Replace Gear Change Shaft on a 2001 Kawasaki KX100
On the kids’ KX100 the gear change shaft sheared at the neck and needed to be replaced. I wasn’t sure whether I would need to split the engine cases but as it turns out, the engine doesn’t even need to be removed from the frame.
- Remove seat – 2 allen screws
- Remove tank – screw at headset, screws on radiator shrouds, rubber clamp under seat
- Drain coolant
- Drain gearbox oil – drain screw underneath
- Remove kick start
- Disconnect clutch cable from actuator arm
- Remove clutch cover – 6 x 8mm screws
- Remove outer plate on clutch basket – 4 x spring loaded screws
- Remove pin from centre of clutch – should just pull out
- Remove clutch basket – large nut holding clutch basket on, whole assembly should slide off
- Remove powervalve cover – 4 x 8mm screws
- Disconnect powervalve actuator arm – circlip
- Disconnect coolant hoses from water pump
- Carefully remove right side engine cover, it might take a bit of wiggling, be patient – about 8 x 8mm screws
- Slide out the gear change shaft assembly
- Swap the springs and spacers onto the new shaft
- Replace shaft and re-assemble in reverse order
