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Clutches; Clutch Removal; Clutch Installation - Kawasaki KLX110 Service Manual

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Clutch Removal

Remove the clutch cover (see this chapter).
Release Ball Assembly [A]
Release Cam [B]
Ball Bearing [C]
Ball Bearing Holder [D]
Remove the primary clutch hub nut [A], while holding the primary
clutch steady with the primary clutch holder [B].
Special Tools - Primary Clutch Holder: 57001–1507
Pull out the primary clutch hub [C].
Remove the secondary clutch hub nut [A], while holding the sec-
ondary clutch steady with the clutch holder [B].
Search the positions of three notches of clutch holder, which can be
Remove two clutch spring bolts [C] inserted into the two holes of
clutch holder when searching.
Set a clutch holder.
Special Tools - Clutch Holder: 57001–1508
Remove the primary clutch [A] and secondary clutch [B] together.
Do not remove the one-way clutch from the primary clutch.
Remove the spacer from the drive shaft.

Clutch Installation

Apply engine oil to the clutch sleeves, drive shaft, and crankshaft.
Install the spacer [A] to the drive shaft.
Insert the secondary clutch.
Be sure to install the spacer [B] between secondary clutch housing
and clutch wheel.
Hard to install the secondary clutch, turn the drive shaft while pushing
the clutch.
Tighten the secondary clutch nut, while holding the secondary clutch
Torque -
Secondary Clutch Hub Nut: 72 N
Special Tools - Clutch Holder: 57001–1508
m (7.3 kgf
m, 53 ft


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