1) use a little dielectric grease on each connection, recheck each ground.
2) Intermittent hot or cold suggests issue outside engine.
3) pickup coil is still suspect. Starter less though, unless the issue only happens during starting. use a sewing needles into the conector, attach clips, spin it over without a plug in place
4) buy a wrecked kl200 and strip the elctrical system from topend to key it generally works ok
5) starter has to be pulled apart to do brushes, tough job.
6)I use 250 a1 pickups and stators on everything, as far as I'm concerned the hotter the better --- try a resistor type plug -8ES
7) Drink 2 or 3 for me, I'm at work for another 3 hours

 

Thanks!

Follow up:

3) I have another pickup coil on the way! Buts its off a B1 model, which has less resistance (by about 300 ohms). Think that will cause a problem?

4) I have a used wiring harness off of another 200, are you suggesting it makes sense to replace it all and ensure each connection?

6) I've been trying new B7ES and B8ES plugs. B7 is supposed to be hotter. These are resistor type plugs right?

7) When you checked your resistance on your pickup coils, where did you measure it at?

8) Beers will be flowing freely here in about an hour!

Trent

 

USe B8ES plug

try the B1 coil it may improve your issue.

use di-electric grease for each connection it helps.

I was suggesting if you want a "points" machine swipe the harness off the top of a KL enduro dirt bike 80- 82 its perfect for the klt trike

Check the resistance at the 2 wire plug between the stator and CDI check resistance of ground wire from CDI while its running, leakage will give you a high - above 10 ohms reading.

 

Hey! It was a bad pickup coil! I obtained and installed the pickup coil out of an 83 B1 (290-590 ohms) and this thing is running fabulous!

I'm thrilled, just in time for the job I need to do to!

Going to play with it a little then work on the clutch. I had a tip from a bike shop, tell me what you think please. I went there to buy the motorcycle oil, explained my situation, they told me that if just putting in the good oil doesn't work, sometimes it helps to mix diesel and motorcycle oil to get in that clutch and clean out the varnish left behind from sitting so long. Of course they said to only run a little like this and certainly don't wind it up, but work the clutch a bit and see if the diesel can clean out the crap, then drain and replace with all oil.

Feelin groovy!

Trent

 

Never tried it, might work< if you go this route block it up, take off the back wheels and do it without a load on it 1st gear, no more than 1/4 throttle< . Your manual should explain how to adjust the clutch, over tighten an 1/8 turn, run for 1/2 mile and reset it; is what I usually do.
congats on the electrical resolution. its the toughest part of fixing a KLT, next try to take the rear diff apart and rebearing, bushing and spring (next winter)

Continuosly (sp) watch for oil pump failure. start, run for a few minutes, shut off and check under intake valve cover for oil, these things tend to devour cams quickly if the filter is dirty / plugged or the pump fails. My kids have made this a start up ritual on the 200's and 250's and caught 4 to 6 pump failures ($30.00) or filter failures ($6.00) vs $350.00 + for a top end (2 minutes with a 10 mm wrench, alot of grief if it craps out)

 

Thanks again for all the tips oldkawi. You helped me through this more than you'll know! Let me know if you're ever down toward Seguin, I'll meet you and buy the brews.

On the oil pump test, you're suggesting that I open the intake valve inspection cover and look for oil in there, correct? And I presume if no oil then I have a problem correct?

I ask because I do have some oil thats blowing out the cylinder head just below the intake and exhaust where it joins the barrel, I presume its a bad gasket. Can you even find gaskets for these old birds anymore? I think the KZ200 was the same general motor as mine, think finding those gaskets any easier?

Will take ride and play with clutch tomorrow, hopefully more happy trails to report then.

Trent

 

Good news the head gasket is 25.00 CDN and they have thousands of 'em BUT - if its leakin', its pumpin'. The bad news is you gotta drop the timing chain, pull the exaust and carb, yada, yada take the head off change gasket reverse steps retorque to 57 lb etc. BUT - first check the torque spec on the 4 head bolts (numbered 1 -> 4 shoud be 55 to 60 lb) retightenby the numbers ,don't over tighten it will probably stop leaking


Change the oil filter every 10 hours with your oil, the worst sound you can hear is a squeeling in the top end, shut down immediatly, your gonna cook.

I check the oil pump by loosening off bolts on the exaust valve cover while idling if it sprays oil, great I'll wash it; - if it don't, its down for repair, period. My kids do it with a flashlight taking the cover off the intake valve cover (not so Hot) when its shut off, if they see oil no issue, if its dry....... done. I've got 3 spare oil pumps in the shop with gaskets, filters, etc. Its an hour to strip, fix, and put 'em back on the trail, they walk for a month if they abuse a machine.
Good luck on the clutch.

Darrel

 

Clutch works! Easiest clutch I'll ever fix, all it needed was some good oil!

Just took the best ride I've had on it, got the carburetor adjusted and clutch working good, hell feels like a new bike to me!

Hey oldkawi, where do you buy your gaskets, Kawasaki shop or elsewhere?

I can finally start working on some of the little problems like gaskets and goodies, now that the big problems seem to be solved. Hopefully with maintenance this thing will last me a while. Although I would like to ride one with suspension [img]i/expressions/face-icon-small-wink.gif[/img].

Happy trails! Trent

 

Go to Kawi for gaskets the price is right cause you dont wan't to cut these yourself

Ive got 2 K suspended trikes -you'd crap your pants riding them. one 85 t-3 one 86 t-3 riding a 'cate is like having a pitbull on a leash that hates your guts, don't pay attention and it'll take your arm off. Your behind the thing all the time, exaharating beyond belief, biggest adrenaline rush you'll ever have. Stock VS Stock they'll devour any 3 wheel machine of the same vintage off the line. a water cool 250R will take it out on an MX track cause of suspension if the riders are equal, but for flat track or ice races nothing would touch 'em.

Team Green rules!!!!!

Darrel

 

Ok, now I've got to start looking for a 'cate! Hey oldkawi drop me an email with your address please, I've got a part for your 'cate that I'd like to send you. I'm tbonep@austin.rr.com

Thanks!

Trent