2008-2011 Kawasaki KLX140 KLX140L Service Repair Workshop Manual Download PDF

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Tipo: Motorcycle

Proveedor:

SKU: 51588

Etiquetas: 2008 2009 2010 2011 Kawasaki KLX Series KLX140 KLX140L Motorcycle Motorcycles

Variantes de producto

Descripción

The Kawasaki KLX140 and KLX140L models represent Kawasaki's commitment to accessible off-road riding, offering a capable and user-friendly experience for new riders and trail enthusiasts. These lightweight motorcycles, produced from 2008 to 2011, feature a reliable air-cooled, 4-stroke, 138 cc engine with a 5-speed transmission and wet, multi-disc clutch. Known for their robust frame construction and effective disc brakes, the KLX series is designed for stability and performance on trails, making them a popular choice in the entry-level dirt bike segment. This comprehensive Factory Service Repair Workshop Manual provides detailed, step-by-step instructions for the complete disassembly, repair, troubleshooting, and maintenance of all major systems on the Kawasaki KLX140 and KLX140L models from 2008 to 2011. Covering everything from the engine and fuel system to the chassis, brakes, suspension, and electrical components, this manual is an essential resource for owners and technicians. Its extensive illustrations and in-depth procedures ensure that all maintenance and repair tasks can be performed accurately and efficiently, helping to keep the motorcycle in optimal condition.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX140 / KLX140L

Generation

Generation:

First Generation (2008-Present)

Codes

Model Codes Covered:

KLX140A8F, KLX140B8F (2008); KLX140A9F, KLX140B9F (2009); KLX140AAF, KLX140BAF (2010); KLX140ABF, KLX140BBF (2011)

👋 Introduction

Market Position

Vehicle Segment:

Lightweight off-road/trail motorcycle, positioned as an accessible entry-level option in the dual-sport/dirt bike category.

Target Audience:

New riders, younger enthusiasts, and recreational trail riders seeking a user-friendly and capable off-road motorcycle.

Competitive Analysis

Key Competitors:

Honda CRF150F/R, Yamaha TT-R125, Suzuki DR-Z125L

Key Features

Manual Benefits:

Highly detailed factory service manual with extensive illustrations and step-by-step instructions, enabling cost-effective maintenance and repair for owners.

📋 Manual Details

Coverage Areas

Years Covered:

2008, 2009, 2010, 2011

Model Variants Covered:

Includes both standard KLX140 (e.g., KLX140A8F) and long-travel KLX140L (e.g., KLX140B8F) variants.

Page Count

Estimated Page Count:

Hundreds (as per description indicating detailed illustrations and photos)

Manual Type

Manual Type:

Factory Service Repair Workshop Manual

Manual Purpose:

To facilitate in-depth maintenance, repair, and servicing of the specified Kawasaki KLX140/KLX140L models.

Language

Language:

English

Format

File Format:

File Type Details:

Downloadable PDF, accessible via Adobe PDF Reader.

📖 Manual Coverage

Systems Covered

Major Systems:

General Information, Periodic Maintenance, Fuel System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix

Engine Systems:

Engine Top End (cylinder, piston, valves), Engine Lubrication System (oil pump, passages, filter), Engine Removal/Installation procedures.

Drivetrain Systems:

Clutch (operation, adjustments, replacement), Crankshaft/Transmission (gearbox components, shifting mechanism), Final Drive (chain, sprockets, adjustments).

Chassis Systems:

Wheels/Tires (mounting, balancing, pressure), Brakes (hydraulic system, pads, rotors, bleeding), Suspension (forks, rear shock, adjustments), Steering (bearings, linkage), Frame (inspections, repairs).

Electrical Systems:

Ignition system, lighting, charging system, battery maintenance, wiring diagrams, troubleshooting electrical faults.

Procedures Included

Repair And Maintenance Procedures:

Step-by-step instructions for complete disassembly, repair, troubleshooting, and maintenance of all major vehicle systems.

Maintenance Procedures:

Detailed steps for routine checks, fluid changes, filter replacements, lubrication, chain adjustment, brake system service, and general cleaning.

Repair Procedures:

Comprehensive guides for component disassembly, inspection, repair, and reassembly across all major motorcycle systems.

Troubleshooting Guides:

Diagnostic charts and procedures to identify and resolve common mechanical and electrical issues.

Assembly Procedures:

Detailed instructions for reassembling components after repair or overhaul, ensuring proper torque values and alignment.

Technical Depth

Depth Of Coverage:

Comprehensive, suitable for both DIY enthusiasts and experienced mechanics, covering detailed disassembly and repair procedures with illustrations.

Engine Rebuild Depth:

Covers internal engine components, including valve adjustments, piston ring replacement, and full engine teardown.

Electrical Diagnostics:

Includes wiring diagrams and detailed explanations for diagnosing electrical problems, from simple bulb replacements to complex circuit issues.

Diagnostic Capabilities:

Provides technical specifications, tolerances, and troubleshooting flowcharts to aid in accurate diagnostics.

📊 Manual Specifications

File Format

Compatibility:

All versions of Windows & Mac

Searchability:

PDF format typically allows for text searching, enhancing ease of use for finding specific information.

Print Quality

Printability:

All pages are printable

Binding Type

Binding Type:

Digital Download (PDF)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 4-stroke, SOHC, 2-valve single-cylinder

Bore X Stroke:

Refer to manual for exact specifications (typically around 56.0 x 54.4 mm for similar displacements).

Valve Train:

SOHC (Single Overhead Camshaft) with 2 valves per cylinder.

Performance

Displacement:

138 cc (approximate)

Horsepower:

Estimated 11-13 HP (actual dyno figures may vary, manual will provide technical data).

Fuel System

Fuel Delivery:

Carburetor (specific model details would be in the manual)

Carburetor Model:

Likely a Keihin carburetor; specific model and jetting details will be in the manual.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Clutch Type:

Wet, multi-disc

Features

Transmission Features:

Manual operation, direct engagement for optimal power transfer

📐 Dimensions

Exterior

Seat Height:

KLX140: 31.1 in (790 mm); KLX140L: 31.9 in (810 mm) - (Approximate, actual values in manual)

Wheelbase:

KLX140: 49.2 in (1250 mm); KLX140L: 50.7 in (1287 mm) - (Approximate).

Weights

Curb Weight:

Approx. 205 lbs (93 kg) - (Actual values may vary by model and trim)

Fuel Capacity:

Approx. 1.0 US gal (3.8 L) - (Check manual for exact figure).

Engine Weight:

Not specified, but engine is compact and lightweight for its class.

🛡️ Safety Features

Ratings

Safety Features:

Disc brakes (front and rear), robust frame construction for stability

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic off-road motorcycle with minimal electronic features).

Driver Assistance

Rider Aids:

N/A (No electronic rider aids like ABS or traction control are typically found on this model).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for specific mileage/time intervals (typically every few thousand miles or annually for typical use).

Spark Plug Replacement:

Recommended at intervals specified in the manual, typically based on mileage or operating hours.

Fluid Specifications

Engine Oil Type:

Kawasaki recommends specific motorcycle-specific oils. Typically SAE 10W-40 API SG or higher with JASO MA rating. Consult manual for exact specification.

Brake Fluid Type:

DOT 3 or DOT 4, depending on specific hydraulic system design. Consult manual for precise specification.

Transmission Oil Type:

Typically the same as engine oil for wet clutch systems. Refer to manual for specific capacity and type (e.g., SAE 10W-40).

Known Issues

Common Wear Items:

Clutch wear, chain and sprocket wear, brake pad wear, air filter maintenance, spark plug replacement are common for this type of vehicle.

Periodic Maintenance Schedule:

The manual will detail a comprehensive schedule covering valve clearance checks, carburetor cleaning, suspension service, and more.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki is renowned for its performance-oriented motorcycles across various segments, from street bikes to off-road and powersports vehicles.

Model Evolution

Klx Lineage:

The KLX line represents Kawasaki's commitment to off-road riding, with the KLX140 serving as a popular model for youth riders and recreational trail use.

Production

Manufacturing Origin:

Primarily manufactured in Japan (specific plant details may be in the manual).

🏆 Awards & Recognition

Recognitions

Industry Recognition:

While specific awards are not listed, the KLX140/KLX140L is generally well-regarded for its reliability and suitability for its intended market.