Josh Hansen KLX110 Ultimate Pit Bike Build | Bike Builds

On this episode of Bike Builds we take a brand new KLX110L and turn it into the Ultimate Pit Bike! The 110L has a clutch so it appeals to a lot of adults and young kids graduating from clutchless bikes. It was quickly decided to build a Josh Hansen replica 110 because there is no doubt Josh Hansen has played a pivotal role in the world of dirt bikes and his blacked out KX with hints of red featuring a green front end is hard to beat. 

Watch the latest episode below!

Ultimate Pit Bike?

The Pit Bike scene is becoming more and more popular with the aim for adults to race bikes that were first intended for kids. Most builds aim to make the bike stronger, more powerful and race them on tracks they were never designed for! So aspiring to build the ultimate pit bike, we needed the bike to handle bigger jumps, a larger human, and most importantly look trick all at the same time. 

Parts used and why?

Suspension:

The suspension was upgraded with ozminnis suspension kit which increased the ride height and stiffened up for the heavier rider. This kit comes with a complete rear shock, heavier fork springs and extended damping rods so it's easy to install and makes a huge difference to the bikes handling and ground clearance. Perfect for those bigger jumps and larger humans.

• [OZ-SPK-KL-300LBS] Ozminis Kawasaki KLX110L Suspension Kit

Performance:

110's are certainly no powerhouse however we through a bunch of parts at this bike to help it gain some extra hp! To keep the Josh Hansen theme we went with a Pro Circuit exhaust and to help the bike breathe better we installed a Funnel Web air filter. On top of that, we installed a BBR rev box which is designed to help the bike rev and increase its rpm range. The jetting was also changed to suit the exhaust, air filter and rev box. To shave a tiny bit of weight we also installed a SSB lithium battery which is less than half the weight of the original! 

• [4-LH5L-BS] SSB PowerSport LH5L-BS Lithium Ultralite 12V Battery
• [PC0122011F] Pro Circuit Kawasaki KLX110 10-23 T6 Exhaust System
• [FWF435] FunnelWeb Filters KLX110 02-23 Air Filter
• [451-KLX-1102] BBR Kawasaki KLX110L 10-23 Revbox

Wheels:

On Hanny's KX he ran blacked out wheels so we followed the theme and installed black Miniracer rims with black spokes and black cerakoted hubs to achieve the look! Wrapping the wheels in Dunlop MX33 tyres and adding rim locks to allow us to run lower tyre pressures without running the risk of tearing the valve from the tube. We also installed a black Miniracer sprocket along with a gold D.I.D chain to dress up the rear end.

• [17-RL1-01] Kustom Hardware 1.4"/1.6" Alloy Rim Locks x 2
• [DID420NZ3120G] D.I.D 420 NZ3 120L Heavy Duty Gold Motorcycle Chain
• [DMX3312080] Dunlop MX33 80/100-12 Mid/Soft Rear Tyre 
• [DMX3314060] Dunlop MX33 60/100-14 Mid/Soft Front Tyre
• [MR02002-BLK-38] MiniRacer Kawaskai KLX110 Elite Series Black Rear Sprocket - 38T
• [CWC-SSK-BLKNIC-KLX110-F] Central Wheel Components Kawasaki KLX110 Black Front Spoke Set
• [CWC-SSK-BLKNIC-KLX110-R] Central Wheel Components Kawasaki KLX110 Black Rear Spoke Set
• [D58-02-104] DRC Black Rim Lock Nuts
• [D58-01-104] DRC Black Rim Lock Spacers
• [Special Order] MiniRacer 12" Alloy Rear Rim - CRF110/KLX110 - Black
• [Special Order] MiniRacer Factory Series 14" Front Rim - KLX110/TTR110 - Black
• [Special Order] Lux Billet KLX110 Wheel Spacer Kit - Red

Controls:

To allow a larger rider to fit comfortably on the bike we installed a Pro Circuit triple clamp along with Renthal Pit Bike Handlebars, grey diamond grips with red grip donuts to go with the theme! Due to installing taller handlebars, we had to install longer cables for the brake, clutch, and throttle. The genuine throttle tube was plastic so we upgraded that with a billet Pro Circuit throttle tube along with Miniracer adjustable clutch and brake levers. The gear lever and brake pedal were upgraded with extended versions thanks to Pro Circuit and Thrashed Minis along with Haunted Hard Parts heavy duty peg bar paired with Ballard's Titanium footpegs!

• [A090] Renthal Full Diamond Grey Medium Grips
• [53-363-10] A1 Kawasaki KLX110 Extended Throttle Cable
• [53-425-30] A1 Kawasaki KLX110/L 10-23 Extra Long Front Brake Cable
• [53-449-20] A1 Kawasaki KLX110/L 09 23 Long Clutch Cable
• [G186] Renthal Grip Donutz Red
• [PC39220111] Pro Circuit Kawasaki KLX110/L 02-23 Top Triple Clamp and Bar Mount
• [61101BK] Renthal Honda CRF110 Black Handle Bar with Bar Pad
• [MR0019-BLKBLK-00] MiniRacer Elite Series Front Brake Assembly - Black/Black
• [BA-TFP-YA1] Ballards Yamaha YZ-YZF 98-23 Titanium Footpegs
• [Special Order] Haunted Hard Parts Heavy Duty Peg Bar
• [Special Order] MiniRacer Elite Series Clutch Lever Assembly
• [TB-10] Pro Circuit Billet Throttle Tube KLX110
• [KSL20110] Pro Circuit Billet Extended Gear Shift Lever KLX110
• [TM-BP-K01] Thrashed Minis Kawasaki KLX110 OTT Extended Rear Brake Pedal

Aesthetics:

We had the suspension, swingarm, hubs, and engine cases cerakoted to complete the look along with red Pro Circuit engine plugs. Thanks to the legends at Lux Billet we installed their red gear shift shaft brace, bump start cover, and chain adjusters to add some extra bling to the engine! We also installed a black BBR bash plate and we kept the theme of the bike going with Acerbis black plastics for the rear of the bike with a green front fender and front number plate covered in a NineTwo Decals custom graphics kit. We paired this with a Strike Seats seat cover and tall seat foam to improve the rider triangle.

• [23996.09] Acerbis Kawasaki KLX110 10-23 Black Plastics Kit
• [23997.130] Acerbis Kawasaki KLX110 10-23 Green Front Fender
• [24001.130] Acerbis Kawasaki KLX110 10-23 Green Front Plate
• [ST-062627] Strike Seats Kawasaki KX65 00-23 KLX110 02-23 Suzuki RM65 03-05 DRZ110 03-05 Gripper Ribbed White/Black/Black Seat Cover
• [ST-F1013-T] Strike Seats Kawasaki KLX110 02-23 KX65 00-23 Tall Seat Foam
• [LUX-BSC-KLX-RED] Lux Billet Kawasaki KLX110 L Red Bump Start Cover
• [LUX-SSB-KLX-RED] Lux Billet Kawasaki KLX110 L Red Shift Shaft Brace
• [Special Order] Lux Billet KLX110 L Red Chain Adjusters
• [320-KLX-1111] BBR Kawasaki KLX110L Black Skid Plate
• [PC4009-0017] Pro Circuit Kawasaki KLX110 10-22 Red Engine Plug Kit

Check it out!

Check out more photos here

We hope 'Hanny' is proud!

We are beyond stocked with how the bike turned out and believe us when we say, this bike looks even better in person! Stay tuned for what we end up doing with this build and what we have planned for the Pit Bike scene in the years to come. Thanks to everyone who helped us along with way with this bike build; 727 Moto, Haunted Hard Parts, Miniracer, Lux Billet, Ozminis, Thrashed Minis and Featherstone Motorsports!