Market Segment:
Entry-level to mid-range recreational and utility All-Terrain Vehicles (ATVs) of the mid-1980s.
Target Audience:
Owners, mechanics, and enthusiasts of the Kawasaki KLT110 and KLT160 ATVs requiring technical repair and maintenance information.
Competitors:
Competed with ATVs from Yamaha (e.g., Moto-4 series), Honda (e.g., TRX series), Suzuki (e.g., QuadRunner series), and Polaris during its production run.
Vehicle Features:
Known for their ruggedness, simplicity, and suitability for trail riding and light utility tasks. Often featured shaft drive or chain drive systems.
Manual Advantages:
Instant downloadability, ease of use for on-the-spot repairs, printable pages, and lifetime protection policy for lost/damaged files.
Covered Models:
1984 Kawasaki KLT110 ATV, 1984 Kawasaki KLT160 ATV, 1985 Kawasaki KLT110 ATV, 1985 Kawasaki KLT160 ATV
Estimated Page Count:
Estimated 300-500 pages (typical for comprehensive service manuals of this era, exact count not specified)
Type:
Service Manual / Repair Manual / Shop Manual
Engine:
Comprehensive coverage including disassembly, inspection, reassembly, tuning, and troubleshooting of engine components.
Fuel System:
Detailed information on carburetor operation, adjustment, cleaning, fuel pump, and fuel lines.
Lubrication And Cooling:
Lubrication system components, oil pump, oil filter (if applicable), cooling system (air-cooled), and related maintenance.
Transmission Drive Chain:
Service and adjustment of the drive chain, sprockets, and potentially internal transmission components (e.g., centrifugal clutch, gearbox).
Steering:
Components of the steering system, linkage, adjustments, and common wear points.
Shocks Suspension:
Service and maintenance for front and rear shock absorbers, suspension linkages, and adjustment procedures.
Bodywork:
Information related to fenders, racks, plastics, and basic body panel removal/installation.
Intake Exhaust:
Air filter service, intake manifold, exhaust system components, and muffler maintenance.
Electrical System:
Wiring diagrams, ignition system, lighting, battery, starter (if applicable), and basic troubleshooting of electrical faults.
Routine Maintenance:
Covers all essential routine maintenance tasks, including fluid changes, filter replacements, lubrication, and general inspections.
Engine Rebuild:
Detailed step-by-step procedures for engine removal, disassembly, component inspection, measurement, repair, and reassembly.
Troubleshooting:
Advanced troubleshooting guides and diagnostic flowcharts for identifying and resolving common and complex issues.
Component Replacement:
Instructions for replacing wear items and major components across all covered systems.
Adjustments:
Specific procedures for adjusting carburetor settings, ignition timing, brakes, and suspension.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, including diagnostic procedures.
Type Klt110:
4-stroke, air-cooled, single-cylinder OHC (Overhead Cam)
Displacement Klt110:
Approximately 110cc (Specific cubic centimeter measurement would be in the manual)
Bore Stroke Klt110:
Specific measurements will be detailed in the manual (e.g., 52.0 mm x 51.8 mm or similar)
Type Klt160:
4-stroke, air-cooled, single-cylinder OHC (Overhead Cam)
Displacement Klt160:
Approximately 160cc (Specific cubic centimeter measurement would be in the manual)
Bore Stroke Klt160:
Specific measurements will be detailed in the manual (e.g., 60.0 mm x 56.0 mm or similar)
Horsepower Klt110:
Estimated 7-9 HP (Exact figures in manual)
Horsepower Klt160:
Estimated 9-11 HP (Exact figures in manual)
Torque Specifications:
Specific torque figures for various engine fasteners and components will be detailed in the manual.
Carburetor Type:
Single Mikuni carburetor (likely VM series, specific model number in manual)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Typically around 2.0-2.5 gallons (specific capacity for each model in manual)
Type:
Automatic (likely CVT - Continuously Variable Transmission, or a torque converter with planetary gears).
Gear Selection:
Likely High/Low range, Reverse, Neutral.
Drive System:
Shaft drive (KLT110) or Chain drive (KLT160, though some KLT110 models also used chain drive - manual will clarify).
Transmission Fluid Type:
Specific transmission fluid type and capacity will be listed in the manual.
Wheelbase Klt110:
Approximately 44.5 inches (Manual will provide precise figure)
Wheelbase Klt160:
Approximately 46.5 inches (Manual will provide precise figure)
Dry Weight Klt110:
Approximately 300 lbs (Manual will provide exact figure)
Dry Weight Klt160:
Approximately 320 lbs (Manual will provide exact figure)
Payload Capacity:
Specific payload and towing capacities would be detailed in the manual.
Front Tire Size Klt110:
Typically 22x8-10 or similar (Manual will specify exact sizes and pressures)
Rear Tire Size Klt110:
Typically 22x10-10 or similar (Manual will specify exact sizes and pressures)
Front Tire Size Klt160:
Typically 22x8-10 or similar (Manual will specify exact sizes and pressures)
Rear Tire Size Klt160:
Typically 22x10-10 or similar (Manual will specify exact sizes and pressures)
Safety Standards:
Manufactured to meet AT V safety regulations of the era; no specific star ratings apply.
Braking System:
Drum brakes, front and rear (typical for the era). Specific brake component service and adjustment covered.
Parking Brake:
Mechanical parking brake mechanism (details on operation and maintenance will be in manual).
Rollover Protection:
N/A (Standard ATV design without ROPS)
Oil Change Interval:
Typically every 100-200 hours or annually, depending on usage. Specific recommendation in manual.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions. Specific intervals based on inspection.
Spark Plug Replacement:
Typically every 1,000-1,500 miles or annually. Specific spark plug type and gap in manual.
Engine Oil Type:
Likely SAE 10W-30 or 20W-40 API SE, SF or SG classification. Manual will confirm specific viscosity and API rating.
Engine Oil Capacity:
Approximately 1.5-2.0 quarts (manual will provide exact capacity).
Brake Fluid Type:
DOT 3 or DOT 4 (if hydraulic brakes are present; check manual if drum brakes are all that is present).
Common Wear Items:
Drive chains and sprockets, wheel bearings, suspension bushings, carburetor jets (clogging), and brake components are common wear items for this era.
Carburetor Issues:
Carburetors can be prone to clogging due to fuel contamination or age, affecting fuel delivery and engine performance.
Electrical Gremlins:
Aging wiring harnesses, corroded connections, and failing ignition components can lead to intermittent electrical issues.
Kawasaki Atv History:
Kawasaki has a long history of producing motorcycles and powersports vehicles, entering the ATV market with robust and reliable machines.
Klt Series Evolution:
The KLT series represented Kawasaki's early offerings in the ATV market, focusing on practical utility and recreational riding. The KLT160 was an evolution from smaller displacement models, offering more power.
Production Years Klt110:
1984-1985 (for this specific manual's coverage)
Production Years Klt160:
1984-1985 (for this specific manual's coverage)
