This manual covers the KLX110 models manufactured between 2010 and 2014. The KLX110, known by its generation code KLX110 (A1-A5), is a versatile off-road motorcycle celebrated for its robust engineering and reliability, making it a popular choice for recreational riding and youth competition. Its design emphasizes rider control and durability, reflecting a strong heritage in performance motorcycle manufacturing. The vehicle features a four-stroke, air-cooled single-cylinder engine with a displacement of 112 cm³, delivering approximately 8.7 horsepower, and a 4-speed semi-automatic transmission with a wet, multi-disc clutch. This comprehensive service and repair manual provides full service repair coverage for the KLX110. It is meticulously designed to assist professional technicians and advanced DIY enthusiasts in maintaining and repairing the vehicle. The manual details procedures for engine overhaul, transmission service, electrical systems, chassis and suspension, brakes, fuel and exhaust systems, and bodywork. It also includes scheduled maintenance guidance, troubleshooting diagnostics, and rebuilding instructions, all presented with detailed illustrations and numbered steps for clarity. Safety notes, cautions, and warnings are integrated throughout the repair procedures to ensure safe and effective servicing. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX110 Years Covered: 2010, 2011, 2012, 2013, 2014 Generation Generation Code: KLX110 (A1-A5) 👋 Introduction Market Position Target Audience: Professional technicians and advanced DIY enthusiasts. Competitive Analysis Value Proposition: Provides professional-level repair and maintenance information, saving costs on professional servicing. Key Features Illustration Quality: Detailed illustrations, drawings, and photos with enlarged inset views for clarity. Instruction Format: Numbered steps with bold figure numbers for easy reference. Navigation: Numbered table of contents for quick information retrieval. Safety Notes: Notes, cautions, and warnings integrated within repair procedures. 📋 Manual Details Coverage Areas Coverage Scope: Full Service Repair Page Count Estimated Page Count: Information not explicitly stated, but implied to be comprehensive. Manual Type Type: Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service: Complete engine overhaul, top end, bottom end, cooling system, lubrication. Transmission Service: Clutch, gearbox, shifting mechanism, lubrication. Electrical System: Ignition system, lighting, charging system, starting system, wiring diagrams. Chassis Suspension: Front forks, rear shock absorber, swingarm, steering system. Brakes: Front and rear brake systems, hydraulic components, pads, rotors. Fuel System: Carburetor, fuel lines, fuel tank. Exhaust System: Muffler, exhaust pipes, mounting hardware. Wheels Tires: Wheel bearing service, tire replacement, spoke tension. Bodywork: Fairings, fenders, seat, fuel tank cover. Procedures Included Maintenance: Scheduled maintenance, lubrication points, filter replacement, valve clearance adjustment. Troubleshooting: Detailed diagnostic procedures for common and uncommon issues, electrical troubleshooting. Repair: Step-by-step instructions for component repair, disassembly, and reassembly. Rebuilding: Comprehensive procedures for engine rebuilds, transmission overhauls, and suspension rebuilds. Restoration: Guidance on refurbishing and restoring the vehicle to original specifications. Electrical Diagnostics: Combined with detailed wiring diagrams for effective electrical system fault finding. Technical Depth Depth: Professional Technician Level, with adequate data for DIY mechanics. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Full Printable Pages Binding Type Binding: Digital Download (Printable) Paper Type Paper Type: N/A (Digital) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinRAR Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, 2-valve, Air-cooled single cylinder Displacement: 112 cm³ (6.8 cu in) Bore X Stroke: 53.0 x 53.0 mm (2.1 x 2.1 in) Compression Ratio: 9.7:1 Performance Horsepower: Approx. 8.7 hp @ 7,500 rpm (Varies slightly by model year and market) Torque: Approx. 9.0 Nm @ 5,500 rpm (Varies slightly by model year and market) Fuel System Carburetor Type: Keihin PB20 (specific model may vary) Fuel Type: Unleaded gasoline Lubrication Oil Type: SAE 10W-40 API SG or SH Oil Capacity: 0.7 L (0.7 US qt) for filter change 🔧 Transmission Standard Transmission Type: Automatic (4-speed semi-automatic clutch operation) Optional Transmission Options: N/A (standardized for KLX110 models) Features Clutch Type: Wet, multi-disc Final Drive: Chain drive 📐 Dimensions Exterior Overall Length: Approx. 1,675 mm (66.0 in) Overall Width: Approx. 735 mm (28.9 in) Overall Height: Approx. 1,020 mm (40.2 in) Wheelbase: Approx. 1,170 mm (46.1 in) Ground Clearance: Approx. 255 mm (10.0 in) Weights Curb Weight: Approx. 77 kg (169.8 lbs) 🛡️ Safety Features Ratings Safety Ratings: Not applicable for off-road motorcycles in the same way as street vehicles. Active Features Braking System: Disc brakes front and rear for effective stopping power. Passive Features Frame Construction: High-tensile steel perimeter frame for durability and rider control. 💡 Technology Features Infotainment Infotainment Features: Basic motorcycle instrumentation (speedometer, odometer, indicator lights). No advanced infotainment systems. Driver Assistance Assistance Systems: N/A (off-road motorcycle focus on rider control and feedback). Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 1,000 km (600 miles) or 6 months, whichever comes first. Air Filter Cleaning: Every 600 km (375 miles) or 3 months. Valve Clearance Check: Every 6,000 km (3,700 miles)...