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Transmission Shaft Disassembly; Transmission Shaft Assembly - Kawasaki KLX110 Service Manual

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Apply clean engine oil to the shift fork fingers, and fit each
shift fork into its gear-groove so that the shift fork guide
pin is in the proper shift drum-groove.
Fingers of the 1st/3rd shift fork are longer than the fin-
gers of the 2nd/4th shift fork.
Apply clean engine oil to the shift rods [A], and insert each
rod running it through each shift fork [B].
Set the shift drum in neutral position, that is, drive and
output shaft turn freely.
Assemble the crankcase (see Crankcase Assembly).
Shall be checked that it is impossible to shift change
from top position to neutral position when output shaft
is driven.

Transmission Shaft Disassembly

Remove the transmission shafts.
Using the circlip pliers to remove the circlip, disassemble
the transmission shaft.
Special Tool - Outside Circlip Pliers: 57001-144

Transmission Shaft Assembly

Assemble the transmission gears as shown.
Replace the old circlip with a new one if it is removed.
The drive shaft gears can be identified by size; the small-
est diameter gear is 1st gear, and the largest it 4th. Be
sure that all parts are put back in the correct sequence,
facing the proper direction, and that the circlip and the
washer are properly in place.
2nd Gear [A]
3rd Gear [B]
4th Gear [C]
1st Gear [D]
Circlip [E]
Spacer [F]
Apply Engine Oil [G]
Bushing [H]


Table of Contents

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