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External Shift Mechanism; External Shift Mechanism Removal; External Shift Mechanism Installation - Kawasaki KLX110 Service Manual

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External Shift Mechanism

External Shift Mechanism Removal

Remove:
Clutch Cover
Primary Clutch
Secondary Clutch
Shift Pedal Clamp Bolt [A]
Shift Pedal [B]
Move the shift mechanism arm out of its position on the end of the
shift drum and pull out the shift shaft [A].
Remove the screw [A] and pivot bolt [B].
Remove the gear positioning plate [C], gear positioning lever [D] and
its spring [E] as a set.

External Shift Mechanism Installation

Apply non-locking agent to the lever pivot bolt.
Install the gear positioning lever, plate and spring.
Check that the return spring pin [A] is not loose.
Check that the return spring [B] and shift arm spring [C] are properly
fitted on the mechanism.
Torque -
Shift Drum Positioning Lever Pivot Bolt: 5.2 N
46 in
lb)
1
Shift Drum Position Plate Screw: 5.2 N
Apply high-temperature grease to the oil seal lips.
Install the shift shaft.
Install the removed parts.
Torque -
Return Spring Pin: 22 N
Install the shift pedal [A] to the shift shaft so that the pedal upper
surface [B] is level with the step upper surface [C].
m (0.53 kgf
1
m (0.53 kgf
m, 46 in
1
1
m (2.2 kgf
m, 16 ft
lb)
1
1
1
m,
1
lb)
1
CLUTCH 5-15

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