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Transmission And Shift Mechanism Installation - Kawasaki KLX110 Service Manual

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Table of Contents
Apply Engine Oil [G]
Always install circlips so that the opening is aligned with a spline
groove. To install a circlip without damage, first fit the circlip onto the
shaft expanding it just enough to install it, and then use a suitable
gear to push the circlip into place.
[A] Opening of Circlip
[B] Groove of Shaft Spline

Transmission and Shift Mechanism Installation

Fit the shift drum to the right crankcase half.
Install the shift drum cam [A] aligning its hole [B] with the dowel pin
Install the holder and tighten the Allen bolt.
Torque -
Shift Drum Allen Bolt: 5.2 N
Apply a clean engine oil to the transmission gears, bearings, and
shaft journal, and fit the output [A] and drive shaft [B] assemblies as
a set into the right crankcase half.
Set the shift drum in neutral position.
Apply a clean engine oil to the shift fork fingers, and fit each shift fork
into its gear-groove so that the shift fork guide pin is in the proper
shift drum-groove.
Fingers of the 1st/3rd shift fork are longer than the fingers of the
2nd/4th shift fork.
Apply a clean engine oil to the shift rods [A], and insert each rod
running it through each shift fork [B].
Set the shift drum in neutral position, that is, drive and output shaft
turn freely.
Assemble the crankcase.
m (0.53 kgf
m, 46 in


Table of Contents

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