Two Brothers Racing DR-Z110 User Manual

Kawasaki KLX-110 & Suzuki DR-Z110

Complete Oil Cooler Kit

part# 022-2-01

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.

Two Brothers Racing products are intended for closed course competition purposes only, and therefore are sold
“as is” without warranty. Two Brothers 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.

Warranty

1. Make sure the bike is completely cool before starting the
installation. Make sure the bike is secure on a
centerstand or ideally a service lift.

2. Drain the gas tank into an approved container and remove
the tank. Drain the engine oil into an approbved container.

3. Remove the stock oil filter cover and filter.

4. Remove the two screws securing the filter housing cover

5. Turn the housing over and apply a thin film of oil around
the 2 1/4” circular groove on the back of the housing and
place one supplied o-ring in the groove. Apply another
thin film of engine oil around the o-ring.

6. Insert the two supplied bolts through the filter housing
and attach filter housing to engine case. Tighten both
bolts securely.

7. Apply a thin film of oil around the 2 1/4” circular groove
and place the other supplied o-ring in the groove. Apply
another thin film of engine oil around the o-ring. Insert
the oil filter element into the supplied filter housing and

attach filter housing cover.
Tighten securely.

8. Orient the heat exchanger so that the rectangular flange
is to the left and the mounting bracket is to the right.
Attach the oil line with the right-angle connector to the
lower port of the exchanger. Attach the remaining hose to
the upper port - it does not matter which end connects to
the exchanger. Securely tighten both connections.

Installation Instructions

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Parts List

IMPORTANT - PLEASE READ CAREFULLY

Qty. Description

1 Braided Stainless Steel Upper Oil Line
1 Braided Stainless Steel Lower Oil Line
1 Oil Line Bracket Retaining bolt
1 Oil Line Retaining Bracket Assembly
1 Oil Filter Housing Assembly
2 O Rings
2 Oil Filter Housing Retaining Bolts
1 Heat Exchanger

9. Thread the upper oil line through the frame and route the
lower line over the engine case behind the air intake
manifold.

10. Attach the heat exchanger to the frame. Tighten securely

11. Bring both oil lines down behind the head pipe keeping the
“lower” line on the left and the “upper” line to the right.

12. Attach the upper line to the rear port of the new filter
housing. Tighten securely. Attach the lower oil line to the
forward port. Tighten securely.

13. Remove the bolt securing the two halves of the supplied
oil line retainer bracket. With the mounting hole of the
bracket facing rearward, secure the two oil lines into the
mounting bracket and replace the bolt. Do not fully
tighten.

14. Attach the oil line mounting bracket to the engine case
using the supplied bolt. Tighten securely.

15. Securely tighten the bolt securing the oil lines to
the bracket.

16. Re-attach gas tank. Re-fill engine oil to OEM
specifications and add an additional 150cc’s to allow for
the added capacity of the oil cooler.

17. If you are using a Two Brothers Racing skid plate, you
must remove a section alond the top edge to allow
passage of the oil lines.

18. Double check your work and make sure all hardware is
securely tightened. After and hour of riding re-check all
hardware and tighten if needed.

Installation Instructions

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