KLX110: Making a Free Bump Start

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KLX110: Making a Free Bump Start

This is a discussion on KLX110: Making a Free Bump Start within the Misc forums, part of the How-To's / Tutorials category; 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 ...

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  1. #1
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    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.




  2. #2
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    Re: Test of tutorial on how to make free bumpstart

    i submitted this to the Tutorial forum. what do you all think of it?



    i needed to post it in full because i was 15 pic limited by the first post when submitting it to the forum

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    Re: Test of tutorial on how to make free bumpstart

    Makes me wanna go buy a bumpstart...

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  5. #4
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    Re: Test of tutorial on how to make free bumpstart

    Quote Originally Posted by BORN2RIDE#56
    Makes me wanna go buy a bumpstart...


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

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    Re: Test of tutorial on how to make free bumpstart

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

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    Re: Test of tutorial on how to make free bumpstart

    Quote Originally Posted by Jimi86
    good job. Very helpful, for when I get a 110.


    woot, coming over to the dark side!

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    Re: Making a Free Bump Start

    im looking.

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    Re: KLX110: Making a Free Bump Start

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

  10. #9
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    Re: KLX110: Making a Free Bump Start

    Quote Originally Posted by 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...


    we agree on something! haha

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    Re: KLX110: Making a Free Bump Start

    Quote Originally Posted by z50king
    we agree on something! Haha


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

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    Re: Test of tutorial on how to make free bumpstart

    Quote Originally Posted by BORN2RIDE#56
    Makes me wanna go buy a bumpstart...


    lmao....

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    Re: KLX110: Making a Free Bump Start

    ghetto mod

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    Re: KLX110: Making a Free Bump Start

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

  15. #14
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    Re: KLX110: Making a Free Bump Start

    Quote Originally Posted by j440
    mines done like this but its grounded behind the bumpstart plate and tucked away nicely.


    how did you ground it back there?

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    Re: KLX110: Making a Free Bump Start

    yah same with mine. Ill post up pics later

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