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Kick Shaft Inspection - Kawasaki KLX110 Service Manual

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Kickstarter
Apply molybdenum disulfide grease to the inside of the
kick gear [A] and kick shaft [B].
Replace the removed circlips with new ones.
When assembling the ratchet gear onto the kick shaft,
align the punch mark [A] on the ratchet gear with the
punch mark [B] on the kick shaft.

Kick Shaft Inspection

Visually inspect the parts and portion listed below.
Kick shaft return spring [A]
Ratchet gear spring [B]
Ratchet portion [C] of the kick gear [D] and ratchet gear
[E]
If there is any kind of damage, replace the damaged part.
Measure the kick shaft diameter [A] where the kick gear
fits.
If it is under the service limit, replace the shaft.
Measure the inside diameter [B] of the kick gear.
If it exceeds the service limit, replace the gear.
Kick Shaft, Kick Gear Inside Diameter
Standard:
Kick Shaft
Kick Gear
Service Limit:
Kick Shaft
Kick Gear
15.941 ∼ 15.968 mm
(0.62760 ∼ 0.62866 in.)
16.000 ∼ 16.018 mm
(0.62992 ∼ 0.63063 in.)
15.91 mm (0.6264 in.)
16.04 mm (0.6315 in.)
CRANKSHAFT/TRANSMISSION 8-23

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