My 2006 KLX 110 kickstart was slipping. At the time I wasn’t sure what was wrong as some suggested it could be the one way clutch. As it turns out the Output Shaft was the culprit. After some research I found out that it was quite the extensive fix, as you have to split the crank case to remove the broken output shaft. Here is a list of tools, parts, and resources you will need to get the job done in no particular order.

On a side note I replaced the left half crankcase due to some abnormal wear. I probably could have gotten away with using the old case but in the end I just replaced it. There are concerns about replacing just one half and they are supposed to be a “matching set”... However, the new case matched nicely and from all the research I did there doesn’t seem to be any problems for anyone else who has replaced one half of their case either.

If you are reading this then I hope it helps you determine what tools you will need and offer some insight on the cost of what it will be to do the job yourself.


//**Resources**//
KLX 110 parts diagram & parts numbers -
https://www.kawasaki.com/en-us/owner-...

Link to KLX 110 Service Manual - http://boss.csteam.free.fr/Moto/SM_KL...

KLX 110 Forum on Thumpertalk -
https://thumpertalk.com/forums/forum/...

//**Tools List**//
Tusk Crankcase Splitter - $70
Tusk flywheel puller - $15
Tusk pulley holder - $20( If you have an impact wrench you could probably skip out on this tool)
Crank Puller - $55( this helps pulling the case back together but serves well if you want to pull the crank out or replace with the 55mm stroker crank)
Blind bearing puller - (optional but could be useful for the needle bearing replacement.)
Hand Impact Driver 3/8 - $20 (this is a must have if you want to remove the Phillips head case bolts)
Butane torch or any other form of heat source comes in handy

Now for some of the parts you will want to replace while your bottom end is apart.

//**Parts List**//
KLX 110 complete gasket set - $40( includes rubber seals for case as well)
Hondabond- $9
Oil filter - $5
New case bolts Allen head - $25(these will replace those pesky Phillips head bolts)
Crankcase bearing and seal kit -$70
HD Output Shaft - $70
Magnetic oil drain plug - $6.50(optional)
BBR 4 speed shift drum - $73(optional)