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Crankshaft, Connecting Rod; Crankshaft Disassembly; Crankshaft Assembly - Kawasaki KLX110 Service Manual

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Crankshaft, Connecting Rod

Crankshaft Disassembly

Since assembly of the crankshaft demands exact-
ing tolerance, the disassembly and reassembly
of the crankshaft should only be performed by
experienced mechanics with the necessary tools
and equipment. The crankpin, connecting rod, and
right crankshaft are available separately as spare
parts, however it is recommended that the crank-
shaft assembly be replaced rather than attempting
to replace the components.
If it should be necessary to disassemble the crankshaft,
follow the following procedures.
Remove the oil pump drive gear and bearing, using the
bearing puller.
Special Tool - Bearing Puller: 57001-158
Use a press to remove the crankpin.
Removal of the crankpin separates the flywheels, con-
necting rod, big end needle bearing, and crankpin.

Crankshaft Assembly

Carefully align the oil passage hole in the right flywheel
[A] with the one in the crankpin [B] at rebuilding of the
crankshaft as shown.
Apply engine oil to the big end bearing.
Press the crank halves onto the crankpin, noting the
crankpin direction until connecting rod side clearance is
within specification as shown.
Side Clearance [A]: 0.1 ∼ 0.2 mm (0.004 ∼ 0.008 in.)
Crankpin Depth [B]: 0.8 ∼ 1.2 mm (0.0315 ∼ 0.0472 in.)
Press the bearing [A] and oil pump drive gear [B] until they
bottom out.


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