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External Shift Mechanism; Shift Pedal Removal; Shift Pedal Installation; External Shift Mechanism Removal - Kawasaki KLX110 Service Manual

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External Shift Mechanism

Shift Pedal Removal

Remove the shift pedal bolt [A] and take off the shift pedal
[B] from the shift shaft.

Shift Pedal Installation

Install the shift pedal [A] to the shift shaft so that the up-
per surface of pedal [B] is level with the upper surface of
footpeg [C].
Torque - Shift Pedal Bolt: 5.2 N·m (0.53 kgf·m, 46 in·lb)

External Shift Mechanism Removal

Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).
Clutch (see Clutch Removal (KLX110C/D) in the Clutch
Shift Pedal (see Shift Pedal Removal)
Move the shift mechanism arm [A] out of its position on
the end of the shift drum and pull out the shift shaft [B].
Remove the screw [A] and pivot bolt [B].
Remove the gear positioning plate [C], gear positioning
lever [D] and its spring [E] as a set.

External Shift Mechanism Installation

Apply a non-permanent locking agent to the lever pivot
bolt [A].
Install the gear positioning lever, plate and spring.
Torque - Shift Drum Position Lever Pivot Bolt: 5.2 N·m
(0.53 kgf·m, 46 in·lb)
Shift Drum Position Plate Screw [B]: 5.2 N·m (0.53
kgf·m, 46 in·lb)


Table of Contents

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