KLT 200 Carb help

[toyota_guy83]

Hey Guys, said to try posting in trikesylvania so here goes. Ive got an '80-something KLT 200 that has what I beleive is a Carb issue, heres the details: It ran horribly when I bought it and since have cleaned the carb many times (made a little improvement) Replaced the cam, rockers, and valves. The engine was previously rebuilt 0.5 mm over and has excellent compression. I have cleanded the fuel tank, replaced all the fuel lines/surge line, fuel filter and fuel pump all together. Air filter/box are nice and clean, airway not obstructed, intake manifold siliconed to the head, all hose clamps are tight. Once I get it running, it runs great on choke for a while, then once it starts to warm up and I bring it down to idle, it idles great and tip in is fantastic, but If I blip it into the needle jet circuit it will stall out and die until I let off. If I rev it up a bit in the pilot circuit, then it will rev at any throttle position. I have tried every clip position on the needle with no change and tried screwing with the airscrew as well. After it warms up it starts missing a bit at idle, the idle gets really sensitive to adjustment and if I rev it, it comes back down and slowly drops rpms until it stalls out. Any ideas? Could the float be too low? Please help me out, Ive put more money into this thing than its worth and still havent gotten to ride it yet.

[Yamaha_Rules69]

Do you have a spare coil you could try? A lot of times you swear it is the carb, but it is really the coil - when it gets warm, it runs crappy. This has happened to me more than once. It could be the float level set too low, if not a spark problem, it deffinatly sounds like it is not getting enough gas somewhere. Good luck, and keep trying, and sure enough you will get it eventually.

[Nightmare]

........+1

[MTS]

Ditch the sillycone on the intake for one..use a proper gasket....Also...the stock 200 4 strokes Weather it be a honda/kawasaki/ yamaha/ are choked up a lot in stock form...have had a few that do that...They need more flow...Open air-filter or no air-box lid...and Jetted accordingly..Even the old 4 strokes tend to run lean when there hot...Too bad your 5-6hrs away from Edmonton..would be glad to help you with it.

[toyota_guy83]

Thanks for the help guys. No spare coil, I dont believe this is the problem as there isnt alot of heat radiating up to the coil by the time it starts running poor. The silicone was to rule out a possible vacuum leak, I prefer gaskets myself but the Kawi dealer is almost an hour away and they would have to order one anyways. I'll try raising the float to see if thats the problem. Oh and MTS if I ever get out to Edmonton, I'll bring my '85 Z if youre up for a ride. Shes the polar opposite of the klt, a real trooper hated by many 4 stroke quad owners. What you say about the airbox sounds good, I used to have an '83 tri-moto 200 that did this too, except she idled great. It just seems like it should be fixable without modding, you know...It couldnt have done this when it was new. Keep the ideas coming, I'm gonna fix this thing come hell or high water

[squirrel1182]

Mine does similar to what your describing. I put in the next bigger main jet available and it helped a little bit but not much. Have you tried choking it when you go to rev it up? Choking mine is sometimes the way i can get above 1/4 throttle.

[shortline10]

Sounds like the pilot jet is still a little dirty . Need to run a fine piece of wire threw the jet to make sure its perfectly clear or just buy a carb kit . You can buy gasket material at your local auto parts store and just make a new one .

[toyota_guy83]

Shortline, I like that idea. It was plugged solid when I first got it and would barely come up about a thousand rpm or so off idle at first. Ive cleaned it with carb cleaner and compressed air but what I found on other forums is alot of people like to bump up their factory pilot to improve cold starting and help remove pilot to needle circuit bogging. The reason stated was they are jetted as lean as possible from factory for emissions standards. I think youre right about it still being dirty, I'm just going to buy a new one and a couple sizes up. Luckily the float bowl has a rubber o-ring that seals nicely. I should be riding her soon! Its been a long time coming. Thanks again guys

[toyota_guy83]

Well this pisses me off...I went and bought brand new 42 and 45 keihin pwk pilot jets, ordered them in, picked them up and...they dont fit! so I take them back and we look through the parts book and they have pictures and dimensions (these are oem keihin jets) and find the ones I ordered but the one in the trike doesnt match any specs in the book. WTF I say and the parts guy tells me that Yamaha has a few proprietary jets for a few of their bikes. So I head on over to Kawasaki to talk to them and find out its the same deal. Kawi made the KLT 200 pilot jet just a little different than what Keihin factory jets are! The threads are the same pitch but a little bit bigger diameter so the standard keihin jets are loose in the threads. And they discontinued them! So now Ive got a carb that some decided to screw with and now I cant get parts for it. Where is the logic? Going through all the little details of this trike makes me wonder how competent their engineers were. Exhaust right above oil fill cap, crappy expensive ignition module, starter motor draws to much amperage so it wont start if battery voltage is low, oil bath stator and pickup coil drown if oil level is too high, engine drops out bottom of frame, cylinder head is the biggest PITA to remove with the engine in the machine. Its so ill-designed and ass-backwards its no wonder everyone rides honda and yamaha. Ok, end rant. Any ideas? Ive put alot of time, money and hard work into this pile and just want to ride the damn thing. The only thing I can think of is epoxy or red loctite the new pilot jet in place. I hate the idea but its about all I can think of.

[MTS]

Did you Take the venturi Out of the carb when you cleaned it..? Some have a Passage in there If i remember right, Never have had a KLT 200 carb...There is always Jet-drills if you can find someone that has them still...Only problem being...You cant undo-what you drilled....Could also Try Sudco..They Might have something.