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4th gear

This is a discussion on 4th gear within the KLX110, DRZ110, TTR90 forums, part of the General Talk category; Do you need to split cases to put the 4th gear drum in? And how hard is it?...

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Thread: 4th gear

  1. 02-18-2010, 10:06 PM #1
    Factory110 [OP]
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    4th gear

    Do you need to split cases to put the 4th gear drum in? And how hard is it?
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  2. 02-18-2010 10:06 PM
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  3. 02-18-2010, 10:11 PM #2
    firepower354
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    Re: 4th gear

    Yes. The entire motor needs to come apart, for the most part. You can leave the crank and trans in the left case half, so it saves a few steps, but it's no cake-walk. Getting the OE case sealant all out without complete gutting is tough.
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  4. 02-18-2010, 10:15 PM #3
    Factory110 [OP]
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    Re: 4th gear

    ok well i already have the topend off and just doing this since ive got it torn down. I have a service manual, and i guess taking photos will help aswell. Do you have any other suggestions to put in while they are split and Im going to need a new gasket correct.
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  5. 02-18-2010, 10:28 PM #4
    firepower354
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    Re: 4th gear

    Quote Originally Posted by Factory110
    ok well i already have the topend off and just doing this since ive got it torn down. I have a service manual, and i guess taking photos will help aswell. Do you have any other suggestions to put in while they are split and Im going to need a new gasket correct.


    There's no center gasket, but you'll likely need a clutch gasket, and of course the top end set. If it's an '07 or older, you'll want an output shaft. Shame to have it that far apart and not bore the cases for later upgrades, and toss in a stroker crank
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  6. 02-18-2010, 10:48 PM #5
    Factory110 [OP]
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    Re: 4th gear

    lol its an 06 and ive got a tb165 kit going in so i have the headgaskets. Besides the stroker crank how much is a outputshaft
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  7. 02-18-2010, 10:57 PM #6
    firepower354
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    Re: 4th gear

    Quote Originally Posted by Factory110
    lol its an 06 and ive got a tb165 kit going in so i have the headgaskets. Besides the stroker crank how much is a outputshaft


    $59, with free shipping for the output shaft.
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  8. 02-18-2010, 11:20 PM #7
    5nine8
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    Re: 4th gear

    Also if you stroke it w/ the 165 kit you'll need to bore the cases
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  9. 02-19-2010, 06:15 PM #8
    mo-tarded
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    Re: 4th gear

    Quote Originally Posted by firepower354
    There's no center gasket


    You have to use sealant....
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  10. 02-19-2010, 07:28 PM #9
    redirt78
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    Re: 4th gear

    get a manual clutch (if you dont already have one) and buy my new, never used c.f. primary gear (if you dont already have one)

    $75 shipped
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  11. 02-19-2010, 08:01 PM #10
    ja564rm80
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    Re: 4th gear

    bud u DEFF need the output shaft! or u will be splitting the cases again after one kick
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  12. 02-23-2010, 08:19 PM #11
    Factory110 [OP]
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    Re: 4th gear

    Other than just taking my time and taking photos, with my service manual is it not that hard to do?
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  13. 02-24-2010, 01:36 PM #12
    Factory110 [OP]
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    Re: 4th gear

    for an outputshaft would just getting a 2009 oem shaft be fine?
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