2022 Kawasaki KLX 110R Drive Chain Owners Manual

2022 Kawasaki KLX 110R Drive Chain

Drive Chain

For safety and to prevent excessive wear, the drive chain must be checked, adjusted, and lubricated be- fore riding. If the chain becomes badly worn or mal-adjusted either too loose or too tight- it could jump off the sprockets or break.
WARNING
A chain that breaks or jumps off the Sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. In- spect the chain for damage and proper adjustment before each ride.

Chain Slack Inspection

• Set the motorcycle up on its side stand, then rotate the rear wheel to find the place where the chain is tightest (because it wears unevenly).
• Push up the drive chain in the middle of the lower chain run to measure the chain slack. The distance between the chain and the swingarm should be within the standard value.

Drive Chain Slack
KLX110C: 11 16 mm (0.4 0.6 in.) Standard KLX110D: 8 13 mm (0.3 0.5 in.)

• Adjust the drive chain if its slack is out of specification

A. Chain Slack

• In addition to checking the slack, rotate the rear wheel to inspect the drive chain for damaged rollers, loose pins, and links, and the sprockets for unevenly or excessively worn and damaged teeth
• If there are any such defects, replace the drive chain and/or the sprockets.
  Chain Slack Adjustment
• Remove the cotter pin from the torque link nut, and loosen the torque link nut.

A. Torque Link Nut
B. Cotter Pin

• Remove the cotter pin from the rear axle nut.
• Loosen the rear axle nut and both chain adjuster locknuts.
• Turn both chain adjusting nuts evenly until the drive chain slack (measured between the chain and the swingarm) is within the standard value. For the rear wheel to be properly aligned, the notch of the left chain adjuster should align with the same swingarm mark that the notch of the right chain adjuster aligns with.

Drive Chain Slack
KLX110C: 11 16 mm (0.4 0.6 in.) KLX110D: 8 13 mm (0.30.5 in.)

A. Rear Axle Nut
B. Adjusting Nut
C. Locknut
D. Marks
E. Notch
F. Cotter Pin
NOTE

• Wheel alignment can also be checked using the straightedge or string method.

WARNING
Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. Align the rear wheel using the marks on the swingarm or measure the distance between the center of the axle and the SWingarm pivot.

• Tighten both chain adjuster locknuts.
• Tighten the axle nut to the specified torque.

Tightening Torque
Rear Axle Nut
64 Nm (6.5 km, 47 ft:lb)
Rotate the wheel, measure the chain slack again at the tightest position, and readjust it if necessary. Install a new cotter pin through the axle nut and axle, and bend its ends.

A. Cotter Pin
NOTE

• When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise up to the next alignment.
• lt should be within 30 degrees.
• Loosen once and tighten again when the slot goes past the nearest hoe.

A. Turning Clockwise

• Tighten the torque link nut.

Tightening Torque
Torque Link Nut:
25 Nm (2.5 kgf-m, 18 ft 1b)

• Install a new cotter pin through the torque link bolt, and bend its ends.

WARNING
A loose axle nut and torque link nut can lead to an accident resulting in serious injury or death. Tighten the axle nut and torque link nut to the proper torque and install new cotter pins.

• Check the rear brake pedal play.

Chain Wear Inspection
When the chain has reached its wear limit (i.e., when it has stretched by 1.7% of its original length), it is no longer safe for use and should be replaced. Since it is impractical to measure the entire length of the chain, determine the degree of wear by measuring a 20-ink section of the chain.

• Remove the bolts and chain cover.

A. Bolts
B. Chain Cover

• Tighten the chain either by using the chain ad justers or by hanging a 10 kg (22 lb) weight on the chain.
• Measure the 20-link length on a straight part of the chain from the center of the 1st pin to the center of the 21st pin. If the length exceeds the service limit, the chain should be replaced. Since over-worn sprockets will cause a new chain to wear faster, inspect both the engine and rear sprockets whenever the chain is replaced, and replace them if necessary.

A. Weight
B. Tape Measure
Drive Chain 20-Link Length
Standard 254.0 254.6 mm (10.00 10.02 in.)
Service Limit 259 mm (10.2 in.)

NOTE

• The drive system was designed for use with a DAIDO DID 420DX 90-links chain. For maximum stretch resistance and safety, a genuine part must be used for replacement.
• To minimize any chance of the master link coming apart, the master link clip must be installed with the closed end of the “U” pointing in the direction of chain rotation.

A. Master Link Clip
B. Direction of Chain Rotation

Chain Slipper Wear Inspection
Visually inspect the chain slipper on the swingarm and replace it if worn or damaged.
A. Chain Slipper
B. Swingarm
C. Chain Slipper (KLX110D Model only)

Sprocket Wear Inspection

• Visually inspect the sprocket teeth and replace the sprocket if its teeth are worn or damaged.

Sprocket Teeth Wear

A. Good Teeth
B. Worn Teeth
C. Damaged Teeth
NOTE

• Sprocket wear is exaggerated in the illustration.

Chain Lubrication
Lubrication is necessary after riding through rain
or on wet roads, or any time that the chain appears
dry. Use a lubricant for drive chains. If the chain is especially dirty, clean it using a cleaner to drive chains following the instructions supplied by the chain cleaner manufacturer.

• Apply lubricant to the sides of the rollers so that it will penetrate the rollers and bushings.
• Wipe off any excess lubricant. Wipe off any lubricant that gets on the tire surface.