1984 Kawasaki KLT200C

[FRANKENMARO]

So i guess i must post here as i cant post in trikesylvania.

Ok I have a 1984 kawasaki KLT200C has new piston, rings, valves, and timing chain. The plastics are in great shape its only missing front fender. Everything seems to be here, but poorly wired fuel pump and all. This model seems to have the locking diff but only has a small knurled knob to lock and unlock with lots of turning... I plan on welding a small crank arm onto it for speed and ease.
Now everything looks to be in order but the guy who sold it to me (and did the work himself) said after all the work he did it never ran again.

Now i cleaned and rebuilt the carb, flushed the gas tank, replaced fuel filter, and changed the spark plug. No Luck...... Started getting into it and pulled the valve covers and cam access plate. The valves are all moving good, i haven't checked lash yet.(i will be readjusting) BUT i do need specifications possibly scans from a clymer manual or something.

Im about to check the timing next then figure out the cobbled home made wiring... Anyone have a diagram of an 84 200c? this one looks to be CDI ignition. I've found diagrams for points ignition though they don't help me much lol.

PDFs are nice XD and helpful while offline in my garage

ANYWAY Wish me luck on this $100 venture lol (not bad imo)

[FRANKENMARO]

Already began tearing into it before thinking of taking pics.
179340

Already removed all the shotty wiring and set the timing right.... the cam sprocket was 180 off couldn't get the marks to match up period... flipped the sprocket and got timing set first try.
179341

wiring all replaced with new key ignition, must run a neutral indicator light still.
179342

i still need info on the valve lash procedure for this.

[FRANKENMARO]

btw i found a 200c wiring diagram :D

[FRANKENMARO]

ugh this limited membership thing sucks... cant post this where it belongs and wont get response from other noobies. lol kind of a hindrance

[MonroeMike]

http://www.3wheelerworld.com/showthread.php/126871-KLT200-250-Service-Data

[FRANKENMARO]

Thank You Sir. :beer

[FRANKENMARO]

Well it now runs.
BUT it wont rev up the rpms are same at idle as WOT and it black smokes @ WOT choke off but will not start unless choke on and you cover carb and choke with hand. as if its leaned out.

now ive got a question about the cam sprocket. which mark was i supposed to use?. Its currently set using the KL250V/KR200C mark IF memory is correct. as i couldnt get it to line up period 180* out

also the valves had no gap in the lash they were past zero lash like my honda 250, except the specs says there is supposed to be a gap. i re-lashed the valves to specified gap but now it ticks like a SOB

[FRANKENMARO]

only thing that has changed from the past was that the jug was bored n honed with oversized rings and piston the guy got it all back and re assembled it and couldnt set the timing. now he said he did nothing other than unbolt the head and never de lashed the rockers or anything.... im a little stumped and i do have a simmilar issue with my honda 250 as i constantly have to adjust the lash on it like every 50 hrs it wont start till i adjust it

[FRANKENMARO]

and once my honda does start it will not rev up and i have to further adjust the lash till it will rev up, but heres the odd part its always either the same spot before or after what it was set at when i got it. ive pulled the cam out of it and it isnt wearing away so i dont understand the constant adjustments to keep that one running good. so i moved on to this project and specs say to do one thing but results say to do another cus if i tighten the lash on the kaw the idle smooths out and it begins to try to rev up. if it stalls though i have to de lash the intake valve to get it to start up again. quite frustrating lol as im partial to 2 strokes and reed valves lol. as for cars you go a little past 0 lash so thats why i tried it with some sucess. also the carb on this kaw 200 is absurdly small the bore is no bigger than the diameter of a quarter. where as my honda 250 n all my old equal displacement machines all had much larger bore carbs,

[FRANKENMARO]

anyway the main concern now is the Kaw KLT200C

[FRANKENMARO]

http://s1365.photobucket.com/user/The_Mechanic89/media/kaw200_zpsd679b2fc.mp4.html

[FRANKENMARO]

CAN SOMEONE LINK THIS IN TRIKESYLVANIA? lol
IM trying to get this running by the end of fall before snow hits....

[FRANKENMARO]

could it be my oem electric fuel pump?

[FRANKENMARO]

it seems to have good flow and volume and the threewheeler is black smoking like its really rich but idk it looks to be the original electric fuel pump