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Shift Fork Ear/gear Shift Fork Groove Wear Inspection; Shift Fork Guide Pin/shift Drum Groove Wear Inspection; Gear Dog/gear Dog Hole Damage Inspection - Kawasaki KLX110 Service Manual

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8-20 CRANKSHAFT/TRANSMISSION
Transmission
Shift Fork Ear/Gear Shift Fork Groove Wear
Inspection
Measure the thickness [A] of the shift fork ears.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
3.9 ∼ 4.0 mm (0.154 ∼ 0.157 in.)
Standard:
Service Limit: 3.8 mm (0.150 in.)
Measure the width [A] of the gear shift fork grooves in the
transmission gears.
If a gear shift fork groove is worn over the service limit,
the gear must be replaced.
Gear Shift Fork Groove Width
4.05 ∼ 4.15 mm (0.159 ∼ 0.163 in.)
Standard:
Service Limit: 4.3 mm (0.17 in.)
Shift Fork Guide Pin/Shift Drum Groove Wear
Inspection
Measure the diameter [A] of each shift fork guide pin, and
measure the width of each shift drum groove.
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.)
Standard:
Service Limit: 4.8 mm (0.189 in.)
If any shift drum groove [A] is worn over the service limit,
the drum must be replaced.
Shift Drum Groove Width
5.05 ∼ 5.20 mm (0.199 ∼ 0.205 in.)
Standard:
Service Limit: 5.3 mm (0.21 in.)

Gear Dog/Gear Dog Hole Damage Inspection

Visually inspect the gear dogs [A] and gear dog holes [B].
Replace any damaged gears or gears with excessively
worn dogs or dog holes.

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   Also See for Kawasaki KLX110

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Klx110l

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