2020 Kawasaki KLX140 Valve Adjustment - Page 1

Article Last Updated: June 10, 2024


2020 Kawasaki KLX140L

This is a step-by-step guide to checking and adjusting the valve clearances on a Kawasaki KLX140. It is based on the author’s observations and experience performing a valve clearance adjustment on a 2020 Kawasaki KLX140L and on information contained in the official Kawasaki KLX140 service manual, 2020 (part no. 99924-1390-14) which covers model years 2008 - 2021 and models KLX140A/KLX140/KLX140R, KLX140B/KLX140L/KLX140RL and KLX140C/KLX140G/KLX140RF. The author is not aware of any mechanical changes to the KLX140 models for the model years 2022-2024, so this guide should apply to those as well. Check with a Kawasaki dealer if in doubt or get the latest version of the service manual.

Read all of the instructions before beginning. It may be helpful to take photos of the bike prior to removing or repositioning parts to aid you later.

To follow the valve clearance inspection and adjustment procedure in the service manual will require you to reference multiple sections in it (lots of jumping back and forth through the manual). There is also some contradictory information. The service manual skips over a few points that would be helpful to know in advance. This guide attempts to fill in some gaps in the service manual, help clarify some points, provide better photos and offer some suggestions to make the valve clearance adjustment procedure a little easier if you're not that familiar doing this sort of thing. The procedure is relatively easy, especially compared to some other bikes that I have adjusted the valve clearances on.

On the KLX140 series, the valve clearances are adjusted via screw-type adjusters (the camshafts do not need to be removed and there are no shims to replace). Use the correct tools for the job, and take your time.

Disclosure: While the author has attempted to provide correct and complete information, sometimes errors or omissions may occur. By using this document and following the procedures and advice below, the user assumes all risk and responsibility for injury or damage to their motorcycle. The author has been servicing motorcycles for many years (not as a profession) and is mostly self-taught (no formal training in motorcycle servicing). It is recommended that you consult the Kawasaki KLX140 owner’s manual and/or service manual.

KLX140A / KLX140 / KLX140R: model with 17”/14” wheel combination
KLX140B / KLX140L / KLX140R L: model with 19”/16” wheel combination
KLX140C / KLX140G / KLX140R F: model with 21”/18” wheel combination

Parts and supplies you may need

Tools you need or may find helpful

Information from the Kawasaki KLX140 Service Manual

Recommended service intervals for valve clearance inspection
Initial: 5 hours or 1 month
Then: every 100 hours or 12 months

Valve Clearances Engine cold: at room temperature
Intake: 0.04 - 0.08 mm (0.002 - 0.003 in.)
Exhaust: 0.11 - 0.15 mm (0.0043 - 0.0059 in.)

Torque Specifications
Valve adjusting cap bolts: 8.8 N.m (78 in.lb)
camshaft chain cover bolts: 8.8 N.m (78 in.lb)
Valve adjusting screw locknuts: 8.8 N.m (78 in.lb)
Alternator cover center cap: 2.5 N.m (22 in.lb)
Alternator cover plug: 2.5 N.m (22 in.lb)
Spark plug: 13 N.m (115 in.lb)

Spark Plug Gap
0.6 - 0.7 mm (0.2 - 0.3 in)

Service Manual Instructions

Note: You will first need to remove the alternator cover center cap. In one location in the service manual, it states to turn the crankshaft clockwise, and in another location, it states to turn the crankshaft counter-clockwise. In another part of the service manual, the text contradicts the diagram showing direction of manual crankshaft rotation. The service manuals I have for other motorcycles all state to rotate the crankshaft counter-clockwise, when viewed from the left side of the engine (rider facing forward).