Planet Minis

KLX110: Making a Free Bump Start

For use with manual clutch. Use this mod to bumpstart your klx/drz 110 while it is in gear!

Note, i have the ignition cover off the engine in these pictures. there is no need to remove the ignition cover

Tools Needed:
8 mm T-handle
electric tape
electric fitting (sitting atop tape)
#2 phillips screwdriver
#3 phillips screwdriver
wire cutters







Procedure

Use 8mm T-handle to take off chain guide, 3 screws





Find the black wrapped set of two wires coming from the Bump Start Unit, and unhook the connector in the Black Boot







Now unscrew the top and bottom screws from the Bump Start Unit

Pro Tip: unscrew the bottom screw first. if done with chain on, roll the bike so chain moves and screw can back all the way out

Pro Tip: press firmly on the Bump Start Unit while unscrewing the top (second) screw. these stock units tend to get brittle with time and the top tab will break off if you do not press firmly on the unit until the screw is out


note, here i am using an allen wrench. your bike may have phillips head screws here if stock





Remove the Bump Start Unit





Now wipe the passage free of dirt and other loose material. Remove Oring, inspect, replace if necessary, then put Oring back into passage







Working with the Stock Bump Start Unit

here is the Bump Start Unit, uninstalled





Now cut the black wrapped wires, like shown, at the Bump Start Unit. Cut as close as you can to the Unit.





After cutting, safely cut away the black wrap, making sure to not damage the 2 wires inside.

Then strip the sheath off of the light green wire





Now take the exposed wire from the light green wire and put it through the Electric Fitting, and wrap excess around end

Pro Tip: I bend this fitting now, for ease of later use. look ahead at how the fitting is screwed onto the cases, and see if this is something you wish to do. If you wish to do it, i would suggest bending it before insertion of the wire





Now place Fitting with wire though, into a vice and shut the hole so the wire is secured into the fitting.



mine looks like this afterward





Now Wrap this end of the wire in electric tape, using enough so it seems somewhat water tight. I use the tape more as protection from pulling the wire out of the fitting.




Now screw the Bump Start Unit back onto the case. Be sure to follow the instructions for pressing firmly on the unit while putting screws in

Note, The unit should now have no wires coming from it





Now attach the connector back into the Black Boot





Now use the #3 phillips to remove the screw on the ignition cover closest to the Black Boot. my screw is an allen head screw, yours will be a pillips head if stock.




Now, the finished product!!




Now put the chain guide back on using the 8mm T-handle




Pro Tip: This is the Igniton Cover, off the bike in my case. This is how the fitting attaches to the case. If you like, you can bend the fitting to go toward the frame for a more sleek fit.

BORN2RIDE#56

Makes me wanna go buy a bumpstart...

Z50King

this took me 10 minutes the first time i did it. there are just lots of pics

Jimi86

good job. Very helpful, for when I get a 110.

Z50King

woot, coming over to the dark side!

Jimi86

im looking.

BORN2RIDE#56

Lol ive had bolth and a 50 kicks my ass! Way to ruff on my back and knees. 110s are were its at...

Z50King

we agree on something! haha

BORN2RIDE#56

& your like 6ft so i knw you hated it... Haha

wogtaz ryder

lmao....

squidwell

ghetto mod

j440

mines done like this but its grounded behind the bumpstart plate and tucked away nicely.

Z50King

how did you ground it back there?

rider34

yah same with mine. Ill post up pics later

rotax10

What do you do with the other wire?, why even remove the bumpstart switch, cant you just cut the wire?

507 brett

thats not really what i did. mines simple as crap. just unplug it, and get a piece of wire, put the ends on it, plug that in and ground it. ill try to get a pic, but youve got two aof the stock wires modded, mine is just one wire and the stock ones arent messed with so if i wanna go back, just take off the ground wire that i made, and plug it back in. yours, youd have to splice the stockers back together..

WESTWORKS RACING 948

Pretty ghetto man..buy wirecuters with crimpers on them and shrinktubing with the 20 bucks you saved:}anyway,I thought you only grounded one wire?

Z50King

i broke my first unit, so i used the connector and wires from it. i have a fully stock unit bolted on there, i just covered the black wrapped wires with my fingers so it looks like i cut them

per the instructions, i only grounded the light green wire. the dark green gets pushed up under the frame

j440

same as you have it on the cover, it touches the frame behind the bumpstart, grounding it.

Z50King

so how does the bump start seal and the oil inside the case?