Question about 2006 kawasaki KLX 110

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My sons klx 110 grinds when downshifting

I just went in and replaced the shifter shaft with both springs. The bike shifts fine from 1-3. It just grinds when you are moving and trying to shift down. Sitting still doesn't make a sound.

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While sitting still the gears are not moving. This sounds like a slightly bent shift fork. In the diagram below the slider gear moves left and right to engage the gears. The gear "dogs" fit into holes cast into the stationary gears. The grinding takes place as the fork moves the slider into first gear but the dogs are not getting moved the full distance needed to fully engage the gear because of the bent fork. The center case must be split to gain access to the gears and shift forks.

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My sons klx 110 grinds when downshifting - 276eff9.gif

Posted on Jun 30, 2009

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