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Crankshaft, Connecting Rod; Crankshaft Disassembly And Assembly; Disassembly; Assembly - Kawasaki KLX110 Service Manual

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Crankshaft, Connecting Rod

Crankshaft Disassembly and Assembly

Since assembly of the crankshaft demands exacting tolerance,
the disassembly and reassembly of the crankshaft should only
be performed by experienced mechanics with the necessary
tools and equipment. The crankpin, connecting rod, and light
crankshaft are available separately as spare parts, however
it is recommended that the crankshaft assembly be replaced
rather than attempting to replace the components.


If it should be necessary to disassemble the crankshaft.
Remove the camshaft chain drive sprockets and bearing, using the
bearing puller if the drive sprocket and bearing remains on the
Use a press to remove the crankpin.
Removal of the crankpin separates the flywheels, connecting rod, big
end needle bearing, and crankpin.
Special Tool -
Bearing Puller: 57001–158


Press the bearing until it bottoms out.
Press the camshaft chain drive sprocket on to the left flywheel as
Apply engine oil to the big end bearing.
Press the crank halves onto the crankpin, noting the crankpin direction
until connecting rod side clearance is within specification as shown.
Side Clearance 0.1
0.2 mm [A]
Crankpin Depth 0.8
1.2 mm [B]
Check the following items after the crankshaft assembly.
Connecting Rod Radial Clearance
Connecting Rod Side Clearance
Crankshaft Runout

Connecting Rod Big End Seizure

In the case of serious seizure with damaged flywheels, the crankshaft
must be replaced.
In the case of less serious damage, disassemble the crankshaft and
replace the crankpin, needle bearing, side washers, and connecting


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