Kawasaki KLX 110 Pit Bike Modification: Introduction
Welcome to the introduction of our project to turn a 2006 Kawasaki KLX110 into a pit bike. This intro is for a series of videos to follow, in which we convert an older Kawasaki dirt bike into a modified pit bike.
Watch the video above or read on below to learn about what upcoming modifications we’re going to do to our Kawasaki KLX 110.
Kawasaki KLX 110 Pit Bike Mod Overview
When dealing with a used older machine, in this case a 2006, we’re going to have to address several areas before we can really transform it. This includes a top end rebuild, because this machine is smoking. Additionally, there are other worn parts we’re going to address, including the brakes, suspension, seals, pivot points, and other areas that need to be refreshed on the machine.
We’ll also be addressing other areas like making the bike seat comfortable for a larger rider. That takes into account the suspension, rims, spokes, and other things we can upgrade to make them stronger, where they can put up with a lot more abuse should we decide to race this bike.
The rims will also be upgraded, as well as the spokes, which are going to be thicker so they can withstand a lot more weight being put on them. We’re going to upgrade the brakes as well, because it’s going to need a lot more stopping power when it gets a lot more weight on it.
Kawasaki KLX110 Pit Bike Modification Parts - Tires, Rims & Brakes
- IRC heavy duty tire tubes
- Excel Takasago rims (front and rear)
- BBR extra heavy-duty spokes
- EBC front and rear brakes
Kawasaki KLX 110 Pit Bike Mods: Suspension + Drive
Kawasaki built this KLX 110 to deal with a 110-115 lb. rider, so we need to modify it to deal with almost double that weight. To do that, we’re going to swap out the internal springs to a stiffer spring rate on both the front and the rear, and then change out the fork dampener rods.
As for the drivetrain, we’ll be upgrading the chain and sprockets, and changing the ratio that those sprockets interact with each other for increased acceleration.
For the sprockets, we’re going with a 15-tooth up front and a 33-tooth in the back. That’ll bring it up one tooth in the front to give it a lot more pulling power coming out of the corners, at the expense of a little bit of top speed.
Kawasaki KLX110 Pit Bike Mod Parts - Suspension, Chain & Sprockets
- BBR shock spring and dampener rods
- RK 420 MXZ chain
- Renthal 15-tooth front sprocket
- Sunstar 33-tooth rear sprocket
Kawasaki KLX 110 Pit Bike Mods: Clutch
The clutch on this Kawasaki KLX 110 is fine for normal riding, but we’re going to upgrade it with stronger fiber discs and clutch springs for more clamping force. That way it can deal with the additional load.
Kawasaki KLX110 Pit Bike Mod Parts - Clutch
- EBC clutch discs
Kawasaki KLX 110 Pit Bike Mods: Top End Rebuild
If you have a newer bike, you really don’t need to open up the top end to keep it in the stock class. However, we know this bike needs a top end rebuild because as soon as we start it up, it smokes excessively.
The real advantage to converting it to a 2018 is that our 2006 KLX 110 has a kickstart motor instead of an electric start, which means the weight will be about 25 lbs. less than a normal 2018 bike for a racer at the starting line.
Kawasaki KLX110 Pit Bike Mod Parts - Top End Rebuild
- TBD (parts pictured for illustration purposes)
Kawasaki KLX 110 Pit Bike Mods: Intake + Exhaust
We’ll be removing the entire stock air filter system, and replacing it with an intake and air filter specifically designed for this particular unit, which will give it much better flow characteristics than the stock system.
Kawasaki KLX110 Pit Bike Mod Parts - Intake + Exhaust
- BBR intake and air filter
- Pro Circuit T6 exhaust
Kawasaki KLX 110 Pit Bike Mods: Control
Creating a pit bike basically means taking a mini-sized bike and adapting it for an adult to ride. That requires a taller seat, plus modified handlebars and more legroom. It also requires larger foot pegs, all so an adult can ride it comfortably.
Somebody apparently started the process of turning our KLX 110 into a pit bike, and they installed a ProTaper pit bike kit, or at least the handlebars and the triple clamps from the kit. It’s a decent kit, and we may replace it with a new ProTaper kit, or go in a different direction.
Kawasaki KLX110 Pit Bike Mod Parts - Control
- IMS foot pegs
- Pro Taper or BBR handlebar kit
- Pro Circuit triple clamp kit
Kawasaki KLX 110 Pit Bike Mods: Body Plastics
It wouldn’t do this bike justice to do all this internal work and then leave all of the old plastics on the outside.
So we’ll be ordering a new set of plastics from UFO, whom we’re betting will come up with a cool skin logo system for this particular machine. Stay tuned to our YouTube channel and blog for updates on our Kawasaki KLX 110 pit bike project.
