This manual covers the KLX110 and KLX110L models produced for the 2010 and 2011 model years. These versatile off-road motorcycles are powered by an air-cooled, 111 cc, four-stroke engine, featuring a semi-automatic 4-speed transmission and a wet, multi-disc clutch. Known for their robust engineering and reliability, the KLX line has long been a popular choice for recreational riding and entry-level off-road enthusiasts. The KLX110 is recognized as a leading platform in the mini-motocross and trail riding segment, offering a balance of performance and usability suitable for young riders and general off-road enjoyment.
This comprehensive factory service manual provides detailed workshop and repair information essential for maintaining and servicing your KLX110 or KLX110L. It covers all major systems, including engine top end, lubrication, fuel, crankshaft, transmission, clutch, final drive, wheels, tires, brakes, suspension, steering, and frame. Additionally, the manual includes procedures for periodic maintenance, routine checks, lubrication schedules, and complete disassembly and re-assembly instructions. With hundreds of detailed illustrations and step-by-step guidance, this manual is an invaluable resource for both owners and professional technicians to ensure optimal performance and longevity of the vehicle.
Years Covered:
2010, 2011
Model Codes:
KLX110CAF (2010), KLX110DAF (2010), KLX110CBF (2011), KLX110DBF (2011)
Target Audience:
Owners of 2010-2011 Kawasaki KLX110/KLX110L models, ranging from DIY enthusiasts to professional mechanics.
Value Proposition:
Provides comprehensive factory-level repair and maintenance information at an affordable price, enabling cost-effective vehicle upkeep.
Completeness:
100% complete and intact factory service manual.
Accessibility:
Instant download in a universally compatible PDF format.
Primary Coverage:
Service, Repair, Workshop
Estimated Page Count:
Hundreds of pages (typical for comprehensive service manuals)
Type:
Factory Service Manual / Workshop Manual
Engine Systems:
Top End, Lubrication System, Fuel System, Crankshaft/Transmission
Drivetrain Systems:
Clutch, Final Drive
Chassis Systems:
Wheels/Tires, Brakes, Suspension, Steering, Frame
Electrical Systems:
Electrical System
General Information:
General Information, Periodic Maintenance, Appendix
Emission Controls:
Information related to emission control systems where applicable.
Maintenance Procedures:
Periodic Maintenance, Routine Checks, Lubrication Schedule
Repair Procedures:
Complete Dis-assembly and Re-assembly of Machine, Engine Rebuild, Transmission Overhaul, Suspension Adjustments, Brake Servicing, Electrical Troubleshooting
Wiring Diagrams:
Includes detailed electrical system diagrams for easy diagnosis and repair.
Torque Specifications:
Provides essential torque specifications for engine, chassis, and suspension components.
Diagnostic Capabilities:
Detailed troubleshooting guides, diagnostic charts, and repair procedures for both experienced mechanics and DIY enthusiasts.
Illustration Quality:
Hundreds of detailed illustrations and step-by-step instructions.
Diagnostic Procedures:
Covers troubleshooting for common problems, electrical diagnostics, engine performance issues, and chassis-related faults.
Compatibility:
All versions of Windows & Mac
Requirements:
Adobe PDF Reader, WinZip
Printability:
All pages are printable
Binding:
Digital Download (PDF)
Paper Type:
N/A (Digital)
Engine Type:
Air-cooled, four-stroke, SOHC, four-valve single cylinder
Bore X Stroke:
53.0 x 51.3 mm (typical for this engine)
Compression Ratio:
9.5:1 (typical for this engine)
Cooling System:
Air-cooled
Fuel Delivery:
Keihin PB20 carburetor (typically)
Fuel Type:
Unleaded gasoline
Lubrication System:
Forced lubrication (wet sump)
Transmission Type:
Semi-automatic, 4-speed
Clutch Type:
Wet, multi-disc
Gear Ratios:
Detailed ratios available within the manual.
Overall Length:
Approx. 1700 mm (specific to model variant)
Overall Width:
Approx. 760 mm (specific to model variant)
Overall Height:
Approx. 1015 mm (specific to model variant)
Curb Weight:
Approx. 77 kg (specific to model variant)
Fuel Tank Capacity:
Approx. 3.7 Liters
Front Wheel Size:
14-inch (typical)
Rear Wheel Size:
12-inch (typical)
Front Tire Size:
2.75-14 (typical)
Rear Tire Size:
3.00-12 (typical)
Safety Classification:
Off-road recreational vehicle; no formal crash ratings apply.
Braking System:
Front disc brake, Rear drum brake (typical for this model)
Frame Construction:
Steel backbone frame for durability.
Infotainment System:
N/A (Basic recreational off-road vehicle)
Assistance Features:
N/A (Basic recreational off-road vehicle)
Connectivity Options:
N/A (Basic recreational off-road vehicle)
Oil Change Interval:
Refer to manual for specific intervals (typically every 600-1000 miles or annually).
Spark Plug Check Interval:
Refer to manual for specific intervals (e.g., every 600-1000 miles).
Valve Adjustment Interval:
Refer to manual for specific intervals (e.g., every 1000-1500 miles).
Engine Oil Type:
SAE 10W-40 API SG or higher (refer to manual for exact specification).
Engine Oil Capacity:
Approx. 0.8 Liters (dry fill) - refer to manual.
Brake Fluid Type:
DOT 3 or DOT 4 (if hydraulic, check manual for specifics)
Gear Oil Type:
Refer to manual for specific gear oil viscosity and type.
Common Wear Items:
Tires, brake pads, chain and sprockets, spark plugs, clutch plates.
Potential Trouble Areas:
Carburetor cleaning/adjustment, chain tension, carburetor float bowl leaks (less common).
Kawasaki Legacy:
Kawasaki has a long history in motorcycle manufacturing, known for performance and reliability across various categories, including off-road and motocross.
Klx Lineage:
The KLX110 is a staple in Kawasaki's mini-bike lineup, designed for entry-level riders and off-road fun, with ongoing refinements for performance and usability.
Manufacturing Origin:
Typically manufactured in Japan or other Kawasaki facilities.
Model Accolades:
The KLX110 is widely recognized as a leading platform in the mini-motocross and trail riding segment for young riders and recreational use.
