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External Shift Mechanism Inspection - Kawasaki KLX110 Service Manual

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External Shift Mechanism
Check that the return spring pin [A] is not loose.
If it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Return Spring Pin: 22 N·m (2.2 kgf·m, 16 ft·lb)
Check that the return spring [B] and shift arm spring [C]
are properly fitted on the mechanism.
Apply high-temperature grease to the oil seal lips.
Install the shift shaft [D].
Install the removed parts (see appropriate chapters).

External Shift Mechanism Inspection

Examine the shift shaft for any damage.
If the shaft [A] is bent, straighten or replace it.
If the splines [B] are damaged, replace the shaft.
If the return spring [C] and arm spring [D] are damaged in
any way, replace them.
If the shift pawl [E] is damaged in any way, replace the
shift shaft assembly.
Check the gear positioning lever [A] and spring [B] for
breaks or distortion.
If the lever or springs are damaged in any way, replace


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