- 1). Select a flat, level work space and park the KLX 110 on its kick-stand.
- 2). Pull the cotter pin out from the right side of the rear axle with a pair of pliers. Loosen the rear axle nut from the right side of the axle, using a 19 mm socket and a socket wrench. Loosen both chain-adjuster lock nuts, located on both sides of the swingarm, using a 10 mm open-end wrench. Turn the chain-adjuster nuts counterclockwise four complete turns, using a 10 mm open-end wrench, to loosen the drive chain. Push the rear wheel forward, by hand, to further loosen the drive chain.
- 3). Unscrew the adjuster wing nut from the end of the rear brake rod, by hand. Pull the rear brake rod out of the rear wheel brake drum arm, by hand. Pull the cotter pin out of the rear torque arm joining the rear brake drum to the right side of the swingarm, using pliers. Unscrew the rear torque arm nut, using a 14 mm socket and a socket wrench. Pull the rear torque arm away from the rear wheel brake drum.
- 4). Mount the KLX 110 on a dirt bike stand. Pull the drive chain off the rear sprocket, located on the left side of the rear wheel. Pull the rear axle out from the left side of the swingarm, by hand, then lower the rear wheel to the ground and roll it away from the motorcycle.
- 5). Pull the rear sprocket and the sprocket cushions off the left side of the rear wheel hub, by hand. Pry the grease seals off both sides of the rear wheel hub, using a small flat-head screwdriver or a pry bar.
- 6). Insert a long metal punch through one side of the rear wheel and brace it against the back of the wheel bearing on the opposite side of the wheel. Tap the bearing out from the wheel with a mallet, moving the punch along the edge of the bearing to ensure that it is removed evenly to avoid scarring the rear wheel hub. Remove the remaining wheel bearing, using the same method.
- 7). Clean the rear wheel hub, using a parts cleaning spray and compressed air.
- 8). Coat the new right side wheel bearing in high-temperature grease. Push the bearing into the right side of the wheel hub by hand, then tap the bearing into place with a bearing driver and a mallet. Install the left wheel bearing, using the same method.
- 9). Push a new grease seal over both wheel bearings by hand. Tap the grease seals with a bearing driver and a mallet until the seals sit flush with the sides of the rear wheel hub.
- 10
Reinsert the sprocket cushions into the left side of the rear wheel, then push the rear sprocket into place. Lift the rear wheel up between the swingarm legs. Slide the rear axle through the left side of the swingarm and through the wheel. Loosely screw the rear axle nut onto the end of the axle by hand. - 11
Pull the drive chain over the rear sprocket, then spin the rear wheel slightly until the chain is mounted completely on the sprocket. Turn both chain adjuster nuts clockwise four complete turns, using a 10 mm open-end wrench, to tighten the drive chain. Tighten the chain adjuster lock nuts against the swingarm, using a 10 mm open-end wrench. - 12
Push the rear torque link onto the mounting stud on the bottom of the rear wheel brake drum by hand. Screw the rear torque link nut into place, using a socket wrench and a 14 mm socket. Tighten the nut to 18 foot-pounds, using a torque wrench. Push a new cotter pin through the hole at the end of the mounting stud, then bend the pin's legs outward with pliers. Push the rear brake rod through the rear brake drum arm, then screw the adjuster wingnut onto the end of the rod by hand. - 13
Lower the KLX 110 onto its kick stand. Tighten the rear axle nut to 47 foot-pounds, using a 19 mm socket and a torque wrench.
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