TBparts.com highly recommends a professional technician or your local Kawasaki dealer install the performance parts for you. If you do decide to install them yourself, you will need the KLX110 Service Manual. All the TBparts.com performance parts install exactly like the stock OEM parts with the exception of the manual clutch kit (instructions below). You can purchase the KLX110 Service Manual at any Kawasaki dealer. There is also a free download at this site:
Please also check out this site for all kinds of technical, modification, and other info on the KLX110. It provides a wealth of information and is full of fellow enthusiasts willing to share their knowledge and experiences.
We have provided some information below that will be helpful. However, please don’t consider it a substitute for having a professional install your kit or the manual we recommend above.
Here is some general information to help you as well:
The following are common installation errors when installing bore kits and the clutch kits:
– Installing the cam incorrectly which results in loud knocking. Make sure when you line up the 0 on the cam sprocket with the mark on the head, the cam lobes are facing down towards the piston.
– Putting the piston rings on incorrectly – All TBparts.com rings should be installed this way and in this order:
1 – expander ring – (wavy one) – lower groove
2 – lower oil ring – below above ring in lower groove
3 – upper oil ring – above expander ring in lower groove
4 – install the black one in the center groove
5 – Install the silver one in the top groove (markings on ring should face up)
Make sure the end gaps of the piston ring are not aligned with one another -evenly space apart
Carburetor Kit Info:
For your stock OEM carb, its covered in great detail in the Kawasaki service manual. We also have main jet kits available for it.
For the popular Mikuni VM26 carb we include in our complete kits, here is a link to the Mikuni manual:
We also have a variety of main jets and pilot jets for the VM26.
However, its impossible to really provide jetting help via phone or email as every bike is different and we just don’t have the time to compile all the scenarios (location, temp, big bore kit size, other performance parts etc.) and especially, the exhaust info – there so many different types available. If not familiar with jetting a carb properly, please have a technician do it or there is a wealth of info available on the internet if you would like to learn how to do it yourself. We have also listed below some things that may help if your bike is not running properly:
– Make sure your ground wire is not loose and connected to bare (not painted) metal as this may cause issues similar to carb issues. This problem happens quite often.
– Try a plug chop – run it at high rpms and then kill it and check the color of the plug. Based on your plug reading, you may need to move the needle clip or go with a different main jet depending on if it is running rich or lean. When running properly, it should have a nice light brown plug color. If not familiar with how to read a spark plug or make basic carburetor adjustments such as moving the clip or changing the main jet, please see the Kawasaki service manual or there is tons of info on the internet explaining how to jet a carb.
– For bogging, try adjusting the air screw.
– Make sure you did not over lube the air filter.
– Use fresh clean high-octane gas (race gas not needed).
– Check for air leaks.
– Check your petcock and fuel line to make sure you have good fuel flow.
– If you experience backfiring, make sure you reinstalled exhaust gasket and that the exhaust is tightened down and there are no air leaks.
– Double check valve adjustment after you have ridden it with a new bore kit installed.