KLX110 Top End Rebuild | KLX110 Valve Replacement | KLX110 Piston Replacement | Partzilla.com

See how to rebuild the top end on your Kawasaki KLX 110!

Before we convert this KLX110 into a pit bike, we need to do a little engine work. We’re thinking we need to rebuild the top end on this KLX110.

But here’s the catch: a LOT of the parts for the 2006 KLX110 are no longer available. Valves? Nope. Piston? Nope. So we need a workaround, and John found one.

Turns out the 2018 KLX110 has a lot of parts that will transfer right over. So we’re digging into our 2018 Kawasaki KLX110 diagrams to find what we need. You can check that out here: https://www.partzilla.com/catalog/kaw...

John will talk you through why the 2018 KLX110 parts will work on this much older ‘06 bike. Then, we’ll start putting the pieces together.

He'll show you how to get the valves installed on the KLX110 in a brand new head and also get your piston into your cylinder. Then, we’ll start bolting it all to the bottom end.

Check out the cards in the video and the rest of the tools and parts are here:

2018 KLX110 piston ring set:
https://www.partzilla.com/product/kaw...

2018 KLX110 Intake valve:
https://www.partzilla.com/product/kaw...

2018 KLX110 exhaust valve:
https://www.partzilla.com/product/kaw...

Oil valve seal:
https://www.partzilla.com/product/kaw...

Valve spring seat:
https://www.partzilla.com/product/kaw...

Valve spring:
https://www.partzilla.com/product/kaw...

Valve spring retainer:
https://www.partzilla.com/product/kaw...

Collet (valve keeper):
https://www.partzilla.com/product/kaw...

Motion Pro valve spring compressor:
https://www.partzilla.com/catalog-pro...

Rocker shaft:
https://www.partzilla.com/product/kaw...

Snap rings:
https://www.partzilla.com/product/kaw...

Piston pin:
https://www.partzilla.com/product/kaw...

Pin (dowel):
https://www.partzilla.com/product/kaw...

Cylinder base gasket:
https://www.partzilla.com/product/kaw...

Cylinder head gasket:
https://www.partzilla.com/product/kaw...

Camshaft tensioner:
https://www.partzilla.com/product/kaw...

Motion Pro adjustable torque wrench adapter:
https://www.partzilla.com/product/aft...

Tappet adjustment wrench set:
https://www.partzilla.com/product/aft...

Generator cover:
https://www.partzilla.com/product/kaw...

Generator cover gasket:
https://www.partzilla.com/product/kaw...

VIDEO HIGHLIGHTS:
Introduction - 0:00
Removing exhaust - 2:45
Removing airbox - 3:25
Removing carburetor - 3:55
Removing shifter - 5:15
Removing generator cover - 5:20
Removing timing chain tensioner - 7:10
Removing head and cylinder - 8:00
Removing piston - 9:40
2006 vs 2018 piston - 11:05
Checking the ring gap - 18:07
Lapping the valves - 19:00
Installing the valves - 21:20
Installing camshaft - 23:45
PIston installation - 26:20
Installing dowels and gasket - 29:50
Installing cylinder and head - 30:15
Installing the cam gear - 32:00
Setting valve clearance - 35:05

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In the video we’re working with a 2006 Kawasaki KLX 110, but you will have similar steps for your Kawasaki dirt bike. If you’re not sure whether these steps apply to your machine, leave a comment and we’ll get back to you.