🏷️ Basic Information Identification Make: Kawasaki Model: KLX140 / KLX140L Product Type: Service & Repair Workshop Manual Manual Identifier: Service & Repair Workshop Manual Download PDF Codes Model Years Covered: 2008, 2009, 2010, 2011, 2012 👋 Introduction Market Position Target Audience: Owners performing DIY maintenance and repair, professional mechanics Key Features Instruction Detail: Full coverage of all repairs, servicing, and troubleshooting Resource Type: Professionally produced workshop manual, equivalent to factory documentation 📋 Manual Details Coverage Areas Coverage: Complete factory service, repair, and troubleshooting procedures Page Count Estimated Pages: Hundreds (specific count not provided, but described as extensive) Manual Type Type: Professional Workshop Manual Language Language: English (implied by typical manual content) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered 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 Procedures Included 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 Technical Depth 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 File Format Format: PDF Compatibility: Windows and MAC computers Print Quality Print Capability: Printable (single pages or entire manual) Usage Rights Licensing: Unlimited use on multiple devices, no expiry date, no renewal fees ⚙️ Engine Specifications Primary Engine 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) Performance 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 System Fuel Type: Unleaded gasoline Fuel Tank Capacity: 4.0 L (1.06 US gal) 🔧 Transmission Standard Type: 5-speed constant mesh, return shift Features Clutch Type: Wet, multi-disc Final Drive: Chain drive 📐 Dimensions Exterior 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) Weights 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 Passive Features Frame Construction: High-tensile steel perimeter frame Lighting: Halogen headlight, LED taillight 💡 Technology Features Infotainment Features: Basic digital display (odometer, trip meter, clock) - no advanced infotainment system. Driver Assistance Features: No electronic rider aids; focus is on mechanical simplicity and rider skill. 🔧 Maintenance Service Intervals 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 Fluid Specifications 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 Known Issues 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 Brand Heritage Kawasaki Offroad: Kawasaki has a long-standing reputation in off-road motorcycles, with the KLX lineage tracing back several decades. Model Evolution 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 Recognitions 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.