🏷️ Basic Information

Make:

Kawasaki

Model:

KLX140 / KLX140L

Product Type:

Service & Repair Workshop Manual

Manual Identifier:

Service & Repair Workshop Manual Download PDF

Model Years Covered:

2008, 2009, 2010, 2011, 2012

👋 Introduction

Target Audience:

Owners performing DIY maintenance and repair, professional mechanics

Instruction Detail:

Full coverage of all repairs, servicing, and troubleshooting

Resource Type:

Professionally produced workshop manual, equivalent to factory documentation

📋 Manual Details

Coverage:

Complete factory service, repair, and troubleshooting procedures

Estimated Pages:

Hundreds (specific count not provided, but described as extensive)

Type:

Professional Workshop Manual

Language:

English (implied by typical manual content)

Format:

Downloadable PDF

📖 Manual Coverage

Engine:

Engine disassembly, assembly, tuning, lubrication, cooling system

Fuel System:

Carburetor (model specific), fuel delivery, fuel tank

Ignition System:

CDI ignition, spark plug, ignition timing

Transmission:

Clutch operation, gearbox internals, shifting mechanisms

Chassis:

Frame, suspension (front forks, rear shock), steering system

Wheels Tires:

Wheel bearing maintenance, spoke tension, tire pressure recommendations

Brakes:

Front and rear brake system, hydraulic lines, brake pad replacement, bleeding procedure

Electrical System:

Wiring diagrams, battery maintenance, lighting system, starter system

Bodywork:

Fairings, seat, fuel tank removal and installation, fenders

Maintenance:

Routine servicing, lubrication points, filter replacement

Troubleshooting:

Diagnostic procedures for common problems, fault finding guides

Tune Up:

Carburetor adjustment, valve clearance checks, spark plug replacement

Engine Rebuild:

Piston, rings, cylinder, crankshaft, camshaft installation and specifications

Suspension Service:

Fork seal replacement, shock absorber service

Brake Service:

Brake fluid change, caliper service, master cylinder inspection

Electrical Diagnostics:

Testing of components, troubleshooting electrical faults

Cable Adjustment:

Throttle cable, clutch cable adjustments

Depth:

Comprehensive: from basic maintenance to complete engine and chassis overhauls

Diagrams:

Hundreds of detailed photos and exploded diagrams

Instructions:

Step-by-step instructions for all procedures

📊 Manual Specifications

Format:

PDF

Compatibility:

Windows and MAC computers

Print Capability:

Printable (single pages or entire manual)

Licensing:

Unlimited use on multiple devices, no expiry date, no renewal fees

⚙️ Engine Specifications

Engine Type:

4-stroke, SOHC, 2-valve, Single Cylinder

Displacement:

144 cc (KLX140/KLX140L)

Bore X Stroke:

58.0 x 54.4 mm (typical for this class)

Cooling System:

Air-cooled

Carburetor:

Keihin PB20 (typical for KLX140 models)

Horsepower:

Approx. 11.7 HP @ 8000 RPM (estimated, specific dyno results vary)

Torque:

Approx. 8.7 lb-ft @ 6500 RPM (estimated, specific dyno results vary)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

4.0 L (1.06 US gal)

🔧 Transmission

Type:

5-speed constant mesh, return shift

Clutch Type:

Wet, multi-disc

Final Drive:

Chain drive

📐 Dimensions

Overall Length:

KLX140L: 1960 mm (77.2 in) / KLX140: 1840 mm (72.4 in)

Overall Width:

740 mm (29.1 in)

Overall Height:

KLX140L: 1160 mm (45.7 in) / KLX140: 1115 mm (43.9 in)

Wheelbase:

KLX140L: 1355 mm (53.3 in) / KLX140: 1275 mm (50.2 in)

Curb Weight:

KLX140L: 106 kg (233.7 lbs) / KLX140: 99 kg (218.3 lbs)

Seat Height:

KLX140L: 860 mm (33.9 in) / KLX140: 800 mm (31.5 in)

🛡️ Safety Features

Frame Construction:

High-tensile steel perimeter frame

Lighting:

Halogen headlight, LED taillight

💡 Technology Features

Features:

Basic digital display (odometer, trip meter, clock) - no advanced infotainment system.

Features:

No electronic rider aids; focus is on mechanical simplicity and rider skill.

🔧 Maintenance

Oil Change:

Every 3000 km (1860 miles) or 6 months (consult manual for exact figures)

Air Filter Cleaning:

Every 1000 km (620 miles) or as needed based on riding conditions

Valve Clearance Check:

Every 6000 km (3730 miles) or 12 months

Engine Oil:

SAE 10W-40 API SG or higher (recommend using Kawasaki genuine oil or equivalent)

Engine Oil Capacity:

1.4 L (1.5 US qt) without filter change / 1.5 L (1.6 US qt) with filter change

Brake Fluid:

DOT 4

Carburetor Tuning:

Can sometimes require fine-tuning for optimal performance at different altitudes or temperatures.

Chain Maintenance:

Regular cleaning and lubrication of the drive chain is crucial for longevity and performance.

📚 Vehicle History

Kawasaki Offroad:

Kawasaki has a long-standing reputation in off-road motorcycles, with the KLX lineage tracing back several decades.

Klx140 Introduction:

The KLX140 series was introduced to cater to riders seeking a capable, user-friendly off-road machine bridging the gap between smaller beginner bikes and larger, more complex models.

Klx140L Variant:

The 'L' designation typically signifies a longer seat and higher suspension for taller riders or a more aggressive riding stance.

🏆 Awards & Recognition

General Reputation:

While specific awards for these model years are not widely publicized, the KLX140 series is generally well-regarded in the entry-level and youth off-road segment for its reliability and ease of use.