Newbie with KLT200....

[8675309]

So, not only am I a newbie to the forum, but I'm a newbie to the motorbike world. I've rebuilt more car/truck/jeeps than I care to count, but this is my first small engine rig. Seems that I picked a Doozie to start with... LOL
As far as I can tell, folks either love them or hate 'em.

http://img.photobucket.com/albums/v67/jameshunt/3wheeler.jpg

I've got a few questions...
#1. When the clutch is in and the transmission is in gear, the wheels should still roll, correct?
#2. I read that these came with an optional kickstart.... mine doesn't have one. There is a block-off plate on the right side, I'm assuming that's where it would go? If I find the parts, it's possible to convert it easily, right?
#3. What are my options on the fuel pump? I see that bikebandit.com has them, but at $195 a shot it's a 5 spot short of doubling what I have in the thing. I found it on another site for $65, but that site sure did seem shady.
#4. Can the 250 forks fit on this? Sure would be nice to get SOME kind of suspension on this thing.
#5. Anyone have a manual for this thing?

I guess that's enough for now...

Thanks in advance,
Chris

[atctim]

First off - WELCOME to the boards. I will try to answer your questions as best as I can below.


I've got a few questions...
#1. When the clutch is in and the transmission is in gear, the wheels should still roll, correct?
Correct - just like a car - in gear with clutch lever pulled in - it should free wheel
#2. I read that these came with an optional kickstart.... mine doesn't have one. There is a block-off plate on the right side, I'm assuming that's where it would go? If I find the parts, it's possible to convert it easily, right?
I was not aware of this option. Is the block off plate removable - or part of the case casting. If it is not removable you would need to find a side case for this conversion. I know the ATc70s have a spot where the kicker would go for the 70 2 wheelers - but it is cast in
#3. What are my options on the fuel pump? I see that bikebandit.com has them, but at $195 a shot it's a 5 spot short of doubling what I have in the thing. I found it on another site for $65, but that site sure did seem shady. Steer clear of shady sites. You will find that one downfall of this hobby is parts prices and availablility. Is it possible to hook up a fuel pump off of a different machine to save some dough? I would say yes to that - but it would require some inginuity.
#4. Can the 250 forks fit on this? Sure would be nice to get SOME kind of suspension on this thing. I have a set - you can have them for $10 plus shipping if you want them - I am not sure if it is a direct bolt on or not - but the 250 "springer style" front ends sure are unique. (note in the future - list your wanted ads in the classifieds section of these forums)
#5. Anyone have a manual for this thing?
Here is a wiring diagram to start you out with electrical gremlins that these machines are plagued with.
http://www.files.3wheelerworld.com/Wiring/KLT200WiringDiagram1.jpg
Good luck with your endeavors and welcome aboard!

[8675309]

Thanks for the quick response!

I suppose I need to figure out why the clutch won't dis-engage. I tried to adjust it at the lever, but it gets the same results.

The block off is bolted on. I'll get a picture of it later and post it up.

I'm going to stop by 2-wheel world today to see if they have a low volume fuel pump I can slap on there. If need be, i can weld up a mount for it.

I might take you up on the forks.... let me get this thing running and I'll get with you on it! I was just curious if they would fit for future modifications.

Thanks for the wire diagram, I actually found and downloaded it last night after I had registered and was able to search.

Thanks again for all of the information!

[rdlsz24]

Welcome to the boards. Nice user name btw! Jenny, Jenny....

Rob

[8675309]

Thanks!

The name stems from my early Jeep days... My original name was 8376hybridCJ7 and one guy called me 8675309 and it stuck. There are a lot of forums where my name is just "Jenny", which is pretty funny when people meet me in person and haven't been a long-time Jeep guy in the local area.

So, I couldn't help myself, I had to jack with it before I left. I went through the bag of junk that came with the trike, and in it was the carb and thumb throttle. Hooked it up and the carb won't budge, other than the choke. I filled the battery that was in it with DI water and charged it.... it turns over! It will even try to start if I choke it and spray some carb cleaner in there. Even with the throttle hooked up I can't get the carb to budge, I guess I need to rebuild.

Also, it sounds like the pump is circulating, I'm going to try to find a rebuild kit for it. I know I saw one online somewhere.

By the way, before I went through the bag of junk I spent 5 friggen minutes trying to find a carb on this thing. LOL. I was thinking "why isn't the carb attached to the head somewhere?".

Ug.

[8675309]

So, I had some mild success tonight. The carb wouldn't budge earlier today. I had never seen a motorcycle carb up close till today, and I'm not sure that this one is a normal set-up. The throttle cable comes in through the top, and attaches this plunger that adjusts the airflow. I used up 1.5 cans of carb cleaner on this stupid carb. I got to where I put it in my home made bowl to allow it to soak. Took it all apart and let it sit, then scrubbed. It took a LOT of friggen work to make that plunger move. Now it works.

With some rubber hose, a itty bitty funnel, some starter fluid, and the use of a small child (to hold the hose and funnel) I got it to run for about 15 seconds. Now I need to get a fuel pump to make this thing work. I found one that puts out 4-6 psi, but I'm afraid that's going to be a bit too much? There's always lawn tractor pumps? Any ideas?

http://i65.photobucket.com/albums/h230/chriscloud_2006/IMG_3174.jpg
http://i65.photobucket.com/albums/h230/chriscloud_2006/IMG_3175.jpg
Below is the block off plate that I was talking about. Top right. Could a kickstart lever go there?
http://i65.photobucket.com/albums/h230/chriscloud_2006/IMG_3176.jpg
That carb was NASTY!
http://i65.photobucket.com/albums/h230/chriscloud_2006/IMG_3179.jpg
http://i65.photobucket.com/albums/h230/chriscloud_2006/IMG_3183.jpg
http://i65.photobucket.com/albums/h230/chriscloud_2006/IMG_3184.jpg

[atctim]

I like your soaking bowl - Must be a jeep thing!

[Nuke Em]

Hi and welcome to the boards!

I just bought a very similar project to yours... http://www.3wheelerworldforums.com/showthread.php?t=95823 It came with a couple of manuals that may cover your 200 too. I could scan or take pics of parts that you want. There may be an online manual somewhere too??? My KLT250 has some kind of wierd front suspension, nothing like forks though.

Good luck, sounds like you are having fun with it and thats half the fun...love turning wrenches!

Gary

[8675309]

I like your soaking bowl - Must be a jeep thing!
Thanks!
I had spare axles I robbed the shafts from and usually I would have sold the diff cover, but this one was a light duty cover. I welded some legs to it to make it a bowl.

[8675309]

Hi and welcome to the boards!

I just bought a very similar project to yours... http://www.3wheelerworldforums.com/showthread.php?t=95823 It came with a couple of manuals that may cover your 200 too. I could scan or take pics of parts that you want. There may be an online manual somewhere too??? My KLT250 has some kind of wierd front suspension, nothing like forks though.

Good luck, sounds like you are having fun with it and thats half the fun...love turning wrenches!

Gary

Yeah, I was admiring yours yesterday. Looks like the only two major changes form mine to yours is the springer forks and the engine size. That block off plate on the right hand side (as your sittin on it) on the engine right next to the starter, could that be where a kickstart would go?

Thanks for the offer to help!

[8675309]

Hooray! For $55 I got a pump that puts out 2.5 to 3 psi at the parts store!

I got the tank all cleaned up and took a trip around the yard after I got done guessing what I was supposed to do with the carb.

I haven't ridden a trike in almost 20 years!

[Nuke Em]

Congrats! What brand pump and what store if you do not mind posting it. I may need the same thing. Thanks,

Gary

[Autophysn]

Freaking Awsome! New triker Welcome aboard!

[8675309]

I threw the package away and took the trash to the curb last night, but it's a generic from OReilly's auto parts from the shelf where they have all the gauges. I have to go back today to get some oil, I'll get the info off of the package when I get there. It even bolts up to the same holes! With the supplied filter, it's a little long, though.

[Nuke Em]

Cool, thanks for all the info!:beer

[8675309]

So, here's a reason it's a good idea to hold onto old hardware...
These things tore up pretty easy, even with the biggest phillips head I could find. I'm going to put some torx heads in there, that way I Don't have to worry so much about stripping the head.
http://i65.photobucket.com/albums/h230/chriscloud_2006/IMG_3185.jpg
http://i65.photobucket.com/albums/h230/chriscloud_2006/IMG_3186.jpg

I changed the oil filter and dumped the oil out... there wasn't much in there. for some reason the cover doesnt fit flush with the new filter, am I going to have to torque down the screws a little to get a good seal?
http://i65.photobucket.com/albums/h230/chriscloud_2006/IMG_3187.jpg

This cover plate is where I thought the kickstart might go.... LOL
Like I said, I had absolutely NO experience with motorcycle engines before this tuesday.

[200x Basket]

i have a spare klt200 engine with the kickstart parts. let m eknow if you need them.

[MonroeMike]

Get yourself an impact driver for those screws, it will help alot.

Welcome to 3ww.

[Gag_Halfront]

The kickstart lever would be toward the bottom rear of the right side, not the top front. The shaft would be sticking out.

Kickstart was available only certain years. Not ever 200 had it available.

Zoom in on this pic and look at the back of the engine near the battery bungee.

http://i438.photobucket.com/albums/qq101/Gag_Halfront/My%20Trikes/KLT200/DSC01965.jpg

The kicker is missing, but you can see the shaft coming out of the engine.

As for the clutch, these machines have a wet clutch, not dry like a car, truck, jeep, etc. The clutch is bathed in engine oil during normal operation. The oil helps the clutch release. If the motor hasn't ran in a while, it's somewhat normal for the clutch to stick. When you install a new clutch, you usually soak it in oil overnight prior to installation. A dry motorcycle clutch is not a happy clutch. Change the oil, run the bike in neutral for a while, and pull the clutch lever a few times and then see how it does.

[8675309]

Wow... I never saw these last two posts. Thanks!

I have it all apart right now, I was going to change out the points. Turns out mine doesn't have points.

I got the clutch working shortly after I got it to idle a while back. I can drive it around the yard a bit, but it's not 100% yet.

[jonolanracin]

hey what about the fuel pump info you were going to post

[MonroeMike]

hey what about the fuel pump info you were going to post

Post #9 in this thread
http://www.3wheelerworldforums.com/showthread.php?t=95823