Laser cladding experiments on 1-mm-thick Ni60 alloy coatings on a small-modulus gear-tooth surface are conducted using a continuous fiber laser. The analysis on the reason for causing cladding defects by the thin small-modulus tooth top and single-pass laser concentrated in the middle of the gear is performed. A double-pass laser processing method is proposed for the fabrication of nicked-based alloy coatings on the small-modulus gear-tooth surface. Under the condition of constant laser energy input, the energy of the original single-pass laser is distributed to two small spots according to a certain energy ratio scheme. The gear's tooth top and bottom are then sequentially processed. Results show that by using two 1-mm spots with an energy ratio of 4∶6, the proposed method not only reduces the ablation of the gear's tooth top, but also solves the problem of excessive energy being concentrated in the middle of the gear. Additionally, the coatings' dilution rate significantly reduces. Low precipitation of crystalline austenite containing Fe and Ni is observed in the microstructure in contrast to the high precipitation of granular cementite rich in Cr. The wear resistance and strength of the cladding layer are improved compared to those of single-pass laser cladding. Overall, the double-pass laser cladding process significantly promotes the quality of the nickel-based alloy coatings prepared on the small-modulus gear-tooth surface.