GENERAL INFORMATION 1-1
General Information
Table of Contents
1
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.
Before Servicing
GENERAL INFORMATION 1-3
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 per- formance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling
Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a Non-permanent Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or Non-permanent locking agent. Do not apply them ex- cessively. Excessive application can clog oil passages and cause serious damage.
Before Servicing
GENERAL INFORMATION 1-5
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.
Model Identification
GENERAL INFORMATION 1-7
KLX140A8F Left Side View
KLX140A8F Right Side View
Frame Number Engine Number
1-8 GENERAL INFORMATION
Model Identification
KLX140B8F Left Side View
KLX140B8F Right Side View
General Specifications
GENERAL INFORMATION 1-9
Dimensions
Items KLX140A8F ∼ ABF KLX140B8F ∼ BBF
Overall Length 1 820 mm (71.65 in.) 1 895 mm (74.61 in.) Overall Width 790 mm (31.1 in.) ←
Overall Height 1 050 mm (41.34 in.) 1 075 mm (42.32 in.) Wheelbase 1 260 mm (49.61 in.) 1 285 mm (50.59 in.) Road Clearance 235 mm (9.25 in.) 255 mm (10.0 in.) Seat Height 780 mm (30.7 in.) 800 mm (31.5 in.) Dry Mass:
KLX140A8F/B8F 88 kg (194 lb) 90 kg (198 lb) Curb Mass:
KLX140A9F ∼/B9F ∼ 93 kg (205 lb) 95 kg (209 lb)
Front 45 kg (99 lb) 46 kg (101 lb) Rear 48 kg (105 lb) 49 kg (108 lb)
Fuel Tank Capacity 5.8 L (1.5 US gal) ←
Performance
Minimum Turning Radius – ←
Engine
Type 4-stroke, single cylinder, SOHC ← Cooling System Air-cooled ← Bore and Stroke 58.0 × 54.4 mm (2.28 × 2.14 in.) ← Displacement 144 cm³ (8.79 cu in.) ← Compression Ratio 9.5 : 1 ← Carburetion System Carburetor, KEIHIN PB20 ← Starting System Electric starter ← Ignition System DC-CDI ← Timing Advance
Ignition Timing BTDC 10° @1 400 r/min (rpm) ∼
BTDC 30° @4 000 r/min (rpm) ←
Spark Plug NGK CR7HSA ←
Valve Timing: Intake:
Open BTDC 30° ← Close ABDC 44° ← Duration 254° ←
Exhaust:
Open BBDC 45° ← Close ATDC 35° ← Duration 260° ← Lubrication System Forced lubrication (wet sump) ←
Engine Oil:
Type API SG, SH, SJ, SL or SM with
JASO MA, MA1 or MA2 ←
Viscosity SAE 10W-40 ←
Capacity 1.1 L (1.2 US qt) ←
1-10 GENERAL INFORMATION
General Specifications
Drive Train
Items KLX140A8F ∼ ABF KLX140B8F ∼ BBF
Primary Reduction System:
Type Gear ← Reduction Ratio 2.880 (72/25) ← Clutch Type Wet, multi disc ←
Transmission:
Type 5-speed ←
Gear Ratios:
1st 2.667 (40/15) ←
2nd 1.895 (36/19) ←
3rd 1.474 (28/19) ←
4th 1.182 (26/22) ←
5th 1.000 (24/24) ←
Final Drive System:
Type Chain drive ←
Reduction Ratio 3.571 (50/14) 3.923 (51/13) Overall Drive Ratio 10.286 @Top gear 11.298 @Top gear
Frame
Type Tube double cradle ← Steering Angle 41° to either side ← Caster (rake angle) 27° ←
Trail 85 mm (3.3 in.) 96 mm (3.8 in.) Front Tire:
Size 70/100-17 40M 70/100-19 42M Make/Type IRC, IX05H, Tube ←
Rear Tire:
Size 90/100-14 49M 90/100-16 52M Make/Type IRC, IX05H, Tube ←
Rim Size:
Front 17 × 1.40 19 × 1.40
Rear 14 × 1.60 16 × 1.85
Front Suspension:
Type Telescopic fork ←
Wheel Travel 180 mm (7.09 in.) ←
Rear Suspension:
Type Swingarm (Uni-trak) ←
Wheel travel 180 mm (7.09 in.) ←
Brake Type:
Front and Rear Single disc ←
Effective Disc Diameter:
Front (effect. dia.) 192 mm (7.56 in.) ←
Rear (effect. dia.) 150 mm (5.91 in.) ←
General Specifications
GENERAL INFORMATION 1-11
Items KLX140A8F ∼ ABF KLX140B8F ∼ BBF Electrical Equipment
Battery 12 V 6 Ah ←
Alternator:
Rated Output 4.8 A/14 V @9 000 r/min (rpm) ←
Specifications subject to change without notice, and may not apply to every country.
1-12 GENERAL INFORMATION
Unit Conversion Table
Prefixes for Units:
Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c × 0.01
milli m × 0.001 micro µ × 0.000001
Units of Mass:
kg × 2.205 = lb g × 0.03527 = oz
Units of Volume:
L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L × 1.057 = qt (US)
L × 0.8799 = qt (imp)
L × 2.113 = pint (US) L × 1.816 = pint (imp) mL × 0.03381 = oz (US) mL × 0.02816 = oz (imp) mL × 0.06102 = cu in
Units of Force:
N × 0.1020 = kgf N × 0.2248 = lb kgf × 9.807 = N kgf × 2.205 = lb
Units of Length:
km × 0.6214 = mile m × 3.281 = ft mm × 0.03937 = in
Units of Torque:
N·m × 0.1020 = kgf·m N·m × 0.7376 = ft·lb N·m × 8.851 = in·lb kgf·m × 9.807 = N·m kgf·m × 7.233 = ft·lb kgf·m × 86.80 = in·lb
Units of Pressure:
kPa × 0.01020 = kgf/cm²
kPa × 0.1450 = psi
kPa × 0.7501 = cm Hg kgf/cm² × 98.07 = kPa kgf/cm² × 14.22 = psi
cm Hg × 1.333 = kPa
Units of Speed:
km/h × 0.6214 = mph
Units of Power:
kW × 1.360 = PS kW × 1.341 = HP PS × 0.7355 = kW
PS × 0.9863 = HP
Units of Temperature:
