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Posted by: tenney
Hi,
I owned one of these back in the 80s. I had similar problems with the shifter. It took a quite a few miles before it stripped. I didn't know this was a problem for all of them. I just brought it to a local shop and had them weld it on. Of course not to much later the tranny locked up tight. That was a really sad day because I really enjoyed this bike and couldn't afford another at the time. Let us know how it goes! I think these are one of the better 110s out there. I was suprised at the lack of power on the honda the first time I rode it compared to mine.
Posted by: 03P360
Before you tear anything apart too much to fix the tranny, try taking the shift lever off and with out the bolt in it pinch it together in a vice. Next take a hack saw and make a cut where the opening would be if it wasnt pinched shut. After you do this once or twice it will pinch down on the shaft tighter and shouldn't slip as easily.
Posted by: fartman
hey lim, on your parts trike do you have the left side case cover, the part that the pull starter bolts up to? i would be willing to buy it for a fair price. just to let you know there was a stock klt in camo, it was called the "duckster"..klt110 is also very close to a klf110, the diff is the klt is a trike and klf is a quad. if you have that part let me know.
Posted by: fartman
Anyone have any spare parts for there 110?
Posted by: lim599
I'm into an E-bay adventure...Trying to restore an Kawasaki KLT 110. Ended up with two part Trikes 85' 84'. Close to enough parts to rebuild one. I've heard the KLT110 Tranny has common problems with shifter being striped or not working. Is their anybody out there who knows the history of this? How to check for this on my two motors both not on the frame yet?
I'm going to need some help from a KLT 110 owner as most this adventure is coming to me in parts.
Posted by: lim599
Hi dirtbikejunkie-
Thanks for the comeback. I'm a 3 wheeler newbee, for that matter a ATV/ATC newbee.
I picked up a 85' KLT 110 without an engine. It was in pretty good shape with most parts but repainted in camo. It looked like someone had started to rebuild the trike. Only problem it didn't have an engine. Owner said he had bought it in this shape that the tranny had gone bad and Pervious owner tossed the engine with mounting Hardware.
At the same time I saw an 85' engine on ebay listed as "Has good compression"...So my ebay adventure began... I ended up winning the engine with some other choice parts in the catagory of Good Juck. The owner had most of the missing items (so I thought) to make mine whole. The engine does seem to have good compression but the shifter foot lever does not seem to grab the splines on the shift axle. Not knowing what a working shifter lever or shaft should look like... It appears as if the foot lever was worn internally and the lever splines were striped. At least I have an engine.
So I started looking for a shifter and few other engine related parts (air box and exhaust). So I happen upon another ebay 84' KLT 110 parts trike on two flat tires and missing one. It had a engine! the shifter is loose but was able to shift but ... The indicator shaft was broken off with the red indicator gone. At least I have an air box and exhaust.
Since then I found two more ebay KLT110 motors both with shifter problems. I didn't buy these. The first says the tranny was working but the lever is welded to the shaft. The other said the shaft was stripped.
I was just trying to find out if there's a common tranny problem with this model. Or if these are examples of normal old 3 wheeler problems? Hopefully with a common repair. If the shifter is welded how do you get to the tranny parts to repair?
Thanks
Posted by: lim599
QUADRUNNERMIKE/ Dirtbikejunkie-
Thanks for the postings- Good to know someone else has a Kawi.
I don't have a problem opening up the tranny just don't know what I'm looking for.
Once I strighten out the lever problem I'm going to swap the two best shafts.
So I took the shift levers off both my motors. 1. was stripped badly and chewed up.
2. The other the screw head broke off and streads are seized. Looking for the correct
Drill and tap.
QUADRUNNERMIKE- Do you happen to know on your K110 Carb. Where the three lines go?
I got mine in pieces w/o hoses. I think the larger in gas in, But don't know where the bottom line and top right angle line goes?
Thanks
Posted by: lim599
Hi Mike-
Thanks for the info-on lines hook-up.
Will leave the two ports open.
I have parts of two bikes. I actually have one complete carb and lower body part of another for parts. I haven't had a chance to open this partial to see if it even has a float. It's missing the top cap. Would be willing to part with it if I can get the other carb to work. This might take me a while since I haven't finish the motor install yet with the tranny issues.
The shift lever splines are striped on my best tranny so it looks like I'm going to learn how to remove the shaft and replace better one from my other tranny. I drilled out the broken screw in the shift lever and had to put in a helicoil.
Posted by: lim599
Thanks Mike
Will see where we end up on this after the Tranny.
Earnie
Posted by: lim599
Thanks Trailbazer-
Yes with the screw all the way in the two halfs are in contact. I'might saw some clearance in the slot. It's a easier fix the only thing is the collar at the lever is welded quite well and I'm not sure how much I can closed the gap w/o breaking the collar. I'm also researching how bad the shaft change might be. It would be nice if I could get the better shaft in.
I also got a suggestion from a friend. He suggest using a welder just to build material onto the splines making the diameter back to original then dermal in some new splines. Don't think this would look to good the way I weld but it isn't permenant.
Thanks for the tip.
Posted by: lim599
Will let you know how it turns out -
I hope I get mine running!
Posted by: dirtbikejunkie
I have a 1985 KLT250 and have not had any shifter problems with it, but the 110's may be different. If you could describe the exact problem your are refering to I can check my service manual, but again I don't kow if the 250 is different. I will be glad to help if I can. Pretty reliable old machines though. Mine is for sale if anyone is interested.
Posted by: dirtbikejunkie
If the shift lever is welded to the shaft it would be impossible to remove the shaft from the case, but if you aren't concerned about taking apart the trany then it shouldn't be a big deal. The shaft is splined as is the shift lever, and usually the shift lever is made out of a softer metal than the shaft so the shifter will strip out before the shaft. Transmission repairs are pretty costly because you have to split the engine cases, unless you do it yourself. I personally would not be concerned about the lever being welded on because if you end up having transmission troubles it will probably cost more to fix the trany than the trike is worth. As for the shift indicator mine does not have one, and I haven't seen one. My shift pattern is 1-N-2-3-4-5 I don't know if yours is the same or not. I really haven't helped much but if you need anything else I will try to help you out.
Good Luck!
Posted by: QUADRUNNERMIKE
I have a 1985 Klt110, and yes it is a little stripped, and slips from time to time i just replaced the bolt because the solines arent too bad on it. im just wonderin when it will go next
--------------------------
2002 Suzuki Quadrunner500
1985 KLT110
1984 ATC200S
Posted by: QUADRUNNERMIKE
splines*
Posted by: QUADRUNNERMIKE
the bottom is the overfill line it dosent connect to anything, ane the angled one it the breather, or vent line, and dosent attach to anything either
-you have two of these machines right? my carb is a little funky- do you have a spare float assemblt or even a spare carb you would be willing to part with?
thanks, mike
Posted by: QUADRUNNERMIKE
would you be willing to give possible carb parts for free (i pay shipping costs)?
good luck on that tranny im here if you need
Posted by: QUADRUNNERMIKE
do you have the whole carb? and if you do, how much?
i am in south eastern pa
Posted by: atcpowermadman
hey quad runner mike i ahve a spare carb and some odds and end motor parts for sale if interested. just let me knwo what u will need allicallen1@yahoo.com
Posted by: cragman
I own a kawasaki klt 110 and the shifter stripper out. the splines on the shifter strip so we just drilled a hole through the shifter and shaft and stuck a bolt in it. it holds really well and if you ever need the shifter off, youll be able to take it off.
Posted by: Atlas
I also have a kawasaki KLT110, well the shifter striped and i cant seem to fine a new one, i went to my local dealer and they said that the part has been discontinued. Does anybody have one i could buy from them for cheap.
Posted by: gokartracr
i need a muffler for a 1984 kawasaki klt 110 85 and 86 willl also work
