2020 Kawasaki KLX140 Oil and Filter Change - Page 2

Road and Trail Guide

If the motorcycle is really dirty, I recommend that you wash it first, or at least clean around the following areas: oil filler cap, oil filter cover and oil drain plug.

1. Gather your tools, parts and supplies.

2. Start the engine and let it run for a few minutes to warm the oil and resuspend any sediment. Shut off the engine.

3. Spread newspaper or cardboard under the engine to protect the floor from oil spills.

4. Place an oil drain pan or pail below the engine oil drain plug.

5. With a 17 mm socket, 3-inch or 6-inch extension and ratchet, loosen the engine oil drain plug. With a gloved hand, remove the drain plug and crush washer. Try not to drop the drain plug or washer into the bucket of oil. Sometimes the crush washer will stick to the engine; you can use a small flat blade screw driver to loosen it before the drain plug is completely removed so that it comes off with the drain plug instead of falling into the pail of oil.

6. Let the oil drain as much as possible. To increase the amount of oil that is able to drain, tip the bike to both sides. Make sure that the drain pan or pail is in position to catch the oil. Repeat this a few times.

7. Note any differences in the surfaces of the crush washer and then remove it from the engine oil drain plug. If the crush washer is in good condition, and you are planning to reuse it, wipe it off and later install it in the original orientation (same side making contact with the engine). The service manual states to use a new drain plug gasket (crush washer). In my experience it's fine to reuse the crush washer as long as it still looks to be in good condition. If you prefer (or need) to replace the crush washer, it is often much cheaper to buy them in quantity from another source than to buy them as an OEM part from a motorcycle dealer.

8. Clean off the engine oil drain plug and install a new crush washer on it, or the original one if you're reusing it.

9. Once the oil has mostly drained (it might still drip for a while if you continue to wait), wipe the drain plug sealing surface on the engine to remove any dirt or sediment, and install the oil drain plug with a crush washer by hand until tight. With an accurate torque wrench, tighten the drain plug; the service manual specifies a torque value of 18 N.m (13 ft.lb). Don't exceed this amount.

If not replacing the oil filter, skip ahead to step 19 on the next page: add fresh oil to the engine.