Two Brothers Racing Suzuki KLX110 - Manual (Page 2)

13. Reinstall all parts and test. Tighten all the clutch cover screws
to 46 in-lbs. Attach the kickstart lever and tighten. Install the shift lever
and tighten. Tighten the footpeg mounting bolts. Fill the engine with 1
liter of motor oil and replace the fill cap. Check the operation of the shift
lever, brake lever and kickstart lever to in sure they are properly
installed. Adjust as necessary. If the shift lever will not move easily,
tap the end of the shaft with a hammer to seat the thrust washer.
With the engine off, check the operation of the manual clutch by shifting
the bike into gear and pushing it forward. With the clutch lever out, the
bike should not toll. Squeezing the lever in should allow it to troll and
releasing it will cause it to stop. This indicates the is ready to start. Start
the engine and check for oil leaks. If there are any, shut off the engine
and fix as needed. You should be able to operate the bike as before,
only now you have the ability to manually disengage the clutch, offering
the rider greater control. After a few minutes of running, shut off the
engine and allow it to cool down. Once it has cooled, check the retighten
all fasteners as necessary. You are now done with the installation.
14. Maintenance. Before each ride visually inspect the clutch assembly
for proper operation. Check the lever movement for any looseness in the
pivot bolt and tighten as needed. Check the hose for signs of damage or
excessive wear. Replace the hose if necessary. Check for least at the
hose connections and at both the master cylinder and slave cylinder. If
the lever movement feels soft or the clutch does not disengage, check
the fluid level in the master cylinder. Clean the area around the reservoir
lid before removing it. if the fluid has fallen below the half full level, add
fluid up to within 1/8” of the top and pump the lever. If it is still soft or the
clutch does not disengage you will need to bleed the system. Remove
the clutch cover and follow the procedure as described above until no air
is seen bubbling through the fluid. Fill the reservoir to within 1/8” from
the top and replace the lid.
Every 6 months check the fluid level even if it is operating properly.
Normal clutch wear will cause the fluid level to drop and finding this early
will prevent having to bleed the system later. Remove the lever pivot bolt
and apply some waterproof grease to the pivot. This will prevent exces-
sive wear and make the lever action smooth again.
Following these guidelines will ensure many years of trouble-free service
from your clutch kit.
KLX110 Manual Clutch Conversation PAGE 2.qxd