The Kawasaki KLX140 and KLX140L models represent Kawasaki's commitment to accessible off-road riding, offering a capable and user-friendly experience for new riders and trail enthusiasts. These lightweight motorcycles, produced from 2008 to 2011, feature a reliable air-cooled, 4-stroke, 138 cc engine with a 5-speed transmission and wet, multi-disc clutch. Known for their robust frame construction and effective disc brakes, the KLX series is designed for stability and performance on trails, making them a popular choice in the entry-level dirt bike segment. This comprehensive Factory Service Repair Workshop Manual provides detailed, step-by-step instructions for the complete disassembly, repair, troubleshooting, and maintenance of all major systems on the Kawasaki KLX140 and KLX140L models from 2008 to 2011. Covering everything from the engine and fuel system to the chassis, brakes, suspension, and electrical components, this manual is an essential resource for owners and technicians. Its extensive illustrations and in-depth procedures ensure that all maintenance and repair tasks can be performed accurately and efficiently, helping to keep the motorcycle in optimal condition. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX140 / KLX140L Generation Generation: First Generation (2008-Present) Codes Model Codes Covered: KLX140A8F, KLX140B8F (2008); KLX140A9F, KLX140B9F (2009); KLX140AAF, KLX140BAF (2010); KLX140ABF, KLX140BBF (2011) 👋 Introduction Market Position Vehicle Segment: Lightweight off-road/trail motorcycle, positioned as an accessible entry-level option in the dual-sport/dirt bike category. Target Audience: New riders, younger enthusiasts, and recreational trail riders seeking a user-friendly and capable off-road motorcycle. Competitive Analysis Key Competitors: Honda CRF150F/R, Yamaha TT-R125, Suzuki DR-Z125L Key Features Manual Benefits: Highly detailed factory service manual with extensive illustrations and step-by-step instructions, enabling cost-effective maintenance and repair for owners. 📋 Manual Details Coverage Areas Years Covered: 2008, 2009, 2010, 2011 Model Variants Covered: Includes both standard KLX140 (e.g., KLX140A8F) and long-travel KLX140L (e.g., KLX140B8F) variants. Page Count Estimated Page Count: Hundreds (as per description indicating detailed illustrations and photos) Manual Type Manual Type: Factory Service Repair Workshop Manual Manual Purpose: To facilitate in-depth maintenance, repair, and servicing of the specified Kawasaki KLX140/KLX140L models. Language Language: English Format File Format: PDF File Type Details: Downloadable PDF, accessible via Adobe PDF Reader. 📖 Manual Coverage Systems Covered Major Systems: General Information, Periodic Maintenance, Fuel System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix Engine Systems: Engine Top End (cylinder, piston, valves), Engine Lubrication System (oil pump, passages, filter), Engine Removal/Installation procedures. Drivetrain Systems: Clutch (operation, adjustments, replacement), Crankshaft/Transmission (gearbox components, shifting mechanism), Final Drive (chain, sprockets, adjustments). Chassis Systems: Wheels/Tires (mounting, balancing, pressure), Brakes (hydraulic system, pads, rotors, bleeding), Suspension (forks, rear shock, adjustments), Steering (bearings, linkage), Frame (inspections, repairs). Electrical Systems: Ignition system, lighting, charging system, battery maintenance, wiring diagrams, troubleshooting electrical faults. Procedures Included Repair And Maintenance Procedures: Step-by-step instructions for complete disassembly, repair, troubleshooting, and maintenance of all major vehicle systems. Maintenance Procedures: Detailed steps for routine checks, fluid changes, filter replacements, lubrication, chain adjustment, brake system service, and general cleaning. Repair Procedures: Comprehensive guides for component disassembly, inspection, repair, and reassembly across all major motorcycle systems. Troubleshooting Guides: Diagnostic charts and procedures to identify and resolve common mechanical and electrical issues. Assembly Procedures: Detailed instructions for reassembling components after repair or overhaul, ensuring proper torque values and alignment. Technical Depth Depth Of Coverage: Comprehensive, suitable for both DIY enthusiasts and experienced mechanics, covering detailed disassembly and repair procedures with illustrations. Engine Rebuild Depth: Covers internal engine components, including valve adjustments, piston ring replacement, and full engine teardown. Electrical Diagnostics: Includes wiring diagrams and detailed explanations for diagnosing electrical problems, from simple bulb replacements to complex circuit issues. Diagnostic Capabilities: Provides technical specifications, tolerances, and troubleshooting flowcharts to aid in accurate diagnostics. 📊 Manual Specifications File Format Compatibility: All versions of Windows & Mac Searchability: PDF format typically allows for text searching, enhancing ease of use for finding specific information. Print Quality Printability: All pages are printable Binding Type Binding Type: Digital Download (PDF) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, 4-stroke, SOHC, 2-valve single-cylinder Bore X Stroke: Refer to manual for exact specifications (typically around 56.0 x 54.4 mm for similar displacements). Valve Train: SOHC (Single Overhead Camshaft) with 2 valves per cylinder. Performance Displacement: 138 cc (approximate) Horsepower: Estimated 11-13 HP (actual dyno figures may vary, manual will provide technical data). Fuel System Fuel Delivery: Carburetor (specific model details would be in the manual) Carburetor Model: Likely a Keihin carburetor; specific model and jetting details will be in the manual. 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Optional Clutch Type: Wet, multi-disc Features Transmission Features: Manual operation, direct engagement for optimal power transfer 📐 Dimensions Exterior Seat Height: KLX140: 31.1 in (790 mm); KLX140L: 31.9 in (810 mm) - (Approximate, actual values in manual) Wheelbase: KLX140: 49.2 in...