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Introduction
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Market Position
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Market Segment:
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Entry-level to intermediate off-road recreational motorcycle.
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Competitive Analysis
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Competitors:
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Honda CRF150F, Yamaha TT-R125, Suzuki DR-Z125.
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Key Features
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Intended Use:
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Trail riding, recreational off-road use, beginner riders.
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Engine Type:
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Simple, reliable, air-cooled four-stroke engine.
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Ease Of Use:
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Designed for ease of operation and maintenance, suitable for younger or less experienced riders.
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Klx140L Variant Feature:
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The KLX140L (Big Wheel) variant offers larger wheels and a taller seat height, providing increased ground clearance and a more comfortable fit for larger riders.
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Manual Details
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Coverage
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Applicable Years:
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2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015
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Model Coverage Statement:
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Covers 2008-2011 models primarily, with applicable information for 2012-2015 models due to minor updates. Includes both standard and KLX140L (Big Wheel) variants.
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Page Count
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Page Count:
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332
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Manual Type
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Manual Type:
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Factory Repair Manual / Service Manual
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Language
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Language:
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English
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Format
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Format:
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PDF Download
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File Specifications
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Searchability:
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Yes, text is searchable.
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Print Restrictions:
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No restrictions on printing.
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Save Options:
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Allows saving and burning to disc.
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Manual Coverage
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Systems Covered
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Engine:
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Complete engine tear down and rebuild, including valve adjustments, piston and ring replacement, cylinder head service, crankcase assembly, lubrication system.
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Fuel System:
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Carburetor service (identification, removal, cleaning, adjustment, reassembly), fuel tank, fuel lines, fuel filter replacement.
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Transmission Drivetrain:
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Clutch operation and adjustment, gearshift mechanism, transmission disassembly and reassembly, drive chain maintenance and adjustment.
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Suspension:
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Front fork overhaul (oil change, seal replacement, spring replacement), rear shock absorber inspection and adjustment, swingarm and linkage service.
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Brakes:
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Front and rear brake system inspection, pad replacement, caliper service, brake fluid flush and replacement, lever and pedal adjustment.
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Electrical System:
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Ignition system troubleshooting, CDI unit, spark plug, charging system (stator, rectifier/regulator), battery maintenance, lighting system (headlight, taillight, brake light), starter motor operation.
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Chassis Bodywork:
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Frame inspection, handlebars, triple clamps, seat, fenders, plastic components, exhaust system installation and removal.
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Procedures Included
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General Maintenance:
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Scheduled maintenance intervals, lubrication points, tire pressure checks, chain lubrication and adjustment, oil changes.
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Troubleshooting:
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Comprehensive troubleshooting guides for common problems, including starting issues, engine performance problems, electrical faults, and braking concerns.
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Rebuilds Overhauls:
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Detailed step-by-step procedures for complete engine and component overhauls.
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Technical Data Specs:
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Torque specifications for all fasteners, engine specifications, chassis dimensions, fluid capacities, wiring diagrams, component part numbers.
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Technical Depth
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Depth Level:
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Comprehensive - from basic maintenance to complete engine and chassis rebuilds.
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Visual Aids
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Illustrations Diagrams:
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Includes detailed pictures and part diagrams for clear visual guidance.
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Engine Specifications
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Primary Engine
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Engine Type:
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Four-stroke, SOHC, two-valve, air-cooled
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Displacement:
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138 cc
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Bore X Stroke:
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56.0 x 54.6 mm
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Compression Ratio:
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9.5:1
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Performance
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Horsepower:
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Approx. 11.5 HP @ 8,000 RPM (Estimated, factory spec not always readily published)
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Torque:
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Approx. 8.0 lb-ft @ 6,500 RPM (Estimated, factory spec not always readily published)
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Fuel System
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Carburetor Type:
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Keihin PB20 (constant velocity type)
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Fuel Type:
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Unleaded gasoline
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Lubrication
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Oil Type Specification:
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SAE 10W-40 API SG or SH, JASO MA certified motorcycle oil.
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Oil Capacity:
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1.6 Liters (1.7 US qt) for oil change without filter, 1.8 Liters (1.9 US qt) for oil change with filter, 2.0 Liters (2.1 US qt) after disassembly.
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Starting System
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Starter Type:
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Electric Start (Kick starter also present as backup)
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Maintenance
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Service Intervals
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Engine Oil Change:
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Every 3,000 km (1,800 miles) or 6 months.
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Air Filter Cleaning:
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Every 1,000 km (600 miles) or 3 months, clean more frequently in dusty conditions.
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Valve Clearance Check:
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Every 6,000 km (3,700 miles) or 24 months.
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Spark Plug Replacement:
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Every 6,000 km (3,700 miles) or 24 months.
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Drive Chain Maintenance:
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Lubricate and adjust every 500 km (300 miles) or more frequently if needed.
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Fluid Specifications
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Brake Fluid Type:
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DOT 4
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Coolant Type:
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Not applicable (Air-cooled engine)
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Known Issues
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Common Wear Items:
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Chain and sprockets, brake pads, tires, fork seals due to off-road usage.
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Carburetor Adjustment:
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May require periodic fine-tuning for optimal performance, especially after modifications or significant altitude changes.
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