KLX/DRZ110 143cc Big Bore Kit
Part # 042-1-11
Kit Includes:
60mm Cylinder, 60mm Piston, Rings, Wrist Pin, Clips, Head
Gasket, and Base Gasket.
Torque:
Valve Clearance:
Cylinder Head Bolts - 10 ft. lbs.
Cylinder Head Nuts - 16 ft. lbs.
.002” / .004”
IMPORTANT - PLEASE READ CAREFULLY
We recommend that this performance part be installed by a qualified
motorcycle technician. If you have any doubts as to your ability to install this
performance part, please consult with your local motorcycle dealer. Read all
instructions first before starting installation. Make sure the motorcycle and
exhaust system are completely cool before starting the installation. Also,
make sure the bike is secure on a centerstand or ideally a service lift during
installation. Be sure to save all stock components for possible use later.
Warranty Information
PitBoss Racing products are intended for closed course competition purposes only, and therefore are sold “as is” without
warranty. PitBoss Racing specifically disclaims any warranties of merchantability or fitness for a particular purpose and
disclaims all responsibility for consequential and incidental damages or any other losses arising from the use of these
products or parts.
*Check Piston/Valve clearance with any aftermarket cylinder head
INSTALLATION INSTRUCTIONS
1. Make sure the bike is completely cool before starting the
installation.
2. Secure the bike on a centerstand or ideally a service lift.
3. Remove the seat and fuel tank.
4. Remove the exhaust pipe.
5. Remove the skidplate.
6. Drain the engine oil.
7. Remove the left side engine cover to expose the flywheel
and timing “T” marks.
8. Remove carburetor and manifold.
17. Clean gasket surfaces.
18. Install new 60mm Piston using rings and clips provided.
The rings should be positioned as follows:
Top Ring - Brown lettering up.
Second Ring - Black lettering up.
Upper Steel Rail - Thin black
Expander - Copper wave.
Lower Steel Rail - Thin black.
19. Apply engine oil to the piston rings and cylinder inside
surface.
20. Pull camshaft chain through the cylinder and place upper
cam chain guide through cylinder to install cylinder onto
motor assembly. Make sure you use the dowel pins located
on top and bottom of cylinder.
9. Remove camshaft sprocket cover.
10. Turn the crankshaft counterclockwise until the line on
the camshaft sprocket “T” adjoins with the cylinder head
surface projection when the piston is at T.D.C. Also, the
“T” mark on the flywheel aligns with the index mark on
the crankcage to effectively determine T.D.C.
11. Remove cam chain tensioner:
a. Remove 10mm head bolt and O-Ring
b. With a suitable screwdriver inserted in the top
of the tensioner bolt hole, turn clockwise to
compress the cam chain tension
12. Remove oil line from right side of cylinder head.
13. Remove tappet covers.
14. Remove cam sprocket.
15. Remove cylinder head nuts and bolts and remove cylinder.
21. Fit the bottom of cylinder over the piston rings, pressing in
on opposite sides of the rings as necessary. Take care that
the rings do not slip out of their proper positions (make
sure all the ring gaps are not in the same row).
22. If using a Takegawa camshaft, make sure the cam is
installed so that the Takegawa logo is at the top of the
cylinder head.
23. Reinstall cylinder head using the supplied head gasket
and OEM dowel pins.
24. Torque head bolts to 10 ft. lbs. and head nuts to 16 ft. lbs.
25. Install cam chain and cam sprocket with the motor at T.D.C.
being sure that the “T” mark on the flywheel is still aligned
with the crankcase. Also, the “T” mark on the camshaft
should be aligned with the mark on the cylinder head.
26. New engine oil (20w-40w) is recommended.
27. Reinstall parts removed in previous steps.
16. Remove piston.