This manual covers the KLX140 and KLX140L, lightweight, entry-level off-road motorcycles produced from approximately 2008 through 2011. These models are designed for beginner and youth riders seeking an accessible and enjoyable off-road experience. The KLX140L variant offers a taller seat height and potentially longer suspension travel, catering to larger riders or those preferring a higher riding position. Built with a strong steel frame and powered by a reliable 138 cc air-cooled four-stroke engine, these motorcycles are engineered for durability and performance on trails. This comprehensive Service Repair Manual provides detailed information essential for the maintenance and repair of your KLX140/KLX140L. It covers all critical areas, including general information, periodic maintenance, fuel system, engine top-end and lubrication, clutch and transmission, wheels, tires, final drive, brakes, suspension, steering, electrical system, and frame. With step-by-step procedures, troubleshooting guides, torque specifications, and clear wiring diagrams, this manual is an invaluable resource for owners and technicians to ensure optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX140 / KLX140L Model Codes: KLX140A8F, KLX140B8F (2008), KLX140A9F, KLX140B9F (2009), KLX140AAF, KLX140BAF (2010), KLX140ABF, KLX140BBF (2011) Generation Generation: First Generation Codes Vin Code Applicability: 8th digit of VIN corresponds to model year (e.g., 8 for 2008, 9 for 2009, A for 2010, B for 2011) 👋 Introduction Market Position Vehicle Segment: Lightweight, entry-level off-road/trail motorcycles. Target Demographic: Beginner riders, youth riders, and those seeking an accessible and fun off-road experience. Competitive Analysis Key Competitors: Honda CRF150F, Yamaha TT-R125LE, Suzuki DR-Z125L. Key Features Klx140L Distinction: The 'L' designation typically indicates a taller seat height and potentially longer suspension travel, making it suitable for larger riders or those preferring a higher riding position. Manual Value Proposition: Provides dealer-level repair and maintenance information, empowering owners to perform their own servicing, reducing costs and increasing self-sufficiency. 📋 Manual Details Coverage Areas General Information: Included Periodic Maintenance: Included Fuel System: Included Engine Top End: Included Clutch: Included Engine Lubrication System: Included Engine Removal Installation: Included Crankshaft Transmission: Included Wheels Tires: Included Final Drive: Included Brakes: Included Suspension: Included Steering: Included Frame: Included Electrical System: Included Appendix: Included Page Count Estimated Page Count: Not specified in product information, but comprehensive service manuals typically range from 300-700+ pages. Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanics: Complete engine disassembly, inspection, repair, and reassembly, including top-end components (cylinder head, piston, valves) and bottom-end (crankshaft, connecting rod, transmission). Fuel And Carburetion: Carburetor adjustment, cleaning, rebuilding, fuel pump diagnosis, fuel tank inspection, and fuel line maintenance. Lubrication System: Oil pump inspection, oil filter replacement, oil change procedures, and lubrication system troubleshooting. Clutch And Transmission: Clutch engagement/disengagement checks, clutch plate inspection and replacement, transmission gear inspection, shift drum and fork troubleshooting, and transmission oil specifications. Chassis And Suspension: Front fork service (oil changes, seal replacement), rear shock absorber inspection and adjustment, wheel bearing service, swingarm and linkage maintenance. Braking System: Brake fluid changes, caliper inspection and rebuilding, brake pad replacement, brake line checks, and master cylinder service. Steering System: Steering stem bearing inspection and adjustment, handlebar and control lever maintenance. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), ignition system diagnosis, lighting system checks, and switchgear troubleshooting. Frame And Bodywork: Frame inspection for damage, seat removal/installation, fender and plastic component maintenance. Procedures Included Troubleshooting Guides: Diagnostic procedures for common issues, including starting problems, performance issues, and electrical faults. Routine Maintenance: Detailed instructions for oil changes, air filter cleaning/replacement, spark plug checks, chain adjustment, and general inspection. Component Overhaul: Step-by-step instructions for rebuilding carburetors, brake calipers, and other wear-prone components. Wiring Diagrams: High-quality, detailed wiring diagrams for the entire electrical system. Torque Specifications: Crucial torque values for all critical fasteners and assembly points. Technical Depth Depth: Comprehensive, covering everything from basic maintenance and adjustments to complete engine rebuilds and advanced electrical system troubleshooting. Target Audience: Suitable for both DIY enthusiasts and professional mechanics, with clear, easy-to-follow instructions and high-quality diagrams. 📊 Manual Specifications File Format Format: PDF Compatibility: All versions of Windows and Mac operating systems. Print Quality Resolution: High resolution, ensuring clear print quality for diagrams and text. Printability: Pages can be printed as needed, allowing users to create a physical copy for workshop use. Binding Type Binding: Digital Download (PDF), not a physical book with binding. Paper Type Paper Type: N/A (Digital Format) Software Requirements PDF Reader: Adobe PDF Reader required. Unzipping Software: WinZip or equivalent software required for file extraction. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, 2-valve, Air-cooled Displacement: 138 cc (8.4 cubic inches) Bore X Stroke: 56.0 x 54.6 mm Compression Ratio: 9.5:1 Performance Horsepower Estimation: Approximately 11-12 HP (exact figures vary by source and tuning, not explicitly stated in product info). Torque Estimation: Approximately 8-9 lb-ft (exact figures vary by source and tuning,...