Installing a Manual Clutch on KLX (Semi & Full Manual)

1. Remove foot pegs.
2. Release brake spring, loosen rear brake adjuster.
3. Remove brake lever.
4. Lay bike on left side.
5. Drain engine oil.
6. Remove 9 clutch cover (Phillips) bolts. Remove stock clutch cover.
7. Layout all TB parts per photo.
8. Install oil window with WD-40.
9. Install kick start seal.
10. Install small O-ring on shaft located in the groove.
11. Install coil spring on shaft.
12. Install shaft into new cover.
13. Install top hat into hole and rotate clutch cable arm until top hat locks in and arm can actuate the top hat in and out when cable arm is rotated.
14. Clean gasket surface completely on engine.
15. Be sure to reinstall case locating dowels into engine (2 places).
16. Install new gasket (provided).
17. Remove crankshaft oil seal from stock cover and reinstall into new clutch cover. Tighten screws to hold into place.
18. Remove stock bearing assembly and arm from shift shaft, leaving only the ball bearing in clutch hub.
19. Remove all the items in the below photos.

NOTE: This next section will show you how to install the Primary Clutch Removal Spacer. If you want to keep the automatic clutch, skip to number 30.

20. Remove bearing and retainer from clutch.
21. Remove 19mm nut from the clutch (use impact wrench).
22. Remove the 19mm nut from the primary clutch housing (use impact wrench).
23. Remove both the clutch and primary clutch housing together.
24. Remove the clutch shoe and clutch bearing from the primary housing.
25. Reinstall the clutch and primary clutch housing together.
26. Install Trail Bikes spacer into housing.
27. Install clutch collar into housing.
28. Reinstall the (2) 19mm nuts that hold the clutch and housing.
29. Reinstall the bearing and retainer back into the clutch.
30. This is what it should look like before you install the new Trail Bikes cover.
31. Now install Trail Bikes clutch cover.
32. Install clutch cable bracket on case when installing new clutch cover.
33. Install clutch cable.
34. Install kick starter.
35. Install engine oil.
36. Adjust clutch play on new cable to 1/8” free play.

Note: Some aftermarket exhausts may obstruct the cable bracket. If this is the case with your exhaust, you can simply bend the bracket to clear the exhaust. The cable bracket can be bent back to clear pipes after it’s bolted on the engine using a dead blow hammer (be careful not to hit the case) or bend it off the engine in a vise with the same hammer. The pictures above reflect the bracket bent back slightly for that exhaust.

Note: Ensure the oil level sight glass is securely installed using high-quality silicone sealant.

The document 'Install manual clutch' is available for download below

Download the file