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Table of Contents
Crankshaft/Transmission
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools & Sealant..........................................................................................................
Crankcase ..............................................................................................................................
Crankcase Splitting ...........................................................................................................
Crankcase Assembly ........................................................................................................
Crankshaft, Connecting Rod ..................................................................................................
Crankshaft Disassembly ..................................................................................................
Crankshaft Assembly ........................................................................................................
Connecting Rod Big End Seizure Inspection ....................................................................
Connecting Rod Big End Radial Clearance Inspection.....................................................
Connecting Rod Big End Side Clearance Inspection........................................................
Crankshaft Runout Inspection...........................................................................................
Crankshaft Alignment........................................................................................................
Crankshaft Main Bearing Wear Inspection .......................................................................
External Shift Mechanism.......................................................................................................
Shift Pedal Removal .........................................................................................................
Shift Pedal Installation ......................................................................................................
External Shift Mechanism Removal ..................................................................................
External Shift Mechanism Installation ...............................................................................
External Shift Mechanism Inspection................................................................................
Transmission ..........................................................................................................................
Shift Drum Removal..........................................................................................................
Shift Drum Installation.......................................................................................................
Transmission Removal .....................................................................................................
Transmission Installation ..................................................................................................
Transmission Shaft Disassembly ......................................................................................
Transmission Shaft Assembly...........................................................................................
Shift Fork Bending Inspection ...........................................................................................
Shift Fork Ear/Gear Shift Fork Groove Wear Inspection...................................................
Shift Fork Guide Pin/Shift Drum Groove Wear Inspection ................................................
Gear Dog/Gear Dog Hole Damage Inspection .................................................................
Ball Bearing, Needle Bearing, and Oil Seal............................................................................
Ball and Needle Bearing Wear Inspection ........................................................................
Oil Seal Inspection ............................................................................................................
Kickstarter...............................................................................................................................
Kick Pedal Removal..........................................................................................................
Kick Pedal Installation.......................................................................................................
Kick Shaft Removal...........................................................................................................
Kick Shaft Installation........................................................................................................
Kick Shaft Disassembly/Assembly....................................................................................
Kick Shaft Inspection ........................................................................................................
CRANKSHAFT/TRANSMISSION 8-1
Table of Contents
8-2
8-6
8-7
8-8
8-8
8-9
8-12
8-12
8-12
8-13
8-13
8-13
8-13
8-14
8
8-14
8-15
8-15
8-15
8-15
8-15
8-16
8-17
8-17
8-17
8-17
8-17
8-18
8-18
8-19
8-20
8-20
8-20
8-21
8-21
8-21
8-22
8-22
8-22
8-22
8-22
8-22
8-23

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Table of Contents

   Also See for Kawasaki KLX110

This manual is also suitable for:

Klx110l

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