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Crankcase Assembly - Kawasaki KLX110 Service Manual

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Crankcase Assembly

Right and left crankcase halves are machined at the
factory in the assembled state, so the crankcase
halves must be replaced as a set.
Chip off the old gasket from the mating surfaces of the
crankcase halves.
Using compressed air, blow out the oil passages [A] in the
crankcase halves and the crankshaft.
With high flash-point solvent, clean off the mating sur-
faces of the crankcase halves and wipe dry.
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the engine parts in a well-ventilated
area, and take care that there is no spark or flame
anywhere near the working areas.
gasoline or low flash-point solvents to clean parts.
Using a press and the bearing driver set, install new bear-
ings until they bottoms out.
Press the output shaft bearing [B] in the left crankcase
half [A].
Special Tool - Bearing Driver Set: 57001-1129
Replace the oil seals [C] with new ones.
Apply high-temperature grease to the lips of the oil seals.
Press in the oil seals of the left crankcase half so that the
seal surface is flush with the end of the hole.
Apply a non-permanent locking agent to the bearing re-
tainer screws.
Tighten the shift drum and drive shaft bearing retainer
screws to the right crankcase.
Torque - Shift Drum Bearing Retainer Screws [A]: 2.5 N·m
(0.25 kgf·m, 22 in·lb)
Drive Shaft Bearing Retainer Screw [B]: 5.2 N·m
(0.53 kgf·m, 46 in·lb)
Install the shift drum (see Shift Drum Installation).
Insert the crankshaft jig [A] between the crankshaft fly-
wheels opposite the connecting rod big end to protect fly-
wheel alignment. This tool is easily adjustable to fit in any
gap between the flywheel.
Special Tool - Crankshaft Jig: 57001-1174
Do not use


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