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Thread: Newbie with a 198? KLT200 Restoration Puzzle

  1. #1
    Join Date
    Sep 2018
    Location
    New Jersey
    --
    2

    Newbie with a 198? KLT200 Restoration Puzzle

    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.

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    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.

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    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: Click image for larger version. 

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    2007 Yamaha Grizzly 450 - RESTORED
    198? Kawasaki KLT 200 - UNDER RESTORATION

  2. #2
    Join Date
    May 2006
    Location
    Gone
    --
    3,618
    Well you've got alot of work ahead of you but I applaud the effort.

    Welcome to the site

    You might find some help here...

    https://threewheelermanuals.com



    Sent from my Z958 using Tapatalk

  3. #3
    Join Date
    Apr 2014
    Location
    Edmond, KS
    --
    1,441
    It's hard to tell from your pictures, but it appears to have the goofy looking front suspension. If it does, then it's a 1984. That's the only year of the KLT200 that had it.

  4. #4
    Join Date
    Sep 2018
    Location
    New Jersey
    --
    2
    Quote Originally Posted by ironchop View Post
    Well you've got alot of work ahead of you but I applaud the effort.

    Welcome to the site

    You might find some help here...

    https://threewheelermanuals.com



    Sent from my Z958 using Tapatalk

    Thank you. exactly what i was looking for.




    Quote Originally Posted by 350for350 View Post
    It's hard to tell from your pictures, but it appears to have the goofy looking front suspension. If it does, then it's a 1984. That's the only year of the KLT200 that had it.
    1984 it is then - there's some black "U" bar running on the back of the forks in a cantilever fashion.
    2007 Yamaha Grizzly 450 - RESTORED
    198? Kawasaki KLT 200 - UNDER RESTORATION

  5. #5
    Join Date
    Apr 2014
    Location
    Edmond, KS
    --
    1,441
    Yep. That's it. As far as I know, all of the KLT250's had it. I thought I recognized the "U" is the picture of all of the parts in the back of the truck.

  6. #6
    Join Date
    Jul 2010
    Location
    glendive, montana
    --
    1,811
    I have a carburetor for that machine along with a bunch of other parts including the fuel pump. Also I have a different front end these are pics of the one I had that I sold and reaquired destroyed.Click image for larger version. 

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    rectum nothin damn near killed them
    feel free to leave feed back for me here. http://www.3wheelerworld.com/showthr...06#post1119306

  7. #7
    Join Date
    Apr 2012
    Location
    MI, USA
    --
    2,320
    Figured I'd throw it out there that I make wire harnesses, if yours is bad enough you'd want to replace it, I could recreate it with all new parts using the OEM one as a template. I'd just have to see the connectors on the harness just to double check all are still in production. I have KLT160 and KLT250 harnesses, but currently no KLT200's.

    Here's an example of my work, I make harnesses in a more "modern" style with tubing instead of harness wrapping.

    ATC350X harness example - https://www.ebay.com/itm/192097676788

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