Kawasaki KLX140 KLX140L Motorcycle Complete Workshop Service Repair Manual 2008 2009 2010 2011 2012

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Tipo: Motorcycle

Proveedor:

SKU: 76075

Etiquetas: 2008 2009 2010 2011 2012 Kawasaki KLX Series KLX140 KLX140L Motorcycle Motorcycles

Variantes de producto

Descripción

The KLX140 and KLX140L are versatile off-road motorcycles designed for trail riding and recreational use, produced for the model years 2008 through 2012. These models are recognized for their reliable air-cooled engines, lightweight chassis, and the 'L' variant's enhanced adjustable suspension, making them approachable for entry-level to intermediate riders. The heritage in off-road performance is evident in the KLX140's durable construction and ease of maintenance, contributing to its popularity among enthusiasts seeking a capable and user-friendly machine for exploring diverse terrains. This comprehensive workshop service repair manual provides complete A-Z service and repair procedures for the KLX140 and KLX140L. It covers all essential systems, including the engine, transmission, fuel, ignition, electrical, frame, suspension, and braking systems, offering detailed guidance on routine maintenance, troubleshooting, component repair, disassembly, assembly, and tuning. This manual is an indispensable resource for owners, mechanics, and technicians, ensuring the proper upkeep, repair, and optimal performance of these off-road motorcycles.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX140

Model Variant:

KLX140L

Model Years Covered:

2008, 2009, 2010, 2011, 2012

Vehicle Type:

Off-road Motorcycle

Codes

Engine Code:

Not specified in product info, typically K-series 140cc

Chassis Code:

Not specified in product info

👋 Introduction

Market Position

Market Position:

Entry-level to intermediate off-road motorcycle, popular for trail riding and recreational use

Competitive Analysis

Competitors:

Honda CRF150F/R, Yamaha TTR125/230, Suzuki DR-Z125

Key Features

Key Features:

Reliable air-cooled engine, lightweight chassis, adjustable suspension (L model), ease of maintenance

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete Service & Repair Procedures A-Z

Page Count

Page Count:

Not specified in product info, typical for comprehensive manuals is 300-600 pages

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Full engine service, disassembly, assembly, tuning, troubleshooting

Transmission:

Clutch system, gearbox overhaul, maintenance, adjustment

Fuel System:

Carburetor (likely Mikuni VM series), fuel tank, fuel lines, troubleshooting

Ignition System:

CDI unit, spark plug, ignition timing, troubleshooting

Cooling System:

Air-cooled system, cylinder head fins, oil lubrication

Exhaust System:

Muffler, header pipe, inspection and maintenance

Electrical System:

Wiring diagrams, lighting, charging system (stator, battery), troubleshooting

Frame And Body:

Frame inspection, seat, fenders, plastic components, graphics

Suspension Front:

Telescopic fork service, oil change, seal replacement, adjustment

Suspension Rear:

Monoshock suspension, linkage inspection, shock absorber service, adjustment

Brakes Front:

Hydraulic disc brake, caliper service, pad replacement, fluid flush, rotor inspection

Brakes Rear:

Drum brake service, adjustment, inspection

Wheels And Tires:

Spoke wheel maintenance, tire pressure, tire replacement, bearing service

Steering:

Handlebar, steering stem, bearings, lubrication, adjustment

Procedures Included

Maintenance:

Routine checks, lubrication, filter replacement, chain adjustment, brake adjustment

Troubleshooting:

Diagnostic procedures for common and uncommon issues across all systems

Repair:

Step-by-step instructions for component repair and replacement

Disassembly Assembly:

Complete guidance on dismantling and reassembling all major and minor components

Tuning Adjustment:

Carburetor tuning, suspension adjustments, brake adjustments, chain tension

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete engine and chassis rebuilds

📊 Manual Specifications

File Format

File Format:

Portable Document Format (PDF)

Print Quality

Print Quality:

High quality, suitable for printing individual pages or the entire manual

Binding Type

Binding Type:

Not applicable (digital download), but designed for easy printing and binding

Paper Type

Paper Type:

Not applicable (digital download), but original manuals typically use durable, coated paper

Software Requirements

Software Requirements:

Adobe Reader (free download)

Accessibility

Accessibility:

Printable, downloadable to tablets and smartphones

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, SOHC, 2-valve

Displacement:

144 cc (approximately, based on KLX140 designation)

Bore X Stroke:

58.0 x 54.4 mm (typical for KLX140, confirm with manual)

Compression Ratio:

9.5:1 (typical for KLX140, confirm with manual)

Cooling Method:

Forced air cooling

Performance

Horsepower:

Estimated 11-13 HP (at crankshaft, actual varies by year/tune)

Torque:

Estimated 8-9 lb-ft (at crankshaft, actual varies)

Fuel System

Carburetor Type:

Mikuni VM20SS (typical for KLX140, confirm with manual)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

4.5 Liters (approx. 1.2 US gal)

Lubrication System

Oil Type:

SAE 10W-40 API SG or SH (confirm with manual)

Oil Capacity:

0.9 Liters (with filter change, confirm with manual)

🔧 Transmission

Standard

Transmission Type:

5-speed, constant mesh, return type

Clutch Type:

Wet, multi-disc

Features

Gear Ratios:

Specific ratios will be detailed in the manual (e.g., 1st: 2.538, 2nd: 1.750, 3rd: 1.333, 4th: 1.045, 5th: 0.857)

Final Drive:

Chain drive

Transmission Oil Type:

SAE 80 API GL-4 (confirm with manual)

📐 Dimensions

Exterior

Overall Length:

Approx. 1,840 mm (72.4 in)

Overall Width:

Approx. 750 mm (29.5 in)

Overall Height:

Approx. 1,065 mm (41.9 in)

Wheelbase:

Approx. 1,260 mm (49.6 in)

Ground Clearance:

Approx. 255 mm (10.0 in)

Seat Height:

Approx. 800 mm (31.5 in)

Weights

Curb Weight:

Approx. 95 kg (209 lbs)

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable in traditional automotive crash test sense; designed for off-road use

Active Features

Active Safety:

Responsive braking system, predictable handling

Passive Features

Passive Safety:

Durable frame construction, protective body panels

💡 Technology Features

Infotainment

Infotainment Features:

Not applicable for this type of motorcycle; focus is on mechanical function.

Driver Assistance

Driver Assistance Features:

Not applicable.

Connectivity

Connectivity Features:

Not applicable.

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Every 1,000 km or 6 months (typical, refer to manual for exact)

Air Filter Cleaning Interval:

Every 1,000 km or as needed in dusty conditions (typical, refer to manual)

Spark Plug Replacement Interval:

Every 6,000 km or 2 years (typical, refer to manual)

Chain Lubrication Adjustment:

Every 500 km and after washing/riding in rain (typical, refer to manual)

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 (confirm with manual)

Fork Oil Type:

SAE 10W (confirm with manual)

Known Issues

Common Issues:

Carburetor jetting for altitude/temperature, occasional clutch wear with hard use, chain and sprocket wear.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Kawasaki has a long history in motorsports and off-road motorcycles, known for performance and durability.

Model Evolution

Model Evolution:

The KLX140 was introduced to fill a gap in Kawasaki's off-road lineup, offering a capable and user-friendly machine for younger riders and casual trail use. The 'L' variant typically denotes longer suspension travel and a taller seat height.

Production

Production Period:

Introduced in 2008, continuing production with updates through current model years.

🏆 Awards & Recognition

Recognitions

Recognitions:

Often praised by reviews for its ease of use and suitability for beginners and intermediate riders.