Finally time to start this...KLT 185 Build Thread

[TheBlueWale]

I think that will require an impact gun(the speed and force should get it to come apart w/o spinning it), or maybe that should have been the first bolt/nut to be removed before you took apart the rear differential holding the axle in place.

Nice start on the build, the bike is in pretty good shape

[ebaccm26]

Just a small update. Still trying to find one good rear rim so I can get off to powdercoating. Also was able to find out that the tool listed in the manual for holding the bevel gear while taking the bolt off was also used on the 03+ bayou 250's so I ordered one of those through my dealer. Once I get my hands on another rim and the holder there should be some good progress.

[MRSOUND]

Where are you at with this? Your thread is fading off into obscurity. Waiting on some updates!

[ebaccm26]

Where are you at with this? Your thread is fading off into obscurity. Waiting on some updates!

I sold my 200x the other day and finished disassembling the US90. Now that I have space I will be buying a raptor so the KLT will have to wait 1 or 2 months while I gather funds for the raptor. Feel free to frown upon me for setting the KLT to the side to buy something with one too many wheels I did say at the begining that this may be a slow build.

As for an update on the KLT it is just waiting for powdercoat. The only thing that has changed is that I picked up a NOS muffler. Don't worry though the KLT will be finished.

[MRSOUND]

Where did you find the muffler? Have not seen one since I started collecting parts for mine.

[ebaccm26]

Where did you find the muffler? Have not seen one since I started collecting parts for mine.

Picked it up off ebay the other day. The listing said it was new but I was a bit unsure, after recieveing it I can tell it has definately never been ran but it has some shelf wear.

[ebaccm26]

Time for an update!!! Still have some stuff that won't be done for a while but certainly getting there.

Frame and lots of misc. parts have been powder coated. Still need to get all the silver parts done as well as the engine cases.



Exhaust was high temp powder coated but the muffler did not survive, I have another so not that big of a deal....



Engine was filthy



Cleaned it up with a wire brush...



Hated the way that looked so I soda blasted it... came out much better in my opinion



I did find one issue when I took off the outer cases, return spring for the shifter shaft was snapped....



That's it for now, like I said still several things I need to get done but this is where it is at. I am probably going to use the plastics off of my red KLT because that is the best I have... then I'll use the other one as my rider....

[muthey]

that motor looks almost identical to a klf 185 I had this last summer. I cleaned it up put a new muffler same as what you have, on and crafted a new shifter, bought a new header pipe and sold it for a 300$ profit. Moral of the story, check with the klf 185 for some of your parts.

[MRSOUND]

Glad to see some progress! I scored a NOS coil & tail light assembly a few weeks ago on ebay. I'm still looking for that "unicorn" NOS rear black fender

[barnett468]

I did find one issue when I took off the outer cases, return spring for the shifter shaft was snapped.

The spring is temporarily available new below.

92081-1987, $17.75 plus shipping

http://www.ebay.com/itm/KAWASAKI-KLF...-/121243390533


$19.99

http://www.ebay.com/itm/NOS-1986-198...8#ht_355wt_930

That's it for now, like I said still several things I need to get done but this is where it is at. I am probably going to use the plastics off of my red KLT because that is the best I have... then I'll use the other one as my rider.

Did you try Maier Plastic?

[barnett468]

The only part I know that I need (plenty of things I'd love to find mint/NOS but those are wants) still at the moment are one rear rim.

(plenty of things I'd love to find mint/NOS but those are wants).

The following places claim to have a rear rim. I would not hold my breath but who knows.

Rear rim p/n 41025-1122-F2

http://www.2wheelpros.com/oem-parts/...2-f2-part.html

http://www.gearhead.com/kawasaki-410...1025-1122-F2/1


One of the biggest NOS parts suppliers for that model is xtremeusa.com.

cmsnl.com and partzilla.com both have klf185 parts, some are interchangeable.

[ebaccm26]

that motor looks almost identical to a klf 185 I had this last summer. I cleaned it up put a new muffler same as what you have, on and crafted a new shifter, bought a new header pipe and sold it for a 300$ profit. Moral of the story, check with the klf 185 for some of your parts.

They are very similar and I do keep an eye out for klf parts but a lot of the parts have very small differences. But I did find the other muffler I have by looking for klf stuff.

Glad to see some progress! I scored a NOS coil & tail light assembly a few weeks ago on ebay. I'm still looking for that "unicorn" NOS rear black fender

I'm also glad to see some progress haha. I know you got a NOS coil and tail light because I was bidding against you The black NOS rear fender certainly is a "unicorn" but to every once else but you so is the red one

The spring is temporarily available new below.

92081-1987, $17.75 plus shipping

http://www.ebay.com/itm/KAWASAKI-KLF...-/121243390533


$19.99

http://www.ebay.com/itm/NOS-1986-198...8#ht_355wt_930

Thanks. I did actually already pick one of these up, ordered a new one as soon as I found the broken one a few weeks ago. I was relieved that there was some available on eBay.

Did you try Maier Plastic?

I did not. I know people do group buys and stuff with them but that is not something I am familiar with. I'm sure they need a decent amount of interest to reproduce something and unfortunately there just isn't enough people with KLT 185's. I know someone a while back tried to get Clarke to make some tanks but they had the same issue of not having enough interest. Like I said though I am not familiar with how Maier goes about making new plastics, maybe someone could shine some light on that for me.

The following places claim to have a rear rim. I would not hold my breath but who knows.

Rear rim p/n 41025-1122-F2

http://www.2wheelpros.com/oem-parts/...2-f2-part.html

http://www.gearhead.com/kawasaki-410...1025-1122-F2/1


One of the biggest NOS parts suppliers for that model is xtremeusa.com.

cmsnl.com and partzilla.com both have klf185 parts, some are interchangeable.

Thanks I will check some of those sites out.