KLX Service Specs & Torque Settings

Coolant

  • 50% distilled water
  • 50% ethylene glycol
  • Capacity 1.6 liter
  • Level with filler neck.

    Valve Clearance (Cold)

  • Intake: 0.10-0.19 mm
  • Exhaust: 0.15-0.24 mm
  • Adjustment: Shim under tappet

    Spark Plug

  • NGK CR8E or ND U24ESR-N
  • Gap 0.7-0.8 mm ()

    Ignition Timing

  • Crankshaft Rotates CW from ignition (RH) side
  • Idle 10.0 BTDC at 1,700 rpm
  • Full 40.0 BTDC (double marks) at 3,000 rpm

    Carburetor

  • Idle Speed 1,300 100 rpm
  • Pilot Screw (fixed)
  • Main Jet: adjust for...altitude
  • Needle Position: adjust for...altitude

  • Engine Oil

  • SE Class SAE 10W40, 10W50, 20W40, 20W50
  • w/Filter Change 1.5 liter
  • No Filter Change 1.2 liter
  • On center stand
  • Middle of window
  • Pressure (Hot) 2.0-2.5 kg/cm2 at 4,000 rpm, 90C

    Tire Pressure (Cold)

  • Front = 11 psi
  • Rear = 15 psi

    Drive Chain

  • Slack = 50-60 mm on stand

    Rear Suspension

  • Adjust for... Sag
  • Rebound dampening 10 clicks CCW
  • Compression dampening 12 clicks CCW

    Front Suspension

  • Kayaba 01 or SAE 5W
  • Level 97 2mm
  • Air Pressure (Cold) 0 psi
  • Compression dampening 12 clicks CCW


  • Cooling System...

    Water Pump
    Impeller Nut - 69 in-lbs
    Coolant Drain Plug - 18ft lbs
    Thermostat Housing Cap Bolts - 87 in-lbs
    Elbow (Water Pipe) Mounting Bolts - 87 in-lbs
    Thermo. Fan Switch - 78 in-lbs
    Water Temp. Sensor - 78 in-lbs

    Engine Top End...

    Cylinder Head Cover Bolts - 69 in-lbs
    Camshaft Cap Bolts - 8.5 ft-lbs
    Cam Sprocket Bolts - 8.5 ft-lbs (Apply non perm locktite)
    Cylinder Head Bolts (6mm) 8.5 ft-lbs
    Cyl. Head Allen Bolts (First Torque = 11 ft-lbs, final =34)
    Cam Chain Guide Mounting Bolt - 18 ft-lbs
    Cam Chain Guide Bracket Bolt - 87 in-lbs
    Carb Holder Mounting Bolt - 8.5 ft-lbs
    Cam Chain Tensioner Mounting Bolts - 87 in-lbs
    Cam Chain Sub Tensioner Bolt 11 ft-lbs
    Inspection Cap - 22 in-lbs
    Rotor Cap - 22 in-lbs

    Engine Right/Left Side...

    Oil Drain Plug - 11 ft-lbs
    Clutch Hub Nut - 58 ft-lbs
    Clutch Spring Bolts - 29 in-lbs
    Shift Drum Cam Allen Bolt - 8.5 ft-lbs
    Return Spring Pin - 22 ft-lbs
    Primary Gear Nut - 72 ft-lbs
    Magneto Flywheel Bolt (12mm - 87 ft-lbs, 10mm 65 ft-lbs)
    Kick Ratchet Guide Bolt - 87 in-lbs
    Ext. Shift Mech. Cover bolts and nut - 87 in-lbs
    Ext Shift Mech. cover screw - 48 in-lbs
    Position Lever Nut - 87 in-lbs
    Exhaust Pipe Holder Nuts - 18lbs
    Clutch Cover Bolts - 87 in-lbs
    Clutch Cable Mounting Bolts - 87 in-lbs
    Right Engine Cover Bolts - 87 in-lbs
    Magneto Cover Bolts - 87 in-lbs

    Engine Lubrication System...

    Oil Drain Plug - 11 ft-lbs
    Oil Pressure Relief Valve - 11 ft-lbs use non perm locktite
    Oil Pipe Banjo Bolts =(8=87 in-lbs, 10=14.5 ft-lbs)
    Oil Pump Mounting Screws - 48 in-lbs

    Engine Removal/Installation...

    Swing Arm Pivot Shaft Nut - 65 ft-lbs
    Eng. Mounting Nuts - 33 ft-lbs
    Cyl. Head Bracket Bolts (8=22 ft-lbs, 10=33 - ft-lbs)

    Crankshaft/Tranny...

    Shift Drum Bearing Retaining Bolts - 87 in-lbs
    Crankcase bolts - 87 in-lbs and 11 ft-lbs
    Wheels...

    Front Axle Nut - 65 ft-lbs
    Front Axle Clamp Bolts - 87 in-lbs
    Rear Axle Nut - 72 ft-lbs
    Spoke nipples - not less than 13 in-lbs

    Final Drive...

    Rear Sprocket nuts - 22 ft-lbs
    Swing Arm Pivot Shaft Nut - 65 ft-lbs
    Tie-Rod Upper Mounting Nut - 60 ft-lbs
    Rear Axel Nut - 72 ft-lbs

    Brakes...

    Hose Banjo Bolts - 18 ft-lbs
    Front reservoir Cap Screws - 13 in-lbs
    Brake Lever Pivot Locknut - 52 in-lbs
    Front Master Cyl Clamp Bolts - 78 in-lbs
    Caliper Bleed Valves - 69 in-lbs
    Front Brake Disc Mounting Bolts - 87 in-lbs
    Rear Brake Disc Mounting Bolts - 16.5 ft-lbs
    Caliper Mounting Bolts - 18 ft-lbs
    Rear Brake Push Rod Locknut - 12.7 ft-lbs
    Brake Pad Bolts - 13 ft-lbs

    Suspension...

    Front Top Plug - 22 ft-lbs
    Front Fork Upper Clamp Bolts - 14.5 ft-lbs
    Front Fork Lower Clamp Bolts 18 ft-lbs
    Push Rod Nut - 11 ft-lbs
    Front Fork Cyl. Valve - 40 ft-lbs (Use non perm Locktite)
    Rear Shock upper/lower Mounting nut/bolt - 29 ft-lbs
    Swing Arm Pivot Shaft Nut - 65 ft-lbs
    Rocker Arm Pivot Nut - 10 ft-lbs
    Tie-Rod Mounting Nuts upper/lower - 8.3 ft-lbs

    Steering...

    Handlebar Clamp Bolts - 18 ft-lbs
    Steering Stem Head Nut - 33 ft-lbs
    Front Fork Upper Clamp Bolts - 14.5 ft-lbs
    Front Fork Lower Clamp Bolts - 18 ft-lbs
    Steering Stem Locknut - 35 in-lbs

    Electrical System...

    Spark Plug - 10 ft-lbs
    Magneto Flywheel Bolt - 87 ft-lbs
    Stator Coil Mounting Bolts - 52 in-lbs
    Pickup Coil Mounting Screws - 22 in-lbs

    Unlisted items...

         5mm => 30~43 in-lbs
         6mm => 52~69 in-lbs
         8mm => 10~13.5 ft-lbs
        10mm => 19~25 ft-lbs
        12mm => 33~45 ft-lbs
        14mm => 54~72 ft-lbs
        16mm => 83~115 ft-lbs
        18mm => 125~165 ft-lbs
        20mm => 165~240 ft-lbs