Kawasaki KLX110 Engine Assembly - And 143cc Big Bore Conversion!
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- Опубліковано 25 лип 2024
- If you have never rebuilt a dirt bike motor, this video is for you! I go over in detail ever single step. Follow along and you can feel confident that you can successfully rebuild your KLX110 motor!
★CONTRIBUTIONS: patreon.com/user?u=98789230
★SPONSORS and FRIENDS
Special Thanks to: www.TBoltUSA.com
★TIMESTAMPS
0:00 INTRO
03:19 CRANKCASE PREP
04:18 HOW TO USE A CRANK PULLER
06:39 TRANSMISSION INSTALLATION
08:52 CRANKCASE ASSEMBLY
15:53 CYLINDER STUD INSTALLATION
16:12 PISTON INSTALLATION
20:37 CAMSHAFT TIMING CHAIN
21:26 CYLINDER INSTALLATION
23:18 CAMSHAFT INSTALLATION
25:14 ROCKER ARM ASSEMBLY
27:03 CYLINDER HEAD INSTALLATION
27:24 FLYWHEEL INSTALLATION
27:50 TIMING MARKS ALIGNMENT
28:13 CAMSHAFT SPROCKET INSTALLATION
29:11 CAMSHAFT CHAIN TENSIONER
30:09 CAMSHAFT TIMING
30:27 CYLINDER HEAD TORQUING
31:29 OIL PIPE INSTALLATION
31:52 CAMSHAFT SPROCKET COVER
32:10 ROCKER ARM COVER
33:01 SHIFT MECHANISM INSTALLATION
33:45 OIL PUMP INSTALLATION
34:27 GEAR POSITIONING MECHANISM
35:05 KICK SHAFT ASSEMBLY
35:40 SHIFT LINKAGE INSTALLATION
36:13 CLUTCHES INSTALLATION
38:48 CLUTCH COVER INSTALLATION
39:48 MAGNETO COVER INSTALLATION
40:35 GEAR POSITION SWITCH
41:10 OIL FILTER
42:16 THANKS FOR WATCHING!
★AFFILIATE LINKS (I MAY MAKE A COMMISSION FROM SALES GENERATED VIA THESE LINKS)
Products Used:
Assembly Grease: amzn.to/3KVMYRB
Assembly Lube: amzn.to/47QW1wL
Wax and Grease Remover: amzn.to/3Pa3Gz4
High Temperature Grease: amzn.to/47NH0f5
Anti Seize: amzn.to/45ny26Y
Hondabond: amzn.to/3QDwLnA
LocTite Blue: amzn.to/3EejXge
Crankcase Puller/Splitter: (This is the best one): amzn.to/3KW6GMQ
PVC Spacer - 2x1 ½ Schedule 40 Reducer Bushing. (You can probably find this cheaper, but at least you have the info on what you need to buy): amzn.to/3KDldgm
Molybdenum Disulfide Grease: amzn.to/3QVjlU1
Magnetic Bowl: amzn.to/3EekBdE
Brass Hammer: amzn.to/47Qfz4o
Hemostat: amzn.to/3OTvKoS
Silicon Sealant (used on Magneto Cover): amzn.to/3YPhFxm
Oil Filter Wrench: amzn.to/3PchZTP
Oil Filter Wrench (Cheaper): amzn.to/44mHtlD
Clutch Holder: amzn.to/3OPinWT
Valve Adjustment Tools: amzn.to/47PuM5W
Valve Adjustment Feeler Gauge: amzn.to/3Ea526L
Torque Wrench (Low Torque): amzn.to/38onM2V
Torque Wrench (Best Value): amzn.to/3rIVvvD
Multi Purpose Masking Tape (3M-The Best): amzn.to/3v32Wjf
Disposable Shop Towels: amzn.to/3bw3NRS
Hook and Pick Set (Best $$$ I Ever Spent): amzn.to/44rH55w
Socket Phillip: amzn.to/3ceGomV
Video Production Tools:
Camera - Canon M50: amzn.to/3qupANX
Camera - GoPro Hero 9: amzn.to/2O96Lmq
Softbox Light: amzn.to/3epcwHk
Neewer LED Lighting: amzn.to/3t23Sm3
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Sound Recorder: amzn.to/3etXFLP
Camera Tripod - Low Height: amzn.to/3rA9zqU
Camera AC Power Adapter: amzn.to/2PCLEsP
★NON-AFFILIATE LINKS (I DO NOT MAKE A COMMISSION FROM SALES GENERATED VIA THESE LINKS)
Products Used:
TBoltUSA Big Bore Kit: tboltusa.com/store/tbparts-14...
Hondabond: tboltusa.com/store/hondabond-...
Stainless Steel Fasteners Kit: tboltusa.com/store/klx110-drz...
Oil Filter: tboltusa.com/store/oil-filter...
★USEFUL LINKS
2007 Kawasaki KLX110 Service Manual: drive.google.com/file/d/1j-G9...
Kawasaki KLX110 Engine Teardown: • Kawasaki KLX110 Engine...
4-Stroke Pre Assembly Engine Inspection | KLX 110: • 4-Stroke Pre Assembly ...
2 Ways to Adjust Your Honda OHV Engine Valves: • 2 Ways to Adjust Your ...
4 Ways to Set Up Kawasaki KLX Clutches: • 4 Ways to Set Up Kawas...
KLX110 Clutches Rebuild | How To Rebuild (AND Modify!) the Kawasaki Semi Automatic, 2 Clutch System: • KLX110 Clutches Rebuil...
4 Stroke Piston Rings From A to Z || Identify, Install and Orient Gaps CORRECTLY!: • 4 Stroke Piston Rings ...
39¢ DIY Motorcycle Valve Spring Compressor || IT WORKS!: • 39¢ DIY Motorcycle Val...
★MUSIC CREDITS
------------------------------
American Idle
Copyright free music, royalty free music.
Audio Library
• UA-cam Audio Library & Copyright/Royalty free music: • 🎵 UA-cam Audio Librar...
You can use this song in any of your videos.
Source URL: • RKVC - American Idle
------------------------------
Alaska Sky • Patrick Patrikios
Alaska Sky
℗ UA-cam Audio Library
Released on: 2019-10-25
• Alaska Sky
------------------------------ - Авто та транспорт
Thanks so much for these videos!! Not only are you helping those with KLX 110's, but also us in the Z125 PRO community as well. I have a Z143 that'll do 70 mph thanks to folks like you making these videos and sharing your knowledge!! Next step for me will be installing the TB stroker crank, going from 143cc to 155!! That process will be made easy due to your video!! Thanks again man!!
Oh man! Thanks so much! That’s so nice of you! It really means a lot to me to know I’m helping others after putting so much work into making these videos. It’s a massive amount of work to produce one of these videos! Thank you! Keep wrenching!
Excellent sir! Thanks for all the effort and attention to detail!
Thanks so much for the kind words!
Great video. I'll be playing this in the background when I put mine back together.
Thanks Jason. That was a tough video to make! The editing took forever! Thanks for watching!!
Thanks for your time !! And sharing the knowledge
Absolutely! I Joe it helped you! Thanks for watching!
Love your videos ! Thank you Brian !
Thanks so much for the kind words, Steve!
Thank you for sharing your knowledge are very helpful your videos greetings from Mexico 👍👍👍👍👍
Hola! Gracias Jesús!
Thanks a ton for sharing this video, i really appriciate it about how you makes this video, from put the angle camera, till explain everything about it, notice at the small thing like mark or dot on Parts and how the way you explain it then you deviding it in a couple section, makes me more easily to understanding, it's really helpful to me for understanding about this engine, and makes me more easily to doing some maintain in futher👍🏻👍🏻🙏🏻🙏🏻
I’m so glad you found it useful! Thanks for the words of support!
Congratulations Brian!! Great video!! Greetings from Argentina!!
Hi Marcos!!! Thank you! I hear you have a new President. I hope that is a good change for your country.
@@brian.d.mobley It is my wish too. There are many of us who want to live better in this wonderful country.
Can you rebuild a YZ85 engine! Love the CR85 engine video!! Helped a lot with my wife’s bike as well. Need one now for the YZ85 🙏
It sounds fun, but I don’t own a YZ85.
This is great thank you!!
Sure! Glad it helped, Cody!
Great video but when he gets to the fly wheel for those with a 2012 and new just remember you have to put your starter gears in
Great video thank you!
Glad you liked it! Thank for watching!
I'm doing the same thing for a 54x54 zongshen engine now. It is a massive task. The editing takes forever.
I feel your pain Martin! And no one can appreciate the work just by watching the video. I have a lot more respect for feature film makers now!
@brian.d.mobley 100% right! Great work on the build. I was on the phone with Vince today, and he sent me to your videos. I'm using the tbparts 78 mm big bore cylinder and v2 race head for my build as well. I got it all installed and documented everything, and the timing chain is too tight to install the cam sprocket. He said to loosen the bolt under the engine that it was a tensioner. So I'm going to try that tomorrow after I put it back together for the 2nd time. We installed the stock cylinder to check and see if it would fit right, and it did. The new 78 mm cylinder is about 2mm longer with the new gaskets than stock, so the timing chain is about 2mm from where it needs to be to let the cam sprocket bolt in...
@@MartinRacingChannel Wow! Im glad i didn’t have any problem with my chain. The big bore kit had a lot of subtle variations from OEM so I really had to take it slow to be sure I didn’t screw anything up!
@brian.d.mobley Definitely, if it doesn't work, we are going to buy some clay and check the piston to valve clearance to hopefully run the race head with the stock cylinder and piston. I'll have to do some research on how to do that, though.
Great 👍👍
Thanks Mohammad!
I wish you had showed the piston at TDC with the head still off. I am working on a similar project -2011 TTR110 with a 143cc big bore kit. I noticed that the piston comes short of the top of the cylinder!!?? it is a full 3-4mm shy and this will result in lower compression than I was hoping to get! I plan on using modeling clay on top on the piston, turn it over and check for sufficient valve pocket clearance - then have the cylinder milled down several millimeters, re-check clearances and proceed to have a "high compression" big bore kit. Any thoughts? Thanks Bill
Hi Bill. Are you using the recommended crank and rod?
Great video! I thought it was a No-No to pull crank/bearing into case as it may damage bearing. Would heating case bearing boss and freezing crank assembly work for press fit?
Hey Marc. Cold pressing is actually the factory recommended method, but it’s fine to use the method you suggest. I created a video about different bearing replacement procedures and, for me, I just feel pressured to get everything completed quickly when I use the method you mentioned. Cold pressing is lower stress (for me) and I feel better when I can take my work slow and carefully. But, again, that’s just me. My personality demands precision so I find myself drawn to procedures that suit my OCD nature! Thanks for watching and for sharing your question.
I found that T Bolt USA has everything you need including information they need to go anywhere else great prices fabulous service quick efficient thorough
I love the guys at TBOLTUSA too! Great company!
Hello Brian. Finally a video that shows assembly step by step. Thankyou for your time and patience. I just have a little question....Would like to fit a 4 speed shift drum to my bike. Is there anything I should know before hand? I have bought a shift drum without the gear.
Cheers
Hi Halina! Provided your engine is fitted with a four speed transmission and you have the four speed shift drum “star,” there are no other issues. You can always look at the microfiche for your motor to confirm you are using the correct parts for your installation. Hope that helps! Thanks for watching!
🇹🇷 teşekkürler 🙏
My pleasure!
Hey Brian, my son and I are trying to build a Klx 110 and we can’t get the primary clutch to tighten down It spins the crank and the inside of the clutch why the outside stays, locked down by the oil wrench we’re at a loss. What do you think could be wrong?
EXCELLENT JOB !!
Thanks so much! And thanks for supporting our channel!
How come in this video you lined up the expander ring and scraper but in your other video you set the rings differently?
I’m not sure to which video you reference as the “other video” but the rings are aligned using the Kawasaki service manual recommendations.
🥰🥰🥰🥰🥰🥰👍👍👍❤️❤️❤️❤️❤️
Thanks!