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Shift Fork Bending Inspection - Kawasaki KLX110 Service Manual

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Transmission
The output shaft gears can be identified by size; the
largest diameter gear is 1st gear, and the smallest is
4th. Be sure that all parts are put back in the correct
sequence and facing the proper direction, and that the
circlip is properly in place.
2nd Gear [A]
3rd Gear [B]
4th Gear [C]
1st Gear [D]
Circlip [E]
Spacer [F]
Apply Engine Oil [G]
Circlip [H]
KLX110CA ∼ CC, KLX110DA ∼ DC Models [I]
KLX110CD, KLX110DD Models ∼ [J]
Always install circlips so that the opening is aligned with
a spline groove. To install a circlip without damage, first
fit the circlip onto the shaft expanding it just enough to
install it, and then use a suitable gear to push the circlip
into place.
[A] Opening of Circlip
[B] Groove of Shaft Spline

Shift Fork Bending Inspection

Visually inspect the shift forks, and replace any fork that is
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
90° [A]
CRANKSHAFT/TRANSMISSION 8-19

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