1984-1986 KLT110 KLT160 KLT 110 160 Service & Repair Manual

Kawasaki KL T 110/160 MODEL COVERAGE KLT 110-A1 KLT 110-A2 KLT 160-A 1 INDEX GENERAL SPECiFiCATIONS ................................................ 556 ~~~.. . ... ~ External Shift Mechanism .........................................577 MAINTENANCE ............................... ............... ....... 556 Lower End and Transmission .........................577 Lubrication ............ ......................... 556 Splitting the Crankcases .....................................577 Motor Oil ...................................................................... 556 Crankcase Assembly ..................................................... 577 Checking Oil Level..................... ................ ..... 556 Engine Specifications ........................................... 580-581 Changing Oil ................ .. ................................................. 556 Engine Torque Specifications ............................................. 579 Filter Screen .............................................................. ... .557 Final Gear Case ............................................................... 557 Front Forks ......................................................................557 Drive Chain (KLT 110) ...................................................... 557 General lubrication '" ....................... .. .......................... 558 Service Checks and Adjustments ..................................... 558 Drive Chain (KLT 110) ...................................................... 558 Clutch ..............................................................................558 Throttle Cable ............................................................... 558 FUEL SYSTEMS ........ .. .................................. .. ..................... 582 Gas Tank ............................................................ .............. 582 Carburetor (KLT 110) .. ......... ............... ....... .... ............ .. ... 582 Carburetor (KLT 160) ......................................................... 582 Fuel Petcock ................................................... ..... .......... ..... 583 Air Cleaner ........... ........................................ .. ..... ........ 584 Fuel Line s. .................................................. .. .......... 584 Carburetor Specifications .................................................584 Front Brake .................... ............... ................. ..... 558 Rear Brake .... ................ ............... ................ .. .. 559 Steering Stem . .................. .. ............... 559 Fuel System .....................................................................559 AAR~....................................................... .. .._ ELECTRICAL SYSTEM ....... .... .. . ... ....... ....... .. .:..................... 584 Ignition System.......... .. .................................................584 Lighting System ................................................ .. ............... 588 Wiring Diagrams..... .. ................... 586-587 Petcock .......... ................... .. ... 560 Carburetor ......... ...... ..... .. ......................560 Recommended Lubricants .......................561 Periodic Maintenance Intervals............ .................. .. ..... 561 Maintenance Data ..................................................... ........560 CHASSIS ................. ................. ............. 588 Component Removal and Installation .............. ............. ...... 588 Seat........... .. .............. .. .. .............. ......................... 588 Front Fender .......... .. ...............................................588 Rear Fender... ....... .......................................... 588 TUNE-UP ....................................... .................................. ..... 561 Compression Test ............................................................. 561 Cam Chain Tensioner ........................................ .. .......... 561 Valve Adjustment .......................................................... ..... 562 Ignition Timing ....................................................................562 Carburetor ............................................................... .. ... ..... 562 Adjusting Float Level .................................................. .. .. 562 Id le Speed and Mixture ..................................................562 Spark Arrestor Cleaning ....................................................563 Tune-Up Specifications................................. .. ........ .. 563 Front Wheel ....................................................................... 588 KLT 110-A 1 ..................................................................... 588 KLT 110-A2, KLT 160 .. .............. ....... .......................589 Rear Wheels ..................................................................... 590 Front Wheel Bearings..... ..................... .. ........................ 590 In spection ......................................... .......................... 590 Removal ............................................................. 590 Installation ... .................................................................. 590 Front Brake ........................... . ...................... ... .. 590 Removal and Disassembly .............................................. 590 Inspection ....................................... . .. ..... ......... 590 ENGINE AND TRANSMISSION ............. .. ........ .. . ................ 563 Engine Removal and Installation ........................................ 563 Assembly and Installation .............................................. 590 Front Forks (KLT 110-A 1)........................... ............... 591 Removal....................................... ....................... 591 KLT110 .................................................................. 563 KLT 160 ..... .................................................. .............. .. ..564 Top End............................................................. .... 564 KLT110 ......................................................................... .. 564 KLT 160......... .. .. ............................................ .566 Crankcase Cover Components ........................................... 569 KLT 110 ......... . .... .. .......................................................... 569 Recoil Starter ................................. .. ....... 569 Left Crankcase Cover ................................................. 570 Engine Sprocket .........................................................570 Magneto .....................................................................570 Inspection ..................................................................... 591 Installation. ............................................................. 591 Hydraulic Front Forks ..........................................................591 Removal ............... ............................................ 591 Disassembly .................................................................... 591 Inspection ...... .. ..................................... :..........................592 Assembly ........ ......... ............. ........................................... 592 Changing Fork Oil ............................................................ 592 Insta ll ation .....................................................................592 Steering Stem .. ................................................................... 592 KLT 110-A1 ..................................................................... 592 Clu1ch .........................................................................570 Clutch Release ................ .........................572 KLT 110-A2, KLT 160 ....... .. ................. ....................... ..... 592 Rear Axle .............................................................................593 Primary Drive ................... ........................... 572 KLT 110 ........................................................................... 593 Oil Pump............................. ........................... 572 KLT 160 ........................................................................... 593 External Shift Mechanism. ........................ 572 Rear Brake .... ....... ...................................................... 594 KLT 160 ..................... ......... .. . .. .. ........................ ............ 573 Recoil Starter ....................................................... ..... 573 Left Crankcase Cover.. .. ................ .. ...... ..... 573 Magneto.............. ................. .. .. 574 Reverse Lever ........................................................... 574 Clutches .....................................................................574 Clutch Release .. .......................................................... 575 Primary Drive ..............................................................576 Removal and Disassembly .............................................. 594 Inspection ........................................................................594 Assembly and Installation ................................. 595 Rear Axle Bearings ..............................................................595 KLT 110 ................................595 KLT 160 .........................................................................595 General Torque Specif icat ions ............................ .. ..............595 Chassis Torque Specifications ..................... ... .................... 595 555

.. Kawasaki KL T 110/160 ENGINE Type Bore x Stroke (mm/in.) Displacement (cc/ci) Compression ratio Carburetor Ignition system Starting system Lubrication TRANSMISSION Clutch Primary reduction Transmission type Gear ratios 1st 2nd 3rd 4th 5th Reverse Final drive Final reduction Overall reduction DIMENSIONS Overall length (mm/in.) Overall width (mm/in.) Overall height (mm/in .) Wheelbase (mm/in .) Ground clearance (mm/in.) Seat height (mm/in.) Dry weight (kg/lbs.) Turning radius (min.) (m/ft.) Fuel tank capacity (1/gal.) FRAME Type Caster Trail (mm/in.) Track (mm/in.) Front tire Rear tires Brakes (fir) MAINTENANCE NOTE: Common maintenance procedures are expJained in detail in the "General In- 'formation" section of this manual. LUBRICATION Molor Oil I. Use motor oil service rated "SE" or "SF." 2. For all· temperature use, the following grades are recommended: SAE IOW·40, lOW-50, 20W-40or 20W·50. Checking Oil Level 1. Oil level should be checked every time before riding the machine. 2. A sight glass for checking oil level is GENERAL SPECIFICATIONS KLT110 4-stroke, SOHC 51 .0 x 50.6/2.01 x 1.99 103 /6.2 8.2:1 Keihin PC18 COl Rope Wet sump Centrifugal 3.619 (76/21) 5-speed, constant mesh 3.307 (43/13) 2.111 (38/18) 1.545 (34/22) 1.285 (27121) 1.111 (30/27) Chain 4.166(50/12) 16.754(5th gear) 1700/66.9 975/38.4 970/38.2 1075/42.3 130/5.1 705/27.8 109/240 1.8/5 .9 9.5/2.5 Tubular, single cradle 19.5" 10/0.39 700/27.6 22 X 11.00-8 22 x 11.00-8 Drum 3. Be sure the machine is parked on a level surface to ensu re an accurate reading. 4. Level should be checked after tbe engine has been running for a few minutes. Shut it orf and let the oil settle for a minute or so. 5. Oil level should be between the upper and lower l evel marks inscribed on the crank- fitted to the right crankcase cover. Oillevel.ighl gla •• CA) and lavel markl (8) 556 KLT160 4-stroke, SOHC 61 .0 x 52.4/2.40 x 2.06 153 /9.3 9.5:1 Mikuni VM22SS COl Rope Wet sump Centrifugal 3.695 (85/23) 5-speed, constant mesh 3.076 (40/13) 1.842 (35/19) 1.304 (30/23) 1.076 (28/26) 0.928 (26/28) 3.384 (28/13 x 33/21) Shaft 3.712 (2 1/18 x 35/11) 12.738 (5th gear) 1730/68.1 1000/39.4 1000/39.4 1110/43.7 135/5.3 695/27.4 124/273 1.7/5.6 9.5/2.5 Tubular , semi-double cradle 23" 17/0.70 740/29.1 21 x 9.00-8 22 x 11.00-8 Drum case. If the level is too l ow. add just enough lubricant of the correct grade to bring it up between the marks. Do not ove rfill. Changing Oil I. The oi l should be cha nged every 30 days when the machine is in reg ul ar use. Oil drain plug (A) (110)

2. Oil should be drained when the engine is at operat ing temperature. This ensures more compl ete draining and makes it more likely that the oi l will carry off any par- ticula tes with it. 3. Park the mac hine on a level s urface. 4. Place a s ui ta ble container (about 2q ts. capacity) beneath the drain plug. 5. Remove the drain plug and allow the oil to drain for several minutes. 6. C lean the drain plug in a safe solvent. Check gasket condition. Replace it if damaged. 7. After the oil has drained completely, insta ll the drain plug. Tighten it to 22 fe Ibs. on 110 models and 58 ft. Ibs. on 160 models. Oil drain plug (A) and filter Icreen plug (160) 8. If the filter screen is to be cleaned, see below. This procedure should be carried out at every third oil change (90 days) . 9. Remove the crankcase filler cap and add the correct quantity and grade of oil. 10. Crankcase capacit ies are: KLTIW,1.2qts.(1.1L) KLT I 60,1.8qts.(1.7L) These are app roximations. Dete rmine the exact amount of oil to be added by watching the sight glass. II. When the sight glass in dica tes that o il level is correct, install the filler cap, start the engine and a llow it to run for several minutes. Check for leaks. Shut the engine off and recheck the level after a minute or so. Filter Screen KLT110 1. The cnginc is fitted with an oil filter screen ins id e the right crankca se cover. The screen should be cleaned every third oil cha nge, or after every 90 days of operation. 2. Have a new crankcas e cover gasket on hand. 3. Drain the oil as outlined above. 4. Place a dr ip pan beneath the right crankcase cover. FiIt.r screen (A)(110) Kawasaki KL T 110/160 5. Disconnect the oil line at the front of the cover. 6. Remove the crankcase cover screws. 7. Remove the crankcase cover. If it is stuck, tap around the top and bottom with a plastic ma ll et to free it. 8. Remove the cover gasket. 9. Remove the filter screen. 10. Clean the screen in a safe solvent. Remove all foreign matter. 11. Check the debris for met al particles. If any are present, severe engine wear is taking place. Determine the cause. Th is may be due to a leak in g air filter, insufficient engine oil, etc. 12. If the screen is punctured or cannot be cleaned effectively, replace it. 13. Install the screen. 14. Clean the gasket surface thoroughly, removing all traces of old gasket material. 15. Install the new gasket. 16. Check that the two cover dowel pins are in place. Check that the clutch release lever and clutch bearing are in place. 17. Install the crankcase cover. 18 . Tighten the cover screws evenly. 19. Rll the crankcase wi th the proper quantity and grade of oil. Check level with the sight gl ass. Run the engine for several minutes and check for leaks. KLT160 1. The engine is fitled with a filter screen in a plug located near the oi l dra in pl ug. 2. The screen shou ld be cleaned at every third oil change, or after every 90 days. 3. Drain the oil as outlined above. 4. Remove the filter sc reen bolt near the drain bolt. 5. Clean the 'filt er screen in a clean, safe solvent. Remove all foreign matter. 6. Check the debris fo r metal particles. If any are present, severe engine wear is taking place. This may be due to a leaking air filter, insufficient eng in e oi l, etc or other, more ser- ious, problems. 7. If the screen is punctured or cannot be cleaned effectively. replace it. 8. In spect the plug gasket and replace it if damaged. 9. Insta ll the plu g and tighten it to 58 f1. Ibs. 10. Fill the crankcase with the proper grade a nd quantity of oil. Check level with the sight glass. Run the engine for several minutes and check for leaks. Final Gear Case I. SAE IOW-40 motor oil, service rated "SE" or "SF" is recommended. 2. Gear case capacity is 0.2 qts. (0 .2 L). 3. The gear case oil shou ld be changed once a year under conditions of normal use. (8) CHECKING OIL LEVEL 1. Park the machine on a level surface. 2. Remove the level plug from the gear case. Oil should just begin to come out of the level holc. Ifit does not, add just enough SAE 10W·40 SF motor oil so that the oil sta rts to come out. 3. Check the condition of the level plug gasket and replace it if it is crushed or otherwise damaged. 4. Tighten the level plug to about 7 ft.lbs. CHANGING OIL 1. Run the machine until operat ing temperature is reached. 2. Park the machine on a level surface. 3. Place a drip pan beneath the final gear case. 4. Remove the filler plug. Remove the gear casedrain plug. Allow the oi l to drain for several minutes. 5. Clean the drain plug thoroughly in a safe solven t. Check gasket condition. Us ing a new gasket is recommended. 6. Install the drain plug. Tighten it to 22 ft.lbs. Final gear cas. drain plug (A) 7. Inspect the drained oil for metal parti - cles. If present, it indicates that the dr ive tra in is undergoing severe wear. The ca use should be determi ned before the machine is operated any more. 8. Fill the gear case with about 0.2 qts of SAE I OW· 40 motor oi l. service rated SF. 9. Remove the level plug. Add more oi l, if necessar y, until oi l just begins to seep out of the level hole. 10. Install the level plug and the filler plu g. Th e level p lu g shou ld be tightened to about 7 ft. Ibs. The filler plug should be tightened to 22 f1. lbs. CAUTI ON: Check that none of the drained oil has gotten on the lire. lfit has, wipe it o fr. Front Forks I. Oil in hydraulic-type front forks should be changed every 90 days. 2. Forks useSAE5W-20 motor oil. 3. The change procedure in volves removing each fo rk leg and dumping the fluid o Ul. This procedure is given in the "Chassis" section under " H ydro.ulic Front Forks." Drive Chain (KL T 110) 1. The drive cha in is fitted with rubber O-rings between the cha in plates to seal in lubricant and keep out dirt. Therefore, the chain should be lubricated only with oil (SAE 90 is recommended). Do not use commercial chain lubricants or petroleum-based solvents as they may damage the O-rings. 557

• Kawasaki KL T 110/160 Chain case inspection hole (A) and cap (9) 2. Remove the rubber im:pection cap from the chain case and check chain condi· tion. If it is dirty. it shou ld be removed and thoroughly cleaned before lubrication. Refer to "Rear Axle" in the "Chassis" section for removal and installation procedures. 3. Support the rear wheels off the ground. 4. Slowly rotate the real wheels while brushing SAE 90 oil onto the chain. Be sure that the lubricant is applied to both the inner and outer plates. 5. After the chain has been thoroughly lubricated. adjust slack as outlined under "Service Checks and Adjustments", below. General lubrication I. General lubrication points include control cables, control lever pivots and joints, brake cams, the propeller shaft joint (KLT 160), wheel and steeriug bt:arings and the throttle lever housing. 2. The service interval will depend on how the machine is used. Cables, levers and chassis pivots should be lubricated about every 30 days of use under normal operating conditions. Wheel and steering bearings should be attended to about every 90 days of use. 3. Refer to the "Chass i s" section for procedures to reach wheel and steering bea r- ings. SERVICE CHECKS AND ADJUSTMENTS Drive Chain (Kl T 110) I. The drive chain should have 0.4-1.0 in. (10-25mm) of total up and down slack when measured at the inspection hole on the chain case. 2. Before check ing or adjusting cha in slack. the fo llowing conditions must be met: Chain adjuster locknut (A) and axle mount· ing bolts (B) 558 a. The rear wheels of the machine should be supported off the ground. b. The chain must be clean and well lubricated. c. The chain shou ld have been checked for tight spots by slowly rotating the rear wheels and checking tension at severa l points. If a tight spot exists, the chain should be adjusted to the proper slack at the tight spot. Note, however, that such a condition indicates that chain, sprockets or both are worn and should be inspected and probably replaced as soon as possible. 3. If total up-and-down cha in slack at the inspection hole is not within the 0.4-1.0 in. (lO-25mm) range, refer to the illustration and procede as follows. 4. Loosen the chain adjuster locknut (A). 5. Loosen the four axle mounting bolts (B) . 6. Turn the adjuster locknut clockwise (as seen from the back of the machine) to tighten a slack chain. To provide more slack to a tight chain. turn the locknut counterclockwise and push !he axle forward. 7. When slack is correct, tighten the four axle mounting bolts (torque is 43 f1. Ibs.). Tighten the adjuster locknut (43 ft. Ibs.). 8. Recheck chain slack. Repeat the procedure if it is not within specification. Clutch KLT110 1. The clutch should be adjusted after every 10 days of operation. 2. Remove the clutch adjusting screw rubber cap on the right crankcase cover. 3. Loosen the adjusting screw locknut. 4. Back the adjusting screw off (CCW) a bit, then turn it clockwise until resistance is felt. Clutch adjusting screw (A) and locknut (8) (110) 5. Hold the adjusting screw in this position and tighten the locknut. 6. Install the rubber cap. Clutch adjusting screw (A) and locknut (8) (160) KLT160 I. The clutch should be adjusted after every 10 days of operation. 2. Remove the clutch adjusting screw rubber capon the right crankcase cover below the oil filler cap. 3. Loosen the adjusting screw locknut. 4. Turn the adjusting screw clockwise until resistance is felt. Stop. 5. Turn the adjusting screw counterclockwise until resistance is felt. 6. Hold the adjusting sc rew in this position and tighten the locknut. 7. Install the rubber cap. Throttle Cable 1. Throttle cab le free-play should be checked about every 10 days of operation. 2. The throttle cable has adjusters at the hand lever and at the carburetor. Either can be used for adjustment. 3. The throttle lever should be able to move 2-3mm (0.OS -0.12 in.) beforc the throttle slide sta rts to open. Throttle lever fr ... pla1 (A), adjuster (B) and locknut (C) 4. To make this adjustment, slide back the rubber adjuster cover. Loosen the adjuster locknut and turn the adjuster in or out un til lever frce·play is correct. Tighten the adjuster locknut and put the cover back in place. 5. Let the engine idle and turn the hand- lebars slowly from lock-to-Iock. Idle speed must not change. If it does, the cable is either too tightly adjusted, or is binding somewhere along its route. Determine the cause before operating the machine. CAUTION: Throttle cable adjustment is an important safety item. Front Brake KLT11D-A1 1. The brake cab le adjuster is fitted to the drum end of the cable. 2. When the brake hand lever is applied, the gap between the hand lever and the lever holder should be 4-5mm (0.16-0.20 in.) before the linings contact the drum. 3. To make this adjustment , turn the adjusting screw at the lower end of the cable. 4. Check that the brake wear indicator stays within the "Usable Range" when the brake is fully applied. If it does not, the brake shoes must be replaced. 5. After adjusting the cable, support the front wheel off the ground and spin the tire. There should be no noise indicating dragging brakes. Apply the brake hand lever several times and ensure that the brakes release each

time. If they do not, determine t he cause-and~ remedy the co ndition. Possible causes incl ude a binding cable due to dirt, corrosion or incor - rect routing, worn or d amaged brake return sprin gs or a corroded or damaged brake cam. 6. When the brake hand lever is fully app lied, the ang le formed by the lever at the dr um an d the cable should be 80·90· for maximum bra ke effectiveness. If not within this specificat ion, it is possible to remove the lever from the spli ned shaft and reposition it so that the angle is cor rect. CAUTION: Do not change the position of the brake wear indicator. KL T 110- A2, KL T 160 I. Brake cable adjusters arc fitted to the hand lever bracket and to the brake drum. Use the upper adjuster for minor brak e adjustments. When it starts to pass about half of its adjustment range, use the adjuster at the drum. 2. When the brake hand lever is applied, the gap between the hand lever a nd the lever holder should be 4- 5mm (0 .16-0.20 in.) before the linings contac t the drum. 3. Make minor adjustments with the adjus ter at the hand lever. Loosen the adjuster locknut and screw the adjuster in or out until the gap is correct, then tighten the locknut. 4. For major a djustments. or when the handlebar adjuster has used up more than ha lf of its usa ble range, use the a djuster at the dru m. S. Loosen the upper adjuster locknut and turn the adjuster in all the way. Tighten the locknu t. 6. Back off the drum adjuster mounting nuts and slide the adjuster on its bracket so that hand lever free movement is 4-Smm (0. 16-0.20 in.). 7. Tighten the mou riti ng nuts. Recheck adjustment and make minor corrects, if required, with the hand lever adjuster. 8. After adjusting the cable, support the front wheel off the ground and spin the tire. There should be no noise indicating dragging brakes. Apply the lever several times and ensu re t he brakes release each time. If they do not, determine theca use and remedy thecon - dition. Possible causes include a cab le binding due to dirt, corrosion or incorrect routing, worn or damaged brake return springs or co rroded or damaged brake cam. Rear Brake 1. Th e rear brake is contro ll ed by both a hand lever and a foot pedal. Both lever and pedal must be adjusted at the same time. 2. The brake pedal on KLT 160 models is adjustable for position. To position the pedal, back off the rod adjuster, loosen the stop bolt Brake pedal.diulter (A) Kawasaki KL T 110/160 locknut and turn the stop bolt so that the - pedal at- rest position is comf ortable for the operator. Adjust the pedal travel as outlined in the following steps. 3. Adjust the brake pedal first. The pedal shou ld have about 25mm (l in.) of free movement before the linings contact the drum . Adjust by means of the adjuster on the end of the rod or cable al the rear brake drum. 4. To adjust the hand lever, adjusters are fitted to the han d lever bracket and to the end of thecable at the brake drum. 5. Use the hand lever adjuster for minor adju stments. When it sta rts to pass about half of i ts adjustment range, use the .adju ster at the brake drum end of the ca bl e. 6. The hand lever should have 4-Smm (0.16-0.20 in.) of free movement before the linings con tact the dr um. This distance is measured between the hand lever and the lever holder. Brake hand lever adjuster (A) 7. To adjust at the handlebar, loosen the adjuster locknut and turn the adjuster in or out until free play is correct. Tighten the lockn ut. 8. To adjust at the drum, first screw the handlebar adjuster all the way in. 9. Turn the adjuste r at the brake d rum until hand lever free pl ay is correct. Make minor correction s, if required, with the adjuster at the handl ebar . 10. Afler adjusting both the brake pedal and the brake hand lever, support the rear wheels off the ground and check operation. Spin the wheels and apply both pedal and lever several times. Ens ure that the brakes release "full y afte r every application. There should be no noise to ind icate dragging. If there i s, determine the (''ause and remedy the condition. Possible causes include weak or damaged brake ret urn springs, a corroded or damaged brake cam, an unlubr ic ated or corroded brake cable, pedal or lever pivot or incorrectly routed cab le. Steering Stem I. Steering stem bearing adjustme nt should be checked every 90 days of operation. 2. To check bearing adjustment, su pport the front wheel off the ground. Gra sp the lower ends of the fork tubes and attempt to move the forks back a nd forth in line with the machine. There should be no detectable movement. If there is, bear ings must be adjusted . 3. Turn the forks slowly from lock- to-lock, aga in with the front wheel off the ground. Movement should be smooth, silent and effortless. , If any binding or uneven movement is felt, the balls and races are Checking steering stem bearing adjustment either too tight ly adjusted or are worn. If the steering feels uniformly stiff, the bearings are too tightly adjusted. If any noise is noted, the bearings are damaged and/or some are miss- ing . 4. With the front wheel off the ground, release the forks from a position a few degrees to either sid e of the centered position. They should fall freely to the lock of their own accord. If they do not, the bearings are too tightly adjusted, the steering stem is bent, the races are worn or some of the bearings are mi ssing. 5. Remove the gas tank. 6. Remove the upper triple clamp rubber cover. 7. Loosen the upper triple clamp oolts above the fork tubes. 8. Loosen the steering stem bolt. Steering stem bearing adjulter nut (A) 9. Use a pin wrench to turn the adjuster nut benea th the upper triple clamp until bearing action conforms to behavior described above- i.e., no play and smooth movement. Do not turn the adjuster nut more than 1/8 turn at a time. 10. When bearing movement is correct, tighten the boilS above the fork tubes (22 f1. Ibs.) and the steering stem bolt (40 fLlbs .). II. Recheck bearing operation. NOTE: If correct bearing operation cannot be achieved, or ifit is necessary to turn the adjuster nut more than two turns, suspect worn or damaged bearings and/ or races. See "Chassis" for disassembly instructions. FUEL SYSTEM Fuel system maintenance involvescleaning the ai r filter element, cleaning the fuel petcock screens and cleaning the car buretor fl oat bowl. Theair filter element should beclea ned every 10 da ys of use. The petcock and carbur - etor should be atte nded to every 90 da ys of use. 559

Kawasaki KLT 110/160 Air Filter REMOVAL 1. Remove the seat. 2. Remove the air cleane r cover which is secured by two screws. 3. Lift the air cleaner element with holder straight up and out. Air cleaner cover screws (A) Filter ,lIIement gasket (A), element (8) and holder (e) SERVICE 1. Ca refully remove the air cleaner element from the frame. 2. In a well-ventilated area, cl ean the elemen t in a safe solvent. CAUTION: Lo w flash point soivents5uch as gasoline should not be used as th ey present a safety hazard. Fuel tank capacity (gal/L) Engine oil capacity (qts.l L) Final gear case (qts .l L) Hydraulic forks (oz.lcc each leg) Tire pressure (psi) Front Rear Chain slack (mm/in.) CD Total capacity 560 3. Squeeze the element to dry it. Do not wring it out as the pores may be damaged or the element itself may be ripped. 4. When a ll dir t has been purged. dry the ele ment thoroughly. 5. Inspect element condition. If it cannot be cleaned effectively, or if the fabric is worn, 10m or otherwise damaged, the element should be replaced. 6. Soak the element in clean SAE 30 motor oil or a commercial air cleaner oil. Squeeze out the excess. INSTALLATION I. Pull the element back over the frame. 2. Install the element holder in the air cl eaner case engaging the lower end in theslot provided. 3. Grease the clement gasket with a light- weight general purpose grease. 4. Slip the element into the case with the gasket side towards the engin e. Be sure it is fully seated. 5. Fit the air cleaner cover with the in · take tube towards the rear of tbe machine. 6. Be sure to hook the lip on the front edge of the cover under the forward edge of the case. 7. Secure the cover screws. Petcock I. The fuel petcock is fitted with ftIter screens on the pipes inside the fuel tank. The petcock should be removed a nd the screens cleaned aft er every 90 operati ng days. 2. The procedure involves remov ing the fuel tank. Refer to "Fuel Systems" for pnx:ed ures. Carburetor 1. Although a thorough cleaning of the carburetor necessitates its removal from the machine, water and foreign matter can be removed from the float bowl by unscrewing the float bowl dr ain plug and allowing the gasoline to drain in to a suitable container. CAUTION: Be sure to do this in a well· ventilated area a safe distance from spa rks or open flames. MAINTENANCE DATA KLT110 2.5/9.5 1.2/ 1.1 3.0/ 88 0 2 2 25/ 1.0 Carburetor 'loa l bowl drain plug (A) Fuel petcock filler Icreena (A) 2. Check the drained gasoline for foreign matter, water, etc. If there seems to be a fair amount of it, check that the air filter is clean and properly installed. 3. Turn the petcock to the "RES" posi· tion wi th the dra in plug unscrewed and watch the gasoline which drains out. If it has more foreign matter in it, the tank should be removed and purged and the petcock filter screens should be cleaned. 4. If flow from the carburetor float bowl seems sluggish, a clogged fi lter or clogged fuel cap vent may be the problem. C heck the fu el system and clean it thoroughly. Refer to "Fuel Systems" for procedures. 2.5/9.5 1.8/1.7 0.2/0.2 3.0/88 0 3 2 KLT160

TUNE·UP NOTE: Common tunc-up procedures are explained in detail in the "General Infor- mation"scction. COMPRESSION TEST 1. A compression test should he performed before and after a complete tune-up, as it will providec1ues to the general mechan- ical condition of the engine. 2. A hold-in type gauge can be used ifit is so constructed that clearance is not a problem. If a screw-in type gauge is used, a 12mm adapter is required to fit the spark plug hole. 3. Run the engine until it is at operating temperature. 4. Disconnect the spark plug lead and remove the plug. 5. Fit t he compression gauge. Hold the throttle wide open while cranking the engine and note the compression reading. The high- est reading is the measurement to be con- sidered. NOTE: The KLT /60 is equipped with an automatic compression release which wi// make a dramatic difference in compression readings. TheACR maya/so bea cause of compression problems. Be aware of this before troubleshooting for a possible engine problem. 6. Standard compression for the KLT 110 is 164-192 psi. The minimum acceptable n:auifl~ is 125 psi and the maximum accept- ab le reading is 192 psi. 7. Standard compression fo r the KLT 160 is 14-43 psi. This is due to the operation of the ACR and is not true engine compression. S. If the compression reading is too high, it is likely that the piston crown and/or com- bustion chamber is carboned up. The cylinder head should be removed and the head and piston decarbonized. On the KLT 160, a higher-than- normal compression reading may also indicate a defective AeR . The unit should be removed and inspected before further work is done. Refer to "Top End" in the "Engine And Transmission" section. 9. If the compression is too low, squirt some motor oil into the cylinder and repeat the test. If the compression reading increases, suspect a worn piston, cylinder and/or rings. [fitdoes not increase, suspect worn, damaged or poorly adjusted valves, leaking seats, etc. Low compression may also be due to a defective ACR on the KLT 160. The unit should be removed and inspected before further work is done. Refer to "Top End" in the "Engine And Transmission" section. . 10. Other causes of low compression include a warped head and/ or blown head gasket. The compression will not increase when o il is added to the cylinder if this is the prob- le m. CAM CHAIN TENSIONER Cam chai n tension is maintained automa- tically. No routine adjustments are required as long as the tensioner is functioning properly. See "Engine And Transmission'~ under "Top End" for tensioner removal and inspection. Kawasaki KL T 110/160 PERIODIC MAINTENANCE INTERVALS® Before each ride Safety items Operation of lights Chain adjustment (KLT 110) Th rottle operat ion Brake operation Engine oil level Tire pressure (check when cold) Every 10 days of operation Brake wear Contro l cable adjustments Tightness of critical fasteners Clutch adjustment Air filter cleaning Every 30 days of operation Change engine oil General lubrication Every 90 days of operation Clean oil filter screen Clean carburetor and petcock Grease propeller shaft joint (KLT 160) Change fork oil (hydraulic forks) Lubricate wheel and steering head bearings Grease brake cams Every year Change final gear case oil (KLT 160) Clean spark arrestor 0) Based on normal usage after initial service and break·in are completed. RECOMMENDED LUBRICANTS Engine SAE 10W-40, service rating "S E" or "SF" SAE 10W-50, service rating "S E" or "SF" SAE 20W-40, service rating "S E" or "SF" SAE 20W-50,service rating "SE" or "SF" Final Gear Case SAE 10W-40, service rating "SE" or "SF" Front Forks (Hydraulic) SAE5W-20 Drive Chain (KL T 110) SAE900il Air Filter Element SAE30 Control cables Light motor oil Graphite-based lubricant Molybdenum disulphide-based lubricant Commercial motorcycle cable lubes 561

Kawasaki KLT 110/160 VALVE ADJUSTMENT Checking Clearance NOTE: Valve clearance must be checked when the engine is COLD. I. Remove the seat. See "Chassis," 2. Remove the gas tank. See "Fuel Systems." 3. Remove lhespa rk plug. 4. Remove the intake and exhaust valve covers. 5. Remove the timing inspection plug on top of the left crankcase cover. 6. Remove the recoil starter case. 7. Use a wrench on the bolt or nut on the cnd of the crankshaft and carefully turn the engine over in a counterclockwise direct ion until the intake valve opens and closes. 8. Continue turning the engine in the same direction while watching the magneto rotor through the inspection hole. Timing indicator (A). "T" mark (8) and inspection plug (e) 9. When the "T" mark on the rotor aligns with the indicator, stop and hold the engine in this position. The piston is now at TDC on the compression stroke, both valves are closed and adjustment can be checked. to. Chec k for clearance at both valves by attempting to move the rocker arms with your fingers. If one seems tight, it may be that the piston is at TOC on the exhaust stroke. In this case, repeat the procedure until you are sure that both valves are closed. Checking valva clearance: feeler gauge (A), adjuster (8), locknul (C) II. Valvc clearances are as follows: KLT 110: Intake: 0.12-0.17mm/0.005-0.007 in. Exhaust: 0.1 2-0. I 7mm/0.005-0.007 in. KLT 160, Intake: 0.12-0.17mm/ 0.OOS-0.007 in. Exhaust: 0.IS-0.23mm/O.OO7-0.009 in. 12. A feeler gauge blade of the thickness shown above should be a slip fit between the adjuster and stem of a correctly adjusted 562 RECOMMENDED LUBRICANTS Wheel and steering stem bearings Waterproof, medium -weight bearing grease Throttle lever housing Waterproof, light duty grease General chassis lubrication Waterproof, medium-weight chassis grease valve. If the blade is too loose or too tight, adjust the va lves as outlined below. Adjusting Clearance I. Check clearance as outlined above. 2. Loosen the ".'a lve adjuster locknut and turn the adjuster so that a feeler gauge blade of the correct thickness is a light slip fit betwecQ adjuster and valve stem. 3. Hold the adjuster in place and tighten the locknut. 4. Recheck clearance. Often it will change when the adjuster locknut is tightened. IGNITION TIMING I. Ignition timing requires a stroboscopic timing light and a tachometer. 2. Timing can be checked by removing the timing inspection plug on the left crankcase cover and noting the alignment of the magneto rotor timing marks with the indicator. The "P' mark should align below 1500 rpm for the 110 and 1350 rpm for the 160. The advance mark should align at 4000 rpm and above for the 110 and at 5000 rpm and above for the 160 . Ignition timing: indicator (A), "F" mark (8) , advance mark (C) and inapection plug (0) 3. Timing is not adjustable, however, and if the proper alignments are not made, the CDl unit must be replaced. Refer to "Elec- trical Systems." CARBURETOR Carburetor adjustments to be made during a tune-up include float level, id le speed and mixture. Adjusting Float Level I. Aoat level is a measure of the amount of gasoline that remains in the carburetor during operation. While it is a crit ical Carburetor float height specification, it will not normally need read- jus tment once properly set. Float level, therefore, need not be adjusted at every mne-up, but should be attended to from time to time. 2. If a fuel level gauge is available, se r- vice fuel level can be obtained without removing the carburetor from the machine. Service fuel levels are as follows: KLT 110: 2.5 ± Imm (0.10 ± 0.04 in.) KLT 160:5.0 ± Imm(0.20 ± 0.04 in.) 3. To adjust float height. remove the carburetor (see "Fuel Systems".) 4. Remove the float bowl. 5. Remove the float bowl gas ke t. 6. Care fully lower the floal until the ta ng just touches the tip of the float needle. 7. The distance from the float bowl mating surface to the top of the fl oat is the float height. It shou ld be: KLT lID, 20mm (0.8 ;n.) KLT 160, 33.3mm (1.3 ;n.) S. If the measurement is not correct, remove the float and bend the tang so the float height is brought within specificatio n. NOTE: The float height adjustment w iJJ be incorrect if the float needle is worn or if there is foreign matter on the needle or needle seat. Idle Speed And Mixture NOTE: The foJJowing adjustments should be performed when the engine is at operating temperature. Other adjustments (valves, air cleaner. etc.) should be done first. Pilot screw (A)(110)

Throtlls atop screw (A)(110) Pilot screw (A,)(180) I. Locate the pilot screw on the side of the carburetor. SPARK PLUG Type COMPRESSION Standard (psi) Minimum (psi) Maximum (psi) VALVE CLEARANCE Intake (mm/in.) Exhaust (mm/in .) IGNITION TIMING Retarded Full advance CARBURETOR Float height (mm/in.) Service fuel level (mm/in.) Pilot screw (turns out) @ ACR-affected ENGINE AND TRANSMISSION NOTE: Engine rebuilding techniques and proct:durcs arc explained ill delu.il in the "General Information" section of this manual. ENGINE REMOVAL AND INSTALLATION KLT 110 Kawasaki KLT 110/160 Throttle slop screw (A)(180) 2. Turn the screw in carefu ll y until it is lightly seated. then back it out the following number of turns: KLT 11 0: 1·3 / 8 KLT 160: 1· 114 CAUTION: Do not overtighten the screw or the calibrated tip will be damaged. 3. Locate the throttle stop screw. 4. Turn the screw as required until the engine is running at the lowest smooth idle speed . SPARK ARRESTOR CLEANING 1. The spark arrestor should be decarbonized every year. TUNE-UP SPECIFICATIONS KLT 110 0-7EA 164-192 125 192 Spark arr.,lor (8) and mounting bolt (A) 2. Remove the bolt that secures the spark arrestor in the muffler. 3. Pull out the spark arrestor. 4. In an open, well-ventilated area clear of flammable materials, start the engine. 5. When operating temperature is reached, rev the engine while tapping the muffler with a plastic mallet. This will dis- lodge built-up carbon particles. CAUTION: This procedure must be carried out in a safearca. Hot carbon particles are a fire hazard. 6. Shut off the engine. 7. Scrape carbon build-up from the arrestor. 8. Install the arrestor and secure it with the bolt. KLT160 O-SEA 14-43@ 14 43 0. 12-0 .17 10.005-0.007 0.12-0.1710.005 -0 .007 0.12-0.17 10.005-0.007 0. 1S-0.23/0.007 -0.009 W@1S00rpm 35' @ 4000 rpm 2010.S 2.5 ± 1/0.10 ± 0.04 H, 10' @ 1350 rpin 35' @ 4600 rpm 33.3/1.3 5.0 ± 1/0.20 ± 0.04 1'14 3. Remove the rear fender. 4. Remove the gas tank. See "Fuel Systems." 5. Remove the carburetor. See "Fuel Systems." 6. Remove the air cleaner case. 7. Loosen the muffler clamp on the exhaust pipe. Remove the muffler bracket bolts on the fra me. Remove the nuts securing the exhaust pipe at the cylinder head. Remove the exhaust system. 1. Drain the engine oil. Engine mounting bolta (A) and bracket bolla 8. Remove the three screws from the engine sprocket cover on the left sid e of the engine. Remove the sprocket cover. 2. Remove the seat. (B) (110) 9. Back off the chain adjuster nut at the 563

Kawasaki KL T 110/160 rear axle and push the axle forward to increase chain slack. 10. Remove the engine sprocket circlip from the shaft. Engine mounting bolt, (A) and bracket bolt. (8) (110) 11. Pull off the engine sprocket and cha in . 12 . Remove the securing hardware a nd take off the upper half of the chain case. 13. Remove the shift lever from its shaft. 14. Di sconnect the lead from the spark plug. 15. Disconnect the magneto wiring at the plastic connectors. 16 . Remove the chain guard Uust to the rear of the engine sprocket). 17. Remove the engine mounting bolts and bracket bolts at the front and rear of the engine and at the cylinder head. See illustra- tions. 18. Installation is the reverse of removal. Tighten the cylinder heHC{ mounting bolt and bracket bolts to 13 ft. Ibs. Tighten the front and rear bracket bolts to 13 ft. Ibs. and the front and rear engine mounting bolts to 22 ft. Ibs. 19. The engine sprocket must be installed with the nu mber facing outward. If the sprocket collar was removed from the main- shaft, a new O-ring should be used. Install the collar with the bevelled side in. 20. Do not forget to refill the crankcase with motor oil. KLT160 I. Drain the engine oil. 2. Remove the seat. 3. Remove the rear fender. 4. Remove the gas tank. Refer to "Fuel Systems." 5. Remove the carburetor . See "Fuel Systems." 6. Loosen the muffler clamp. Remove the two muffler bracket bolts. Remove the exhaust pipe nuts at the cylinder head. Remove the exhaust system. , .... ", --- ,- ..... , Engine mounting bolts (A) and bracket bolls (8)(160) 564 Engine mounting bolt' (A) and bracket bolt, (8)(160) 7. Remove the pinch bah and pull the shift lever from its shaft. S. Disconnect the lead from the spark plug. 9. Disconnect the magneto wiring at the plastic connectors on the frame behind the engine. 10. Loosen the propeller shaft clamp screws. I I. Remove the engine mounting bolts and the bracket bolts. 12. Pull the engine forward to clear the rear mounting brackets and then out to the right side of the frame. 13. Installation is the reverse of removal. Note the following. 14. lubricate the propeller shaft joints with bearing grease. I S. Be sure the joint spring is in stalled on the pinion gcar nut. 16. Turn the rear wheel to a lign the joint splines and the pinion gear splines. 17. Tighten the engine mounting bolts at the front and rear of the engine to 22 ft. Ibs. Tighten the bracket bolts and the mounting bolt at the cylinder head to IS ft.lbs . IS. Be sure to refill the crankcase with motor oil before attempti ng to sta rt the engine. TOP END KLT 110 REMOVAL The top end components (cylinder head, cylinder and piston) can be removed without removing the engine from the frame. I. Remove the seat. 2. Remove the gas tank. Remove the carburetor . See "Fuel Systems" for procedures. Align poinler (A) and sprocket 'lash mark (8) prior to cylinder head removal 3. Loosen the muffler clamp. Remove the muffler bracket bolts. Remove the ex- hawn pipe nuts at the cylinder head. Remove the exhaust system. 4. Remove the recoil st arter assembly. 5. Remove the two bolts and take off the cams haft sprocket cover. Pry slots are provided under the bolt hole bosses. 6. Use a wrench on the magneto rotor nut to turn the engine over until the slash mark on the cam sprocket aligns with the pointer on the top of the cylinder head. 7. Remove the cam chain tensioner in the following manner: a. Remove the lock bolt from the top of the cam chain tensioner. b. Screw in a longer bolt of the same dimensions (6mm dia .l l.Omm pitch). Tighten the bolt securely to hold the push· rod in place. c. Remove the tensioner mounting bolts and take orf the tensioner. CAUTION: Do not turn the engine over with the tcnsioner removed or damage may result. S. Remove the cam sprocket bolts. 9. Full the sprocket off the cam and dis- engage it from the chain. 10. Loop a length of wire through the chain and secure it to prevent the chain from falling into the cylinder. II . Disconnect the lead from the spark plug. 12 . Loosen the spark plug. 13. Remove the cylinder head mounting brackets. 14. Remove the cylinder head oi l pipe banjo bolts at the head and the crankcase. 15. Remove the oil pipe mounting screws and remove the pipe. 16. Remove the 6mm cylinder head bolts near the cam sprocket housing. 17. Remove the Smm cylinder head bolts on the topof the head. 18. Lift the cylinder head from the cylinder and remove it. 19. Note the locations of the dowel pins on the cylinder head/ cylinder mating surface. 20. Remove the head gasket. 21. To remove the cylinder, lift it up while turning the front cam chain guide. 22. Note the location of the dowel pins on the crankcase mating s urface. 23. Remove the wrist pin circlipsand push out the wrist pin to remove the piston. 24. Remove the cylinder base gasket. DISASSEMBL Y 1. Remove the valve adjuster caps from the head. Cylinder head 8 mm bolt, (A) and 8 mm boll,(B)

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1984-1986 KLT110 KLT160 KLT 110 160 Service & Repair Manual

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