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Clutch Plate Wear And Damage; Clutch Plate Warp; Secondary Clutch Housing Finger Damage; Secondary Clutch Hub Spline Damage - Kawasaki KLX110 Service Manual

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Check that the rollers [A] in the one-way clutch is installed as shown
when viewed from the right side of the engine.

Clutch Plate Wear and Damage

Visually inspect the friction and steel plates for uneven wear, discol-
oration, missing friction material, cracks, or other damage.
If any plates show signs of damaged, replace the friction and steel
plates as a set.
Measure the thickness of the friction plates [A] at several points.
Friction Plate Thickness
Service Limit:
If any of the measurement is less than the service limit, replace the
plates as a set.

Clutch Plate Warp

Place each friction plate or steel plate [B] on a surface plate [A] and
measure the gap between the surface plate and each plate with a
thickness gauge [C]. The gap is the amount of friction and steel plate
If any of the clutch plate is warped beyond the service limit, replace
the plate with a new one.
Friction Plate and steel Plate Warp
0.15 mm or less (Steel Plate)
0.2 mm or less (Friction Plate)
Service Limit:
0.3 mm

Secondary Clutch Housing Finger Damage

Visually inspect the clutch housing finger [A] where the friction plate
tangs [B] hit them.
If they are badly worn or if there are groove cuts where the tangs hit,
replace the housing. Also, replace the friction plates if their tangs are

Secondary Clutch Hub Spline Damage

Visually inspect where the teeth on the steel plates wear against the
clutch hub splines.
If there are notches worn into the clutch hub splines [A], replace the
clutch hub. Also, replace the steel plates if their teeth are damaged.
3.3 mm
2.9 mm


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