AndyG47
09-26-2018, 01:20 PM
Hello all
New guy here with a recently acquired 198? Kawasaki KLT 200 (for lack of a better word) Puzzle In a Box. This thing was stripped down to the bare frame and everything tossed into boxes. Plan is simply a restomod - put it back together and make some changes along the way. I'll keep it and ride it for a bit but ultimately trade it up for another ATV project. :crazy:
254753 254754 254755
Although the engine looked imaculate on the inside the piston is seized. A buddy who works at a motorcycle shop managed to drive the piston quite easily back down the cylinder with a few well placed rubber mallet strikes (After marking the timing). You can see it here soaking in Marvel Oil. Going to pull the lower section of the head, hone it, replace the rings, and hope for the best. Trans appears OK for the moment - we'll see once it's drivable.
254756 254757
Engine kill switch assembly was destroyed inside - I'm attempting repairs but it may have to get changed out. Rusty slides and stripped stuck screws are no fun. Wiring harness is intact but needs a cleaning and a re-wrap.
I only have two wheels - is the front single the same as the rear two?
Also need recommendations for a QUIET muffler and new carburetor as both of these parts are missing from the parts bin. I have the main exhaust pipe but nothing else.
Pictures for reference will be a major plus to whomever can get me good quality in depth photos.
This isn't my first resto / overhaul of an ATV. I also have a Grizzly 450 that I fixed up last year that my buddy had laying around in his yard. Needed a whole new front clip, carburetor, coolant system overhaul, major cleaning of the belt drive, electrical repairs and a bunch of other stuff. Thing didn't run when he first dropped it off, looked and smelt terrible. Now it's my plow "truck" and weekend toy.
THEN: 254758 NOW: 254759
New guy here with a recently acquired 198? Kawasaki KLT 200 (for lack of a better word) Puzzle In a Box. This thing was stripped down to the bare frame and everything tossed into boxes. Plan is simply a restomod - put it back together and make some changes along the way. I'll keep it and ride it for a bit but ultimately trade it up for another ATV project. :crazy:
254753 254754 254755
Although the engine looked imaculate on the inside the piston is seized. A buddy who works at a motorcycle shop managed to drive the piston quite easily back down the cylinder with a few well placed rubber mallet strikes (After marking the timing). You can see it here soaking in Marvel Oil. Going to pull the lower section of the head, hone it, replace the rings, and hope for the best. Trans appears OK for the moment - we'll see once it's drivable.
254756 254757
Engine kill switch assembly was destroyed inside - I'm attempting repairs but it may have to get changed out. Rusty slides and stripped stuck screws are no fun. Wiring harness is intact but needs a cleaning and a re-wrap.
I only have two wheels - is the front single the same as the rear two?
Also need recommendations for a QUIET muffler and new carburetor as both of these parts are missing from the parts bin. I have the main exhaust pipe but nothing else.
Pictures for reference will be a major plus to whomever can get me good quality in depth photos.
This isn't my first resto / overhaul of an ATV. I also have a Grizzly 450 that I fixed up last year that my buddy had laying around in his yard. Needed a whole new front clip, carburetor, coolant system overhaul, major cleaning of the belt drive, electrical repairs and a bunch of other stuff. Thing didn't run when he first dropped it off, looked and smelt terrible. Now it's my plow "truck" and weekend toy.
THEN: 254758 NOW: 254759