KLX 110R

2022 Kawasaki KLX 110R TROUBLESHOOTING GUIDE Owner’s Manual

2022 Kawasaki KLX 110R TROUBLESHOOTING GUIDE

NOTE

This troubleshooting guide is not exhaustive and does not give every possible cause for each prob lem listed. It is meant simply as a quick guide to assist you in troubleshooting for some of the more common difficulties.

Starting failure or difficulties

The starter motor does not rotate:

  • Engine stop switch not position
  • Starter lockout switch (KLX110D model only) or
  • gear position switch trouble
  • Starter motor trouble
  • Battery voltage low
  • Starter relay not contacting or operating
  • Starter button not contact
  • Starter system wiring shorted or open
  • Engine stop switch trouble
  • 10 A fuse blown

Starter motor rotating but the engine does not turn over:

  • Starter clutch trouble
  • Starter idle gear trouble

The engine does not turn over:

  • Valve seized
  • Cylinder or piston seized
  • Crankshaft seized
  • Connecting rod small end seized
  • Connecting rod big end seized
  • Camshaft seized
  • Transmission gear or bearing seized
  • Kick shaft return spring broken
  • Kick ratchet gear not engaging

Fuel does not flow

  • No fuel in the tank
  • The fuel tap turned off
  • Fuel tank cap air vent obstructed
  • Fuel tap clogged
  • Fuel line clogged
  • Float valve clogged

Engine flooded:

  • Fuel level too high
  • Float valve is worn or stuck open
  • .Wrong starting technique (when the engine is
  • flooded, kick with the throttle fully open to allow
  • more air to reach the engine.)

Spark missing or weak:

  • Engine stop switch turned off
  • Spark plug dirty, broken, or gap improperly adjusted
  • Spark plug cap or high-tension wiring defective
  • Spark plug cap not contacting properly
  • Spark plug type incorrect
  • Crankshaft sensor defective
  • Igniter defective
  • Ignition coil defective
  • Engine stop switch wiring defective
  • Flywheel magneto damaged
  • Gear position switch defective
  • Wiring shorted or interrupted

Fuellair mixture incorrect:

  • Idle adjusting screw improperly adjusted Pilot jet or air passage clogged
  • Air cleaner element clogged, poorly sealed, or not installed

Compression low:

  • Spark plug lose
  • The cylinder head was insufficiently tightened
  • Cylinder or piston worn
  • No valve clearance
  • Crankshaft oil seal leak
  • Valve spring broken or weak
  • Valve not seating properly (valve bent, worn, or
  • carbon accumulation on the seating surface)
  • Piston ring worn, weak, broken, or sticking
  • Piston ring side clearance excessive
  • Cylinder head gasket damaged
  • Cylinder head warped
  • Cylinder gasket damaged

Poor low-speed performance-

Spark weak:

  • Spark plug dirty, broken, or gap improperly adjusted
  • Spark plug cap or high-tension wiring defective
  • Spark plug cap shorted or not contacting properly
  • Spark plug type incorrect
  • Igniter defective
  • Ignition coil defective
  • Crankshaft sensor defective
  • Flywheel magneto defective
  • Wiring connector not in good contact
  • Fuel/air mixture incorrect:
  • ldle adjusting screw improperly adjusted
  • Pilot jet, needle jet or air passage clogged
  • Air cleaner element clogged, poorly sealed, or not installed
  • Choke valve closed
  • Carburetor fuel level too high or too low
  • Fuel tank cap air vent obstructed
  • Carburetor holder loose
  • Air cleaner duct loose
  • Fuel tap clogged

Compression low:

  • Spark plug lose
  • The cylinder head was insufficiently tightened
  • Cylinder or piston worn
  • No valve clearance
  • Valve spring broken or weak
  • Valve not seating properly (valve bent, worn, or
  • carbon accumulation on the seating surface)
  • Piston ring worn, weak, broken, or sticking
  • Piston ring side clearance excessive
  • Cylinder head gasket damaged
  • Cylinder head warped
  • Cylinder gasket damaged
  • Decompression trouble

Other:

  • Igniter defective
  • Brake dragging
  • Clutch slipping
  • Engine overheating
  • Engine oil level too high
  • Engine oil viscosity too high
  • Ignition timing incorrect
  • Drive chain trouble

Poor or no high-speed performance

Firing incorrect:

  • Spark plug dirty, broken, or gap improperly ad- justed
  • Spark plug cap or high-tension wiring defective
  • Spark plug cap shorted or not contacting properly
  • Spark plug type incorrect
  • Igniter defective
  • Ignition coil defective
  • Crankshaft sensor defective
  • Flywheel magneto defective
  • Wiring connector not in good contact

Fuel/air mixture incorrect:

  • Main jet clogged or wrong size
  • Jet needle or needle jet worn
  • Jet needle clip in the wrong poSition
  • Carburetor fuel level too high or too low
  • Air cleaner element clogged, poorly sealed, or not installed
  • Choke valve closed
  • Fuel contaminated with water or foreign matter
  • fuel tank cap air vent obstructed
  • Carburetor holder lose
  • Air cleaner duct lose
  • Fuel tap clogged
  • Fuel line cloggedd
  • Needle jet or air passage clogged

Compression low:

  • Spark plug lose
  • Cylinder head was insufficiently tightened
  • Cylinder or piston worn
  • No valve clearance
  • Valve spring broken or weak
  • Valve not seating properly (valve bent, worn, or carbon accumulation on the seatng surtace)
  • Piston ring worn, weak, Broken, or stocking
  • PIston ring side clearance excessive
  • Cylinder head gasket damaged
  • Cylinder head warped
  • Cylinder gasket damaged
  • Decompression trouble

Improper acceleration:

  • Choke valve closed
  • Carburetor fuel level too high or too low
  • Main jet clogged
  • hrottie valve does not fully open
  • Air cleaner element clogged
  • Muftler clogged
  • Fuel contaminated with water or foreign matter
  • Brake dragging
  • Clutch slipping
  • Engine overheating
  • Engine oil level too high
  • Engine oil viscosity too high
  • Crankshaft bearing worn or damaged
  • Ignition timing incorrect
  • Crankshaft sensor defective

Knocking:

  • Carbon built up in combustion chamber
  • Fuel quality poor or type incorrect
  • Spark plug type incorrect
  • Igniter defective

Engine overheating

Firing incorrect:

  • Spark plug dirty, broken, or gap improperly adjusted
  • Spark plug type incorrect
  • Igniter defective

Fuel/air mixture incorrect:

  • Main jet clogged or wrong size
  • Carburetor fuel level too low
  • Carburetor holder loose
  • Air cleaner element clogged, poorly sealed, or not installed
  • Air cleaner duct poorly sealed

Compression high:

  • Carbon built up in combustion chamber

Engine overloaded:

  • Brake dragging
  • Clutch slipping
  • Engine oil level too high
  • Engine oil viscosity too high
  • Drive chain trouble

Lubrication inadequate

  • Engine oil level too low
  • Engine oil quality poor or type incorrect

Clutch operation faulty

Clutch slipping:

  • No clutch release play (KLX110C Model)
  • No clutch lever play (KLX110D Model)
  • Clutch cable improperly Model)
  • Clutch cable defective (KLX110D Model)
  • Clutch plate is worn or warped
  • Clutch spring broken or weak
  • Clutch release maladjusted (KLX110C Model) adjusted (KLX110DD
  • Clutch release mechanism defective
  • Clutch hub or housing uneveniy worm

Clutch not disengaging property

  • Clutch release play excessive (KLX110C Model)
  • Clutch lever play excessive (KLX110D Model)
  • Cutch spring tension uneven
  • Engine oil deteriorated
  • Engine oil viscosity too high
  • Engine Oil level too high
  • Cutch housing froze on the drive shaft
  • Clutch release mechanism defective
  • Clutch hub nut lose
  • Clutch plate warped or rough
  • Clutch hub spline damaged

Gear shifting faulty

Transmission does not go into gear; shift pedal does not return:

  • Clutch not disengaging
  • Shift fork bent or seized
  • Gear stuck on the shaft
  • Shift mechanism arm spring broken
  • Shift mechanism arm broken
  • Shift return spring broken or weak
  • Shirt drum broken

Transmission jumps out of gear:

  • Shift fork worn
  • Gear groove worn
  • Gear dogs and/or dog grooves worn
  • Shift drum groove worn
  • Gear positioning lever spring broken or weak
  • Shift fork pin won
  • Driveshaft, output shaft, and/or gear splines worn

Transmission skips gears:

  • Gear positioning lever spring broken or weak
  • Shift mechanism arm spring broken or weak

Engine noise abnormal

Knocking:

  • Carbon built up in combustion chamber
  • Fuel quality poor or type incorrect
  • Spark plug type incorrect
  • Engine overheating
  • Igniter defective

Piston slap:

  • Piston clearance excessive
  • Cylinder or piston worn
  • Connecting rod bent
  • Piston pin or piston pin holes worn

Valve noise:

  • Valve clearance incorrect
  • Valve spring broken or weak
  • Camshaft bearing or cam face worn

Other noise:

  • Connecting rod small end clearance excessive
  • Connecting rod big end clearance excessive
  • Piston ring worn, broken or stuck
  • Piston seized or damaged
  • Cylinder head gasket leaking
  • Exhaust pipe leaking at the cylinder head
  • Crankshaft runout excessive
  • Engine mounts loose
  • Crankshaft bearing worn
  • Camshaft chain tensioner trouble
  • Camshaft chain, sprocket, chain guide worn
  • Flywheel magneto lose
  • Abnormal drive train noise

Clutch noise:

  • Clutch housing/friction plate clearance excessive
  • Clutch housing gear excesSIve
  • Metal chip jammed in clutch housing gear teeth

Transmission noise:

  • Crankcase bearing is worn or damaged
  • Transmission gear is worn or chipped
  • Metal chip jammed in gear teeth
  • Engine Oll level or Viscosity too low
  • Kick ratchet gear not properly disengaging from gear
  • Kick shaft idle gear worn or chipped ICK

Drive chain noise:

  • Drive chain slack improperly adjusted
  • Drive chain worn
  • Rear and/or engine sprocket(s) worn
  • Drive chain inefficiently lubrified
  • Rear wheel misaligned

Frame noise abnormal

Front fork noise:

  • Oil level or viscosity too low
  • .Spring broken or weak
  • Rear shock absorber noise:
  • Shock absorber damaged

Brake noise:

  • Brake maladjusted (lever or pedal play excessive)
  • Brake linings over worn or worn unevenly
  • Brake drum worn unevenly or scored
  • Brake spring(s) broken or weak
  • Foreign matter in hub

Other noise:

  • Bracket, nut, bolt, etc. improperly mounted or tightened

Exhaust smoke

Excessively white:

  • Piston oil ring worn
  • Cylinder worn
  • Valve oil seal damaged
  • Valve guide worn
  • Engine oil level too high

Black smoke:

  • Air cleaner element clogged
  • Main jet too large or fallen out
  • Choke valve closed
  • Carburetor fuel level too high

Brownish:

  • Main jet too small
  • Carburetor fuel level too low
  • Air cleaner duct loose
  • Air cleaner poorly sealed or missing

Poor handling and/or stability

Handlebar hard to turn:

  • Cable, wiring incorrectly routed
  • Steering stem locknut too tight
  • Steering stem bearing damaged
  • Steering stem bearing inadequately lubricated
  • Steering stem bent
  • Tire air pressure tOo low

Handlebar shakes or vibrates excessively:

  • Tire worn
  • Swingarm bushing damaged
  • Kim warpea or out or balance
  • Front and/or rear axle runout excessIve
  • wheel bearingWorn
  • Handlebar clamp loose
  • Steering stem head nut loose

Handlebar pulls to one side:

  • Frame bent
  • Rear wheel misaligned
  • SWingarm bent or twisted
  • SWingarm pivot shaft runout excessive
  • Steering maladjusted
  • Steering stem bent
  • Front fork bent
  • Rightleft front fork oil level uneven

Shock absorption unsatisfactory (suspension too hard):

  • Front fork oil excessive
  • Front fork oll viscosity too nign
  • Front fork bent
  • Tire air pressure too high

Shock absorption unsatisfactory (suspension too soft):

  • Front fork oil level insufficient and/or front fork
  • leaking oil
  • Front fork oil viscosity too low
  • Front fork and/or rear shock absorber spring weak
  • Rear shock absorber leaking oil or gas
  • Tire air pressure too low

Poor braking performance

  • Brake maladjusted (lever or pedal play excessive)
  • Brake linings over worn or worn unevenly
  • Brake drum worn unevenly or scored
  • Brake cam, camshaft, shaft hole worn
  • Oil, grease on lining and drum
  • Dirt, water between lining and drum
  • Overheated

Battery trouble

Battery discharged:

  • Charge insufficient
  • Battery faulty (too low terminal voltage)
  • Battery cable making poor contact
  • Flywheel magneto trouble
  • Wiring faulty
  • Regulator trouble

Battery overcharged:

  • Flywheel magneto trouble
  • Regulator trouble
  • Battery faulty
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