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Shift Fork Bending; Shift Fork Ear/gear Shift Fork Groove Wear; Shift Fork Guide Pin/shift Drum Groove Wear - Kawasaki KLX110 Service Manual

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Transmission

Shift Fork Bending

Visually inspect the shift forks, and replace any fork that is bent. A
bent fork could cause difficulty in shifting, or allow the transmission
to jump out of gear when under power.

[A] 90

Shift Fork Ear/Gear Shift Fork Groove Wear

Measure the thickness [A] of the shift fork ears.
If the thickness of a shift fork ear is less than the service limit, the
shift fork must be replaced.
Shift Fork Ear Thickness
Standard:
Service Limit:
Measure the width [A] of the gear shift fork grooves in the transmission
gears.
If a gear shift fork groove is worn over the service limit, the gear must
be replaced.
Gear Shift Fork Groove Width
Standard:
Service Limit:

Shift Fork Guide Pin/Shift Drum Groove Wear

Measure the diameter [A] of each shift fork guide pin, and measure
the width [B] of each shift drum groove.
If the guide pin on any shift fork is less than the service limit, the fork
must be replaced.
Shift Fork Guide Pin Diameter
Standard:
Service Limit:
If any shift drum groove is worn over the service limit, the drum must
be replaced.
Shift Drum Groove Width
Standard:
Service Limit:
3.9
4.0 mm
3.8 mm
4.05
4.15 mm
4.3 mm
4.9
5.0 mm
4.8 mm
5.05
5.20 mm
5.3 mm
CRANKSHAFT / TRANSMISSION 8-13

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