The KLX140 and KLX140L are versatile off-road motorcycles designed for trail riding and recreational use, produced for the model years 2008 through 2012. These models are recognized for their reliable air-cooled engines, lightweight chassis, and the 'L' variant's enhanced adjustable suspension, making them approachable for entry-level to intermediate riders. The heritage in off-road performance is evident in the KLX140's durable construction and ease of maintenance, contributing to its popularity among enthusiasts seeking a capable and user-friendly machine for exploring diverse terrains. This comprehensive workshop service repair manual provides complete A-Z service and repair procedures for the KLX140 and KLX140L. It covers all essential systems, including the engine, transmission, fuel, ignition, electrical, frame, suspension, and braking systems, offering detailed guidance on routine maintenance, troubleshooting, component repair, disassembly, assembly, and tuning. This manual is an indispensable resource for owners, mechanics, and technicians, ensuring the proper upkeep, repair, and optimal performance of these off-road motorcycles. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX140 Model Variant: KLX140L Model Years Covered: 2008, 2009, 2010, 2011, 2012 Vehicle Type: Off-road Motorcycle Codes Engine Code: Not specified in product info, typically K-series 140cc Chassis Code: Not specified in product info 👋 Introduction Market Position Market Position: Entry-level to intermediate off-road motorcycle, popular for trail riding and recreational use Competitive Analysis Competitors: Honda CRF150F/R, Yamaha TTR125/230, Suzuki DR-Z125 Key Features Key Features: Reliable air-cooled engine, lightweight chassis, adjustable suspension (L model), ease of maintenance 📋 Manual Details Coverage Areas Coverage Scope: Complete Service & Repair Procedures A-Z Page Count Page Count: Not specified in product info, typical for comprehensive manuals is 300-600 pages Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Full engine service, disassembly, assembly, tuning, troubleshooting Transmission: Clutch system, gearbox overhaul, maintenance, adjustment Fuel System: Carburetor (likely Mikuni VM series), fuel tank, fuel lines, troubleshooting Ignition System: CDI unit, spark plug, ignition timing, troubleshooting Cooling System: Air-cooled system, cylinder head fins, oil lubrication Exhaust System: Muffler, header pipe, inspection and maintenance Electrical System: Wiring diagrams, lighting, charging system (stator, battery), troubleshooting Frame And Body: Frame inspection, seat, fenders, plastic components, graphics Suspension Front: Telescopic fork service, oil change, seal replacement, adjustment Suspension Rear: Monoshock suspension, linkage inspection, shock absorber service, adjustment Brakes Front: Hydraulic disc brake, caliper service, pad replacement, fluid flush, rotor inspection Brakes Rear: Drum brake service, adjustment, inspection Wheels And Tires: Spoke wheel maintenance, tire pressure, tire replacement, bearing service Steering: Handlebar, steering stem, bearings, lubrication, adjustment Procedures Included Maintenance: Routine checks, lubrication, filter replacement, chain adjustment, brake adjustment Troubleshooting: Diagnostic procedures for common and uncommon issues across all systems Repair: Step-by-step instructions for component repair and replacement Disassembly Assembly: Complete guidance on dismantling and reassembling all major and minor components Tuning Adjustment: Carburetor tuning, suspension adjustments, brake adjustments, chain tension Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and chassis rebuilds 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: High quality, suitable for printing individual pages or the entire manual Binding Type Binding Type: Not applicable (digital download), but designed for easy printing and binding Paper Type Paper Type: Not applicable (digital download), but original manuals typically use durable, coated paper Software Requirements Software Requirements: Adobe Reader (free download) Accessibility Accessibility: Printable, downloadable to tablets and smartphones ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, 2-valve Displacement: 144 cc (approximately, based on KLX140 designation) Bore X Stroke: 58.0 x 54.4 mm (typical for KLX140, confirm with manual) Compression Ratio: 9.5:1 (typical for KLX140, confirm with manual) Cooling Method: Forced air cooling Performance Horsepower: Estimated 11-13 HP (at crankshaft, actual varies by year/tune) Torque: Estimated 8-9 lb-ft (at crankshaft, actual varies) Fuel System Carburetor Type: Mikuni VM20SS (typical for KLX140, confirm with manual) Fuel Type: Unleaded gasoline Fuel Tank Capacity: 4.5 Liters (approx. 1.2 US gal) Lubrication System Oil Type: SAE 10W-40 API SG or SH (confirm with manual) Oil Capacity: 0.9 Liters (with filter change, confirm with manual) 🔧 Transmission Standard Transmission Type: 5-speed, constant mesh, return type Clutch Type: Wet, multi-disc Features Gear Ratios: Specific ratios will be detailed in the manual (e.g., 1st: 2.538, 2nd: 1.750, 3rd: 1.333, 4th: 1.045, 5th: 0.857) Final Drive: Chain drive Transmission Oil Type: SAE 80 API GL-4 (confirm with manual) 📐 Dimensions Exterior Overall Length: Approx. 1,840 mm (72.4 in) Overall Width: Approx. 750 mm (29.5 in) Overall Height: Approx. 1,065 mm (41.9 in) Wheelbase: Approx. 1,260 mm (49.6 in) Ground Clearance: Approx. 255 mm (10.0 in) Seat Height: Approx. 800 mm (31.5 in) Weights Curb Weight: Approx. 95 kg (209 lbs) 🛡️ Safety Features Ratings Safety Ratings: Not applicable in traditional automotive crash test sense; designed for off-road use Active Features Active Safety: Responsive braking system, predictable handling Passive Features...