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
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![Image]()
Procedure
Use 8mm T-handle to take off chain guide, 3 screws
![Image]()
Find the black wrapped set of two wires coming from the Bump Start Unit, and unhook the connector in the Black Boot
![Image]()
![Image]()
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
![Image]()
Remove the Bump Start Unit
![Image]()
Now wipe the passage free of dirt and other loose material. Remove Oring, inspect, replace if necessary, then put Oring back into passage
![Image]()
![Image]()
Working with the Stock Bump Start Unit
here is the Bump Start Unit, uninstalled
![Image]()
Now cut the black wrapped wires, like shown, at the Bump Start Unit. Cut as close as you can to the Unit.
![Image]()
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
![Image]()
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
![Image]()
Now place Fitting with wire though, into a vice and shut the hole so the wire is secured into the fitting.
![Image]()
mine looks like this afterward
![Image]()
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.
![Image]()
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
![Image]()
Now attach the connector back into the Black Boot
![Image]()
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.
![Image]()
Now, the finished product!!
![Image]()
Now put the chain guide back on using the 8mm T-handle
![Image]()
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.
![Image]()
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.
