How to Replace Kawasaki KLX110 Chain and Sprockets

The chain and sprockets on dirt bikes like the Kawasaki KLX110 wear out much faster than those on road bikes due to the fact that they typically take much more punishment on the track or trail.

When it’s time to change out these two Kawasaki motorcycle parts, watch our KLX110 chain and sprocket replacement video above or follow the steps below to get this job done.

Tools and Parts – Kawasaki KLX 110 Chain & Sprocket Replacement

  • Ratchet and extension
  • 8mm, 14mm, 22mm sockets
  • 10mm, 14mm wrenches
  • Circlip pliers
  • Flathead screwdriver

Buy Kawasaki motorcycle hub sprocket

Buy Kawasaki motorcycle output sprocket

NOTE: The chain and sprockets on a motorcycle should be replaced together as a set because old sprockets will quickly tear up a new chain, and an old chain will cause excessive wear to new sprockets.

Kawasaki KLX 110 chain and sprickets

How to Remove Kawasaki KLX110 Chain & Sprockets

Step 1. Lift the bike on a stand, then loosen the 10mm locking nuts, and back off the adjuster nuts on the chain adjuster bolts on each side of the wheel.

2015 Kawasaki KLX 110 dirt bike drive chain and sprockets removal

2015 Kawasaki KLX 110 drive chain and sprockets removal

Step 2. Pry the clip and the outer plate from the chain master link with a screwdriver, then push out the master link and remove the chain.

2015 Kawasaki KLX 110 chain and sprockets removal

Kawasaki KLX 110 dirt bike drive chain and sprockets removal

Step 3. Remove the cotter pin and nut from the brake drum torque rod.

Kawasaki KLX 110 dirt bike chain and sprockets removal

Kawasaki KLX 110 chain and sprockets removal

2015 Kawasaki KLX 110 chain and sprockets removal

Step 4. Remove the rear brake cable adjustment bolt so the cable can pull free when you take off the wheel.

2015 Kawasaki KLX 110 motorcycle chain and sprockets removal

Step 5. Remove the cotter pin from the axle nut, followed by the axle nut itself. Pull the axle out from the hub and swingarms, and remove the wheel.

Kawasaki KLX 110 motorcycle drive chain and sprockets removal

Kawasaki KLX motorcycle drive chain and sprockets removal

Kawasaki KLX dirt bike drive chain and sprockets removal

Step 6. Pull the hub sprocket and hub assembly off from the brake drum.

Kawasaki KLX dirt bike chain and sprockets removal

Kawasaki KLX motorcycle chain and sprockets removal

Step 7. Remove the four 14mm nuts holding the hub sprocket in place, then remove the sprocket from the hub.

Kawasaki dirt bike sprocket removal

Kawasaki KLX 110 dirt bike sprocket removal

2015 Kawasaki KLX 110 dirt bike sprocket removal

Step 8. Remove the output sprocket cover.

Kawasaki motorcycle drive chain and sprockets removal

Step 9. Remove the circlip holding the output sprocket in place, followed by the sprocket itself.

Kawasaki dirt bike drive chain and sprockets removal

Kawasaki dirt bike chain and sprockets removal

How to Install Kawasaki KLX110 Sprockets

Step 1. Install the new output sprocket, and reinstall the circlip and sprocket cover.

2015 Kawasaki KLX 110 dirt bike new sprockets installation

Step 2. Make sure the flat sides of the hub bolts are flush against the inside of the hub, then install the new hub sprocket.

2015 Kawasaki KLX 110 motorcycle new sprockets installation

Kawasaki KLX 110 motorcycle new sprockets installation

Step 3. Reinstall the hub sprocket and hub assembly back into the brake drum, then reinstall the four 14mm nuts that hold the sprocket, and torque them to 32-foot pounds.

Kawasaki KLX 110 dirt bike new sprockets installation

Step 4. Slide the wheel back between the swingarms, and reinstall the axle. 

Kawasaki KLX 110 dirt bike sprockets installation

Step 5. Reattach the brake drum torque rod and the rear brake cable adjustment bolt, then reinstall the axle nut and torque it to 47-foot pounds.

Kawasaki KLX 110 motorcycle sprockets installation

How to Install Kawasaki KLX 110 Drive Chain

Step 1. Count the number of links on the old chain, then count the same number on the new chain and mark the point you need to break the new chain.

2015 Kawasaki KLX 110 motorcycle new drive chain installation

NOTE: Cutting the new chain too short will result in you having to buy another chain. The golden rule is to measure twice, and cut once.

2015 Kawasaki KLX 110 dirt bike new drive chain installation

Step 2. Use a chain tool to press out the chain pin at the point you want to break the new chain. 

Kawasaki KLX 110 dirt bike new drive chain installation

PRO TIP: If you don’t have a chain tool, you can use an angle grinder to grind away the flared head of the chain pin and then pry off the outer plate.

Kawasaki KLX 110 motorcycle new drive chain installation

Kawasaki KLX 110 motorcycle drive chain installation

Kawasaki KLX 110 dirt bike drive chain installation

2015 Kawasaki KLX 110 dirt bike new chain installation

Step 3. Install the new chain over the new sprockets, then put the outer plate onto the master link and install the clip that secures the outer plate.

Kawasaki KLX 110 dirt bike new chain installation

PRO TIP: Make sure the gap in the clip is facing away from the direction the chain rotates. This reduces the chances of something snagging the clip and pulling it off.

Kawasaki KLX 110 motorcycle new chain installation

Kawasaki KLX 110 new chain installation

Kawasaki KLX 110 new drive chain installation

The next step is to clean and adjust the chain. Watch our Kawasaki KLX110 chain adjustment video above to see how to get that done.