Periodic Maintenance Procedures
Sprocket Wear Inspection
Visually inspect the front and rear sprocket teeth for wear
If they are worn as illustrated or damaged, replace the
[A] Worn Tooth (Engine Sprocket)
[B] Worn Tooth (Rear Sprocket)
[C] Direction of Rotation
If a sprocket requires replacement, the chain is proba-
bly worn also. When replacing a sprocket, inspect the
Rear Sprocket Warp Inspection
Using the jack, raise the rear wheel off the ground.
Special Tool - Jack: 57001-1238
Set a dial gauge [A] against the rear sprocket [B] near the
teeth as shown.
Rotate [C] the rear wheel to measure the sprocket runout
The difference between the highest and lowest dial gauge
readings is the amount of runout (warp).
If the runout exceeds the service limit, replace the rear
Rear Sprocket Warp
Drive Chain Guide and Slipper Wear Inspection
Visually inspect the following parts.
Chain Slipper [A]
Chain Guide Roller [B] (KLX110D Models)
Chain Guide [C]
If the chain guides, chain slipper and chain guide roller
show any signs of abnormal wear or damage, replace
Brake Lever Free Play Inspection
Slide the brake lever dust cover [A] out of place.
Check the front brake lever free play [B] when the brake
is lightly applied.
Brake Lever Free Play
If the lever has improper play, adjust it.
Operate the lever a few times to see that it returns to its
rest position immediately upon release.
Check for brake drag.
Check braking effectiveness.
Slide the brake lever dust cover back into place.
TIR 0.4 mm (0.016 in.) or less
TIR 0.5 mm (0.020 in.)
4 ∼ 5 mm (0.16 ∼ 0.20 in.)
PERIODIC MAINTENANCE 2-27