Motor Terminal Locknut: 6.9 N·m (0.70

kgf·m, 61 in·lb)

•

Insert the armature [A] between the brushes.

Thin Washer [B]

Thick Washer [C]

•

Align the marks [A] of the yoke and end covers.

Torque - Starter Motor Through Bolts: 4.9 N·m (0.50 kgf·m,

43 in·lb)

Carbon Brush Inspection

•

Measure the length [A] of each brush.

If any one is worn down to the service limit, replace the

carbon brush set [B].

Carbon Brush Length

Standard: 7.0 mm (0.28 in.)

Service Limit: 3.5 mm (0.14 in.)

15-38 ELECTRICAL SYSTEM

Electrical Starter System

Commutator Cleaning and Inspection

•

Smooth the commutator surface [A] if necessary with fine

emery cloth [B], and clean out the grooves.

•

Measure the outer diameter [A] of the commutator [B].

Replace the starter motor with a new one if the commu-

tator diameter is less than the service limit.

Commutator Diameter

Standard: 22.1 mm (0.87 in.)

Service Limit: 21.6 mm (0.85 in.)

Armature Inspection

•

Using the × 1 Ω hand tester range, measure the resis-

tance between any two commutator segments [A].

If there is a high resistance or no reading (∞) between any

two segments, a winding is open and the starter motor

must be replaced.

•

Using the × kΩ hand tester range, measure the resistance

between the segments and the shaft [B].

If there is any reading at all, the armature has a short and

the starter motor must be replaced.

Special Tool - Hand Tester: 57001–1394

NOTE

○

Even if the foregoing checks show the armature to be

good, if may be defective in some manner not readily

detectable with the hand tester. If all other starter motor

and starter motor circuit components check good, but

the starter motor still does not turn over or only turns

over weakly, replace the starter motor with a new one.

Brush Lead Inspection

•

Using the × 1 Ω hand tester range, measure the continuity

between the following:

Terminal Bolt and Positive (+) Brush [A]

End Cover and Negative (–) Brush [B]

If there is not close to zero ohms, the brush lead has an

open. Replace the terminal bolt assembly and the brush

holder assembly.

Special Tool - Hand Tester: 57001–1394

ELECTRICAL SYSTEM 15-39

Electrical Starter System

Terminal Bolt Inspection

•

Using the highest hand tester range, measure the resis-

tance as shown.

Terminal Bolt and End Cover [A]

Terminal Bolt and Negative Brush [B]

If there is any reading, the brush holder assembly and/or

terminal bolt assembly have a short. Replace the brush

holder assembly and the terminal bolt assembly.

Special Tool - Hand Tester: 57001–1394

Starter Relay Inspection

•

Remove the seat (see Seat Removal in the Frame chap-

ter).

•

Disconnect the connector [A].

•

Disconnect the starter motor cable [B] and battery positive

(+) cable [C] from the starter relay [D].

•

Connect the hand tester [A] and 12 V battery [B] to the

starter relay [C] as shown.

If the relay does not work as specified, the relay is defec-

tive. Replace the relay.

Starter Relay Inspection

Tester range:

×1Ω

Standard: When battery is connected → 0 Ω

When battery is disconnected →∞Ω

Special Tool - Hand Tester: 57001–1394

•

Install the cables and other removed parts.

Torque - Starter Relay Terminal Screws: 2.9 N·m (0.30

kgf·m, 26 in·lb)

15-40 ELECTRICAL SYSTEM

Electrical Starter System

Electrical Starter System Circuit (KLX140A8 ∼ AA/B8 ∼ BA)

1. Ignition Switch

2. Engine Stop Switch

3. Engine Starter Button

4. Main Relay

5. Starter Motor

6. Main Fuse 10 A

7. Starter Relay

8. Battery 12 V 6 Ah

9. Starter Lockout Switch

10. Neutral Switch

ELECTRICAL SYSTEM 15-41

Electrical Starter System

Electrical Starter System Circuit (KLX140AB ∼/BB ∼)

1. Engine Stop Switch

2. Engine Starter Button

3. Main Relay

4. Starter Motor

5. Main Fuse 10 A

6. Starter Relay

7. Battery 12 V 6 Ah

8. Neutral Switch

9. Starter Lockout Switch

15-42 ELECTRICAL SYSTEM

Switches and Sensors

Switch Inspection

•

Using the hand tester, check to see that only the con-

nections shown in the table have continuity (about zero

ohms).

Special Tool - Hand Tester: 57001-1394

○

For the ignition switch (KLX140A8 ∼ AA/B8 ∼ BA) and the

left switch housing (KLX140AB ∼/BB ∼), refer to the tables

in the Wiring Diagram.

If the switch has an open or short, repair it or replace it

with a new one.

KLX140A8

∼ AA/B8 ∼ BA

LED Inspection

KLX140A8 ∼ AA/B8 ∼ BA

•

Turn the ignition switch ON.

If the LED on the ignition switch do not light, check the

following parts:

Battery (see Charging Condition Inspection)

Main Fuse 10 A (see Main Fuse 10 A Inspection)

Main Harness (see Wiring Inspection)

If the all parts are good, replace the ignition switch.

KLX140AB

∼/BB ∼

•

Push the engine stop switch to RUN position.

If the LED on the ignition switch do not light, check the

following parts:

Battery (see Charging Condition Inspection)

Main Fuse 10 A (see Main Fuse 10 A Inspection)

Main Harness (see Wiring Inspection)

If the all parts are good, replace the left switch housing.

ELECTRICAL SYSTEM 15-43

Main Relay

Main Relay Inspection

•

Remove the fuel tank cover (see Fuel Tank Removal in

the Fuel System chapter).

•

Remove the main relay [A] from the bracket.

○

Remove the boot and connector.

•

Check conductivity of the following numbered terminals

by connecting the hand tester and one 12 V battery to the

main relay as shown.

If the tester does not read as specified, replace the main

relay.

Main Relay Inspection (with the battery disconnected)

Tester Connection Tester Reading (Ω)

3-5

∞

1-2

Not ∞*

*: The actual reading varies with the hand tester used.

Main Relay Inspection (with the battery connected)

Battery Connection

(+) (–)

Tester Connection

Tester R ead in g

(Ω)

1-2 3-5 0

(+): Apply positive lead.

(–): Apply negative lead.

15-44 ELECTRICAL SYSTEM

Fuses

MainFuse10ARemoval

•

Remove the seat (see Seat Removal in the Frame chap-

ter).

•

Disconnect the starter relay connector [A].

•

Remove the main fuse [B] from the starter relay.

Main Fuse 10 A Inspection

•

Removethefuse(seeMainFuse10ARemoval)andin-

spect the fuse element.

If the fuse element is blown, replace the fuse.

Housing [A]

Fuse Element [B]

Terminal [C]

Blown Element [D]

NOTICE

When replacing a fuse, be sure the new fuse

matches the specified fuse rating for that circuit.

Installation of a fuse with a higher rating may cause

damage to wiring ad components.

APPENDIX 16-1

Appendix

Table of Contents

Cable, Wire, and Hose Routing .............................................................................................. 16-2

Troubleshooting Guide ........................................................................................................... 16-20

16-2 APPENDIX

Cable, Wire, and Hose Routing

KLX140A8 ∼ AA/B8 ∼ BA

APPENDIX 16-3

Cable, Wire, and Hose Routing

1. Throttle Cable

2. Clamps

3. Starter Button Lead

4. Choke Cable

5. Ignition Switch

6. Engine Stop Switch Lead

7. Starter Lockout Switch Lead

8. Run the clutch cable to the front of the engine stop switch lead and starter lockout switch lead.

9. Clutch Cable

10. View from Upside

16-4 APPENDIX

Cable, Wire, and Hose Routing

KLX140AB ∼/BB ∼

APPENDIX 16-5

Cable, Wire, and Hose Routing

1. Throttle Cable

2. Choke Cable

3. Clamp

4. Left Switch Housing Lead

5. Starter Lockout Switch Lead

6. Clamp

7. Run the clutch cable to the front side of the left switch housing lead and starter lockout switch

lead.

8. Clutch Cable

16-6 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 16-7

Cable, Wire, and Hose Routing

1. Choke Cable (Run the choke cable to the right side of the motorcycle.)

2. Throttle Cable (Run the throttle cable to the right side of the motorcycle.)

3. Main Harness

4. Ignition Coil Primary Lead Connector

5. Clamp (Fix the ignition coil primary lead and frame ground lead.)

6. Clutch Cable

7. Clamp

8. Frame Ground Lead

9. View from A

16-8 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 16-9

Cable, Wire, and Hose Routing

1. Engine Stop Switch Connector (2-pins Connector, Natural)

2. Starter Lockout Switch Connector (2-pins Connector, Green)

3. Starter Button Connector (2-pins Connector, Black)

4. Ignition Switch Connector (4-pins Connector, Green)

5. Clamp

6. Regulator/Rectifier

7. Main Relay Connector (Black)

8. Regulator/Rectifier Connector (Green)

9. Install the regulator/rectifier so that the regulator/rectifier and down tube become parallel.

10. Igniter Connectors

11. Alternator Lead Connector (Run the alternator lead to the left side of the motorcycle.)

12. Battery Negative (–) Lead Connector

13. To Battery Negative (–) Terminal

14. Left Switch Housing Lead

15. KLX140AB ∼/BB ∼ Models

16-10 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 16-11

Cable, Wire, and Hose Routing

1. Do not pinch the alternator lead between frame and fuel tank.

2. Starter Motor

3. Install the engine ground lead so that the engine ground lead and starter motor become parallel.

4. Bend the clamps of the frame to fix the main harness and alternator lead.

5. Bend the clamp of the frame to fix the main harness and engine ground lead.

6. Bend the clamp of the frame to fix the starter motor cable.

7. Starter Relay

8. Clamps

9. View from A

10. View from B

11. About 25°

12. Front

16-12 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 16-13

Cable, Wire, and Hose Routing

1. Alternator Lead

2. Run the neutral switch lead along the alternator cover as shown in the figure.

3. Neutral Switch

16-14 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 16-15

Cable, Wire, and Hose Routing

1. Clamp

2. Front Brake Hose

3. Front Brake Disc

4. Front Brake Caliper

5. Clamp

6. Front Brake Master Cylinder

7. View from A-A

8. Install the front brake hose so that it touch the front brake caliper.

9. View from B

10. Rear Brake Hose

11. Rear Brake Master Cylinder

12. Clamps

13. Rear Brake Caliper

14. Rear Brake Disc

16-16 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 16-17

Cable, Wire, and Hose Routing

1. Breather Hose (Run the breather hose to the inside of the frame.)

2. Carburetor

3. Clamp

4. Air Vent Hoses (Run the air vent hoses between the middle engine bracket and engine ground

lead.)

5. Overflow Hose (Run the overflow hose between middle engine bracket and engine ground lead.)

16-18 APPENDIX

Cable, Wire, and Hose Routing

APPENDIX 16-19

Cable, Wire, and Hose Routing

1. Breather Hose

2. Run the breather hose to the left side of the carburetor.

3. Carburetor

4. Air Cleaner Housing

16-20 APPENDIX

Troubleshooting Guide

This is not an exhaustive list, giving every

possible cause for each problem listed. it is

meant simply as a rough guide to assist the

troubleshooting for some of the more common

difficulties.

Engine Doesn’t Start, Starting

Difficulty:

Starter motor not rotating:

Starter lockout switch trouble

Starter motor trouble

Battery voltage low

Starter relay not contacting or operating

Starter button not contacting

Wiring open or shorted

Engine stop switch trouble

Fuse blown

Starter motor rotating but engine doesn’t

turn over:

Starter clutch trouble

Engine won’t turn over:

Valve seizure

Valve lifter seizure

Cylinder, piston seizure

Crankshaft seizure

Connecting rod small end, big end seizure

Transmission gear or bearing seizure

Camshaft seizure

Starter idle gear seizure

No fuel flow:

No fuel in tank

Fuel tank cap air vent obstructed

Fuel tap clogged

Fuel tap turned off

Fuel line clogged

Carburetor float valve clogged

Engine flooded:

Fuel level in carburetor float bowl too high

Float valve worn or jammed with foreign

matter

Starting technique faulty (When flooded,

crank the engine with the throttle fully

opened to allow more air to reach the

engine.)

Fuel/air mixture incorrect:

Idle adjusting screw maladjusted

Pilot jet or air passage clogged

Air cleaner clogged, poorly sealed or miss-

ing

Starter jet clogged

No spark; spark weak:

Spark plug dirty, broken or gap maladjusted

Spark plug cap or high tension wiring trou-

ble

Spark plug cap shorted or not in good con-

tact

Spark plug incorrect heat value

Faulty IC igniter

Crankshaft sensor trouble

Ignition coil trouble

Engine stop switch shorted

Neutral switch trouble

Wiring shorted or open

Rotor damaged

Compression Low:

Spark plug loose

Cylinder head not sufficiently tightened

down

No valve clearance

Cylinder, piston worn

Piston ring bad (worn, weak, broken or

sticking)

Piston ring/groove clearance excessive

Cylinder head gasket damaged

Cylinder head warped

Valvespringbrokenorweak

Valve not seating properly (valve bent, de-

formed, worn or carbon accumulation on

the seating surface)

Poor Running at Low Speed:

Spark weak:

Battery voltage low

Spark plug dirty, broken or gap maladjusted

Spark plug cap or high tension wiring trou-

ble

Spark plug cap shorted or not in good con-

tact

Spark plug incorrect heat value

Faulty IC igniter

Crankshaft sensor trouble

Rotor damaged

Ignition coil trouble

Wiring connector not in good contact

Fuel/air mixture incorrect:

Pilot screw maladjusted

Pilot jet or air passage clogged

Needle Jet or air passage clogged

Air cleaner clogged, poorly sealed or miss-

ing

Choke valve closed

Fuel level in carburetor float bowl too high

or too low

Fuel tank cap air vent obstructed

Fuel tap clogged

Carburetor holder loose

Air cleaner duct loose

Compression low:

Spark plug loose

Cylinder head not sufficiently tightened

down

No valve clearance

Cylinder, piston worn

APPENDIX 16-21

Troubleshooting Guide

Piston ring bad (worn, weak, broken or

sticking)

Piston ring/groove clearance excessive

Cylinder head gasket damaged

Cylinder head warped

Valve spring broken or weak

Valve not seating properly (valve bent, de-

formed, worn or carbon accumulation on

the seating surface)

Other:

Faulty IC igniter

Engine oil level to high

Engine oil viscosity too high

Brake dragging

Drive train trouble

Engine overheating

Clutch slipping

Poor Running or No Power at High

Speed:

Firing incorrect:

Spark plug dirty, broken or gap maladjusted

Spark plug cap or high tension wiring trou-

ble

Spark plug cap shorted or not in good con-

tact

Spark plug incorrect heat value

Faulty IC igniter

Crankshaft sensor trouble

Rotor damaged

Ignition coil trouble

Wiring connector not in good contact

Fuel/air mixture incorrect:

Choke valve closed

Main jet clogged or wrong size

Jet needle or needle jet worn

Air jet clogged

Fuel level in carburetor float bowl too high

or too low

Needle Jet or air passage clogged

Air cleaner clogged, poorly sealed or miss-

ing

Air cleaner duct loose

Water or foreign matter in fuel

Carburetor holder loose

Fuel tank cap air vent obstructed

Fuel tap clogged

Fuel line clogged

Compression low:

Spark plug loose

Cylinder head not sufficiently tightened

down

No valve clearance

Cylinder, piston worn

Piston ring bad (worn, weak, broken or

sticking)

Piston ring/groove clearance excessive

Cylinder head gasket damaged

Cylinder head warped

Valvespringbrokenorweak

Valve not seating properly (valve bent, de-

formed, worn or carbon accumulation on

the seating surface.)

Knocking:

Carbon built up in combustion chamber

Fuel poor quality or incorrect

Spark plug incorrect heat valve

Faulty IC igniter

Crankshaft Sensor trouble

Other:

Throttle valve won’t fully open

Brake dragging

Air cleaner clogged

Water or foreign matter in fuel

Clutch slipping

Overheating

Engine oil level too high

Engine oil viscosity too high

Drive train trouble

Crankshaft bearing worn or damaged

Engine Overheating:

Firing incorrect:

Spark plug dirty, broken or maladjusted

Spark plug incorrect

Faulty IC igniter

Fuel/air mixture incorrect:

Main jet clogged or wrong size

Fuel level in carburetor float bowl too low

Carburetor holder loose

Air cleaner clogged, poorly sealed or miss-

ing

Air cleaner duct loose

Choke valve closed

Compression high:

Carbon built up in combustion chamber

Engine load faulty:

Clutch slipping

Engine oil level too high

Engine oil viscosity too high

Brake dragging

Drive train trouble

Lubrication inadequate:

Engine oil level too low

Engine oil poor quality or incorrect

Clutch Operation Faulty:

Clutch slipping:

No clutch lever play

Clutch cable maladjusted

Clutch inner cable sticking

Friction plate worn or warped

Steel plate worn or warped

Clutch spring broken or weak

16-22 APPENDIX

Troubleshooting Guide

Clutch release function trouble

Clutch hub or housing unevenly worn

Clutch not disengaging properly:

Clutch lever play excessive

Clutch spring compression uneven

Engine oil deteriorated

Engine oil viscosity too high

Engine oil level too high

Clutch housing seized

Clutch release function trouble

Clutch hub nut loose

Clutch plate warped or rough

Clutch hub spline damaged

Gear Shifting Faulty:

Doesn’t go into gear; shift pedal doesn’t

return:

Clutch not disengaging

Shift fork bent, worn, or seized

Shift return spring pin loose

Shift return spring weak or broken

Shift shaft lever broken

Pawl guide plate broken

Shift pawl broken

Shift pawl spring tension lose

Gear seized

Gear set lever operation trouble

Shift drum broken

Jumps out of gear:

Shift fork ear worn, bent

Gear groove worn

Gear dogs and/or dog holes worn

Shift drum groove worn

Gear set lever spring weak or broken

Shift fork guide pin worn

Drive shaft, output shaft and/or gear splines

worn

Overshifts:

Gear set lever spring weak or broken

Pawl guide plate worn

Abnormal Engine Noise:

Knocking:

Faulty IC igniter

Carbon built up in combustion chamber

Fuel poor quality or incorrect

Spark plug incorrect heat value

Overheating

Piston slap:

Cylinder/piston clearance excessive

Cylinder, piston worn

Connecting rod bent

Piston pin, piston pin hole worn

Valve noise:

Valve clearance incorrect

Valvespringbrokenorweak

Camshaft bearing or cam face worn

Valve lifter worn

Other noise:

Connecting rod big end and/or small end

clearance excessive

Piston ring worn, broken or stuck

Piston seizure, damaged

Cylinder head gasket leaking

Exhaust pipe leaking at cylinder head con-

nection

Crankshaft runout excessive

Engine mounts loose

Crankshaft bearing worn

Camshaft chain tensioner trouble

Camshaft chain, sprocket, chain guide worn

Primary gear worn or damaged

Alternator rotor loose

Abnormal Drive Train Noise:

Clutch noise:

Clutch housing finger and friction plate tang

worn

Clutch housing gear worn

Metal chips jammed in clutch housing gear

teeth

Transmission noise:

Bearings worn

Transmission gears worn or chipped

Metal chips jammed in gear teeth

Engine oil insufficient, low viscosity

Drive chain noise:

Drive chain maladjusted

Drive chain worn

Rear and/or engine sprocket worn

Drive chain lubrication insufficient

Rear wheel misaligned

Abnormal Frame Noise:

Front fork noise:

Oil insufficient or too thin

Spring weak or broken

Front fork air pressure high

Rear shock absorber noise:

Shock absorber trouble

Spring weak or broken

Disc brake noise:

Pad surface glazed

Disc warped

Caliper trouble

Pad installed incorrectly

Master cylinder damaged

Other noise:

Bracket, nut, bolt, etc., not properly

mounted or tightened

APPENDIX 16-23

Troubleshooting Guide

Abnormal Exhaust Color:

White smoke:

Piston oil ring worn

Cylinder worn

Valve oil seal damaged

Valve guide worn

Engine oil level too high

Black smoke:

Air cleaner element clogged

Main jet too large or fallen off

Choke valve closed

Fuel level in carburetor float bowl too high

Brown smoke:

Main jet too small

Fuel level in carburetor float bowl too low

Air cleaner duct loose

Air cleaner poorly sealed or missing

Handling and/or Stability

Unsatisfactory:

Handlebar hard to turn:

Cable, hose, wire routing incorrect

Steering stem nut too tight

Steering stem bearing damaged

Steering stem bearing lubrication inade-

quate

Steering stem bent

Tire air pressure too low

Handlebar shakes or excessively vibrates:

Tire worn

Swingarm pivot bearings worn

Rim warped or not balanced

Spokes loose

Wheel bearing worn

Handlebar holder bolt loose

Steering stem head nut loose

Front, rear axle runout excessive

Handlebar pulls to one side:

Frame bent

Rear wheel misalignment

Swingarm bent or twisted

Swingarm pivot shaft bent

Steering maladjusted

Steering stem bent

Front fork bent

Right and left front fork oil level uneven

Suspension operation trouble:

(Too hard)

Tire air pressure too high

Front fork oil excessive

Front fork oil viscosity too high

Rear shock absorber adjustment too hard

Front fork bent

Front fork air pressure too high

(Too soft)

Front fork oil insufficient or leaking

Front fork oil viscosity too low

Rear shock absorber adjusted too soft

Front fork, rear shock absorber spring weak

Rear shock absorber oil or gas leaking

Tire air pressure too low

Brake Doesn’t Hold:

Air in brake system

Pad, disc worn

Brake fluid leakage

Contaminated pad

Brake fluid deteriorated

Brake master cylinder cups damaged

Master cylinder scratched inside

Disc warped

Battery Trouble:

Battery discharged:

Charge insufficient

Battery faulty (too low terminal voltage)

Battery lead making poor contact

Load excessive (e.g., bulb of excessive

wattage)

Alternator trouble

Wiring faulty

Regulator/rectifier trouble

Battery overcharged:

Alternator trouble

Regulator/rectifier trouble

Battery faulty

MODEL APPLICATION

Year Model Beginning Frame No.

2008 KLX140A8 JKBLXPA1□8DA00036

2008 KLX140B8 JKBLXPB1□8DA00040

2009 KLX140A9 JKBLXPA1□9DA03214

2009 KLX140B9 JKBLXPB1□9DA04790

2010 KLX140AA JKBLXPA1□ADA05349

2010 KLX140BA JKBLXPB1□ADA08383

2011 KLX140AB JKBLXPA1□BDA05509

2011 KLX140BB JKBLXPB1□BDA09083

2012 KLX140AC JKBLXPA1□CDA06673

2012 KLX140BC JKBLXPB1□CDA11057

□:This digit in the frame number changes from one machine to another.

Part No.99924-1390-05

Printed in Japan