Market Niche:
Entry-level and recreational utility ATVs of the mid-1980s.
Competitors:
Competed with models from Honda (e.g., TRX series), Yamaha (e.g., Bravo, Moto-4), and Suzuki.
Vehicle Positioning:
Designed as user-friendly, reliable, and relatively affordable all-terrain vehicles for recreational and light utility use.
Benefit To Owner:
Enables owners to perform all necessary maintenance and repairs, reducing reliance on dealerships and extending the lifespan of the vintage ATV.
Applicable Models:
1984 Kawasaki KLT110 ATV, 1984 Kawasaki KLT160 ATV, 1985 Kawasaki KLT110 ATV, 1985 Kawasaki KLT160 ATV
Estimated Page Count:
Refer to specific OEM manual for exact count; typical for this era could range from 200-400 pages.
Type:
Service Manual / Repair Manual / Shop Manual
Engine:
Comprehensive coverage including disassembly, assembly, inspection, and tuning.
Fuel System:
Carburetor service, fuel tank, fuel lines, and petcock operation.
Lubrication And Cooling:
Oil pump, oil filter, oil passages, and cooling fins.
Transmission Drive Train:
Gearbox operation, clutch, drive chain and sprocket maintenance, lubrication.
Steering System:
Handlebar, steering column, tie rods, and linkage maintenance.
Suspension Shocks:
Front and rear shock absorber service, spring replacement, and adjustment procedures.
Electrical System:
Ignition system, lighting, battery, charging system, starter, wiring diagrams.
Bodywork Frame:
Fenders, racks, plastic components, frame inspection and repair.
Brakes:
Drum brake servicing, linkage adjustment, fluid (if applicable) and component inspection.
Wheels Tires:
Tire pressure, rim inspection, wheel bearing service.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning.
Engine Rebuild:
Complete engine disassembly, inspection of internal components (pistons, rings, valves), reassembly.
Troubleshooting:
Diagnostic flowcharts and step-by-step guides for common and advanced issues.
Carburetor Tuning:
Adjustment of idle speed, air-fuel mixture, and jetting recommendations.
Electrical Diagnostics:
Testing of ignition coil, stator, CDI unit, and voltage regulator.
Suspension Adjustment:
Guidance on adjusting shock pre-load for different riding conditions.
Depth:
Comprehensive, covering everything from basic owner maintenance to full workshop-level repairs and diagnostics.
Engine Type:
4-stroke, air-cooled, SOHC
Klt110 Displacement:
110cc
Klt160 Displacement:
160cc
Bore X Stroke Klt110:
Approx. 53.0 x 49.0 mm (check manual for exact)
Bore X Stroke Klt160:
Approx. 61.0 x 51.0 mm (check manual for exact)
Horsepower Klt110:
Approx. 8-10 HP (estimated)
Horsepower Klt160:
Approx. 11-13 HP (estimated)
Carburetor Type:
Mikuni VM Series (specific model number in manual)
Fuel Tank Capacity:
Approx. 2.3 US gallons (check manual for exact)
Transmission Type:
Automatic CVT (Continuously Variable Transmission) with torque converter and belt drive.
Gear Selection:
Forward, Neutral, Reverse (FN/R) shifter.
Drive Type:
Shaft drive to rear axle.
Clutch Type:
Centrifugal automatic clutch.
Length:
Approx. 71.0 - 73.0 inches (check manual for exact)
Width:
Approx. 38.0 - 40.0 inches (check manual for exact)
Height:
Approx. 41.0 - 42.0 inches (check manual for exact)
Dry Weight Klt110:
Approx. 290 - 300 lbs (check manual for exact)
Dry Weight Klt160:
Approx. 300 - 310 lbs (check manual for exact)
Ground Clearance:
Approx. 5.0 - 6.0 inches (check manual for exact)
Engine Oil Change:
Typically every 1000-1500 km or annually (refer to manual for exact interval and type).
Air Filter Cleaning:
Frequent checks and cleaning/replacement recommended, especially in dusty conditions (check manual).
Drive Chain Lubrication:
Every 500 km or after washing/wet conditions.
Engine Oil Type:
API SE or SF classification, SAE 10W-40 or 20W-40 recommended (refer to manual for specific grade and capacity).
Transmission Oil Type:
Dedicated gearbox oil or specific motorcycle/ATV gear oil (refer to manual for specification).
Carburetor Performance:
Carburetors can become gummed up with age and infrequent use, requiring cleaning and tuning.
Cvt Belt Wear:
The CVT belt can wear over time and require replacement for proper performance.
Electrical Connections:
Corrosion on electrical connectors is common in older ATVs, leading to intermittent issues.
Suspension Seals:
Front fork seals can degrade, leading to oil leaks.
Kawasaki Legacy:
Kawasaki has a long history in powersports, known for reliable and capable off-road vehicles.
Klt Series Introduction:
The KLT series was Kawasaki's initial foray into the three-wheel and later four-wheel ATV market, establishing a foundation for future models.
Production Period:
Mid-1980s, with the KLT110 and KLT160 being key models in their early ATV lineup.
