Klt 110

[fixer2u]

Hey All new to the forum here.

I have a KLT 110 and the shifter shaft broke off on me. I have located the part online, but have misplaced my service manual and caoont find it! Can anyone help me out with instructions from the manual on the procedure for replacing this part?

Any help would be appreciated!

Thanks.

Nick

[hogmuffin]

not the best quality scans...hope this helps.

[hogmuffin]

basically, pull off the right side engine cover, remove the clutch, and the transmission gear. then pull down on the shift hooks so they are clear of the shift drum cage. then you can pull out the shaft. you'll have to remove the centering spring and shift arm, and install them on the new shaft. then install in reverse order.

[fixer2u]

THank you! Thats a lot better than nothing! Much appreciated!

[fixer2u]

Well I fonally got around to installing the shift shaft and that portion went great thanks to the help on here.... BUT after about 15 minutes of riding the brand new shaft broke off AGAIN! In the exact same spot as the previous one....

Both shafts broke in the dipped spot between the splined areas. WHat gives here? I know people have talked abotu the metal being crappy as I can tell by the dull white color in the fracture. My shifter is in great shape and is a direct OEM replacement, so what can I do here? Are there any tricks to help me avaid this? WHat have others done?

THanks in advance!

[barnett468]

Hello

Sorry to hear you are having trouble with you KLT. I actually did ALL the R and D testing on those when I worked at Kawi do I am very fond of them.

Well I fonally got around to installing the shift shaft and that portion went great thanks to the help on here.... BUT after about 15 minutes of riding the brand new shaft broke off AGAIN! In the exact same spot as the previous one....Both shafts broke in the dipped spot between the splined areas. WHat gives here?

Used or aftermarket parts might be what gives, did you install a brand new factory Kawi one?

Did it come in the original Kawi package?

If you did install a new Kawi made one and it broke then the material has been changed somehow from the original ones made in 1984 and I suggest trying to find a good original one.

A 29 year old used one may have the same problem. If you installed a used one I suggest you buy a new original one. See the link below. Since it will have no fatigue from use it will last many more years.

A failure like this should not happen but still should not be surprising after 27 years or more of abuse. Yes the Honda’s don’t have this 1 single problem but many more that make up for it with ALL the other clutch and shifter problems they have.

Can you post a close up photo directly to the site [not a jpeg url, I can’t view those] or post it to flickr etc and paste a link to it here.

84’-86’ KLT 110 shift shaft p/n 13161-1044 $48.00

http://www.xtremeusa.com/pages/OemPa...1984/080193C-5


partzilla.com

http://www.partzilla.com/parts/detai...3161-1044.html


xxxxx

I know people have talked abotu the metal being crappy as I can tell by the dull white color in the fracture.

It may not be as good as the Honda’s shaft but the prototype I had was tested for around 150 hours or more, half of which was under “race” type conditions. After this time it along with a new pre production bike was tested side by side for another 100 hours side. During ALL the tests my instructions from the 3 Japanese engineers Kawi Japan sent over specifically for this project was to try and break it. I and my friend were both pro riders at the time and so we beat the “bleepin” “bleep” out of those things. There was not a single failure or spark plug change during the entire testing period however the stupid shifter kept coming loose ALL the time.

Xxxxx

My shifter is in great shape and is a direct OEM replacement

If it is an original Kawasaki part p/n 12161-1044 it’s good, if not it’s likely Chinese and I wouldn’t use it.

[fixer2u]

Barnett, THank you for the reply!

http://www.motosport.com/atv/oem-par...ANGE-MECHANISM
That is the shift shaft I installed. It appears to be a brand new Kawi part. I do not recall if it was in a Kawi package you mentioned.

I will take a pic and post it when I get home tonight so you can see.

I will order another new one from one of the sites you posted and see what happens.

Might it be worth putting some JB Weld on the splines of the new one to maybe give things more support?

THanks again!

[fixer2u]

The shifter I got was this one. It appears to be original Kawa? http://www.motosport.com/atv/oem-par...ANGE-MECHANISM
I do not recall if it came in the original packaging...

I will take your advise and get another from one of the sources you posted.

I can post pictures tonight when I get home from work.

THank you for the reply!

Nick

[fixer2u]

The shifter I got was this one. It appears to be original Kawa? http://www.motosport.com/atv/oem-par...ANGE-MECHANISM
I do not recall if it came in the original packaging...

I will take your advise and get another from one of the sources you posted.

I can post pictures tonight when I get home from work.

[jb2wheels]

Interesting... I learned something about KLT 110s today:

http://www.3wheelerworld.com/showthr...-1985-klt-110?

http://www.3wheelerworld.com/showthr...cs-please-help

[shortline10]

Cut the klt shaft and weld on a Honda spline and be done with it LOL . The KLT's have issues for sure with the stock shift shaft either breaking or stripping out .

[fixer2u]

barnett, here is the picture of the fracture along with the shifter.

[Ghostv2]

@barnett468 - I think its pretty cool we have the original guys who worked on these bike and tested these bikes back in the day here to help us out. It must have been one pretty cool job, however one managed to get that job is beyond me. Do we have a lot of others like you here?

Sorry to get a little off topic guys.

[barnett468]

Hello

Can you post a close up photo directly to the site [not a jpeg url, I can’t view those] or post it to flickr etc and paste a link to it here.

Sorry I can’t view the photos the way you posted them.

[fixer2u]

Sorry Barnett I completely misread what you posted.

http://img.photobucket.com/albums/v4...5-28191222.jpg