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Transmission; Transmission And Shift Mechanism Removal; Transmission Disassembly; Transmission Assembly - Kawasaki KLX110 Service Manual

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Transmission

Transmission and Shift Mechanism Removal

Split the crankcase.
Pull out the shift rods and take out the shift forks.
Remove the drive and output shaft assemblies as a set.
Holding the shift drum with suitable bar, unscrew the shift drum Allen
bolt [A].
Remove the cam holder [B], shift drum cam [C] and dowel pin [D].
Remove the shift drum [E].

Transmission Disassembly

Remove the transmission shafts.
Using the circlip pliers to remove the circlip, disassemble the trans-
mission shaft.
Special Tool -
Outside Circlip Pliers: 57001–144

Transmission Assembly

Assemble the transmission gears as shown.
Replace the old circlip with a new one if it is removed.
The drive shaft gears can be identified by size; the smallest diameter
gear is 1st gear, and the largest it 4th (not working). Be sure that all
parts are put back in the correct sequence, facing the proper direction,
and that the circlip and the washer are properly in place.
2nd Gear [A]
3rd Gear [B]
4th Gear (not working) [C]
1st Gear [D]
Circlip [E]
Shim [F]
Apply Engine Oil [G]
The output shaft gears can be identified by size; the largest diameter
gear is 1st gear, and the smallest is 4th (not working). Be sure that
all parts are put back in the correct sequence and facing the proper
direction, and that the circlip is properly in place.
2nd Gear [A]
3rd Gear [B]
4th Gear (not working) [C]
1st Gear [D]
Circlip [E]
Spacer [F]
CRANKSHAFT / TRANSMISSION 8-11

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