83 klt 250

[Fat Tony]

Whats up guys, just picked up my first 3 wheeler a few days ago. It is an 83 Kawasaki KLT 250, paid 80$ for it not running. I bought it mainly for the drivetrain for a go kart build I am doing this winter. For now I am just going to ride it as is. Here are some pics.





A buddy and I spent some time today diagnosing why it didn't run. The ignition was completely shot, and to replace the parts it would have been 3x what I paid for the thing. So we found an alternative. Went to the junkyard and pulled a duraspark II ignition module and coil from an early 80's carbed ford pick up. Wired it in and she fired right up! Had a lot of valve train noise and it kept farting through the carb. Pulled the valve covers off and the lash was way off. After setting it, this thing ran great! Here is a video.

[dream3wheeler]

nice little trike, shine that up, polish the metal, put some bigger pegs on it, some better looking handlebars, polish the plastic, get a seat cover, maybe get some better forks? make it look sweet. you'd have yourself a fun little ride.

[Fat Tony]

nice little trike, shine that up, polish the metal, put some bigger pegs on it, some better looking handlebars, polish the plastic, get a seat cover, maybe get some better forks? make it look sweet. you'd have yourself a fun little ride.

I could do all of that, but I am just ripping the drivetrain out of it haha. Just going to get it functional for now. The engine is going on the bench tomorrow for a cam replacement and head rebuild. Adjusting the lash got it to run better, but turns out the exhaust lobe is extremely worn down. It barely opens the valve lol. Had great compression though, over 140psi.

[TheBlueWale]

Are you using the drivetrain so that you can have a locking rear differential?

[Fat Tony]

Are you using the drivetrain so that you can have a locking rear differential?

Oh yea, its going to be so much better than having a live axle. I will actually be able to turn! It was a craigslist find, I mainly bought it because it was so cheap. Even better than the locking dif is the 250cc 5spd with manual clutch. This go kart is gonna fly.

[TheBlueWale]

I used to have a Klt250 too, but the idea of the locking trans was just a big joke(when you were offroading and making a turn and one rear wheel was in the air, that one would be the one that would be spinning and not the one on the ground), You'd be better of selling that klt250 and with the money that you'd get from it buy an old polaris 250 trailboss 4 wheeler and use it's automatic pvt trans, engine, and rear(parts would also be easier to find for it at a cheaper price). It's a 2 stroke too so it would be like a honda oddyzzey go kart and you'd have reverse too. It's just a thought though.

[0GravityMX]

yeah its not worth tearing up that KLT theres not many around and parts are a pain in the ass at times.

[Fat Tony]

yeah its not worth tearing up that KLT theres not many around and parts are a pain in the ass at times.

I am considering just restoring it and then selling it, but I have a feeling it wouldn't be worth my time and I would end up losing money.

I need to replace the cam in this thing but a new one is over 150 bucks. I found a good KLT 200 cam for cheap. Any idea if these cams are the same? I looked it up on Babbit's and the part numbers are slightly different, but I am wondering if it will still work?

[0GravityMX]

diffrent parts. why you think it needs a cam?

[Fat Tony]

Popped the valve covers off, intake has full travel but the exhaust valve barely moves. The rocker had a ton of lash and setting it helped a little bit, but the valve still barely opens. The exhaust lobe is just about non-existent.

[fox_racing2009]

I am considering just restoring it and then selling it, but I have a feeling it wouldn't be worth my time and I would end up losing money.

I need to replace the cam in this thing but a new one is over 150 bucks. I found a good KLT 200 cam for cheap. Any idea if these cams are the same? I looked it up on Babbit's and the part numbers are slightly different, but I am wondering if it will still work?

I got a 82 klt250 about a mouth ago its my first 3wheeler and i needed a new fuel pump,front brakes,chain tensioner and chain case so i ended up buying all new parts but could find the chain tensioner and chain case and i found another 82 klt250 that had no plasic and the ignition was shot i took the chain tensioner/chain case off and i have a complete extra klt250 besides the pastic,coil,cdi,chain tensioner,and chain case also the motors complete.

[Fat Tony]

Took it for a ride today. The rear dif is acting really strange. It will take a sweeping curve no problem but when it straightens out, the dif pops real loud and almost throws me off. Not sure whats wrong with it, won't know until I take it apart.

Pulled the engine today and took the head apart. The exhaust lobe is almost completely rounded off. Really amazed it ran as well as it did. I have a new cam on its way from canada, so i probably wont see it for at least 20 days. Also ordered a top engine gasket kit, and some new rockers. Heres some pics of the carnage.

[TheBlueWale]

Did you make sure that there's some gear oil in the rear diff? It's just 4 gears in there and a rod going through one of the axles that will engage or disengage the locking diff which is activated with the twisting knob in the rear left wheel. I have the entire rear axle/differnital if it turns out that yours is falling apart/busted. Also does this occur when the differential is locked(solid axle) or unlocked(one wheel spinning). Finally, it's a possibility that your bearings are so far gone(since it sat for a while) that they create so much play that the gears jump teeth.

[Fat Tony]

the left side hub, the one with the knob, has a lot of play in it. I can't get the unlock/lock knob to stay in the unlock position. I raised the rear end and was able to unlock it by holding it, but it just snaps right back to locked as soon as I let go.

I am on a business trip, and I will not be able to mess with it until this weekend. Won't know anything until then. But I will def keep that in mind, I can't find parts for this thing anywhere. Actually the klt 250 i bought is the only one i have seen listed anywhere.

[darrel632]

change your oil pump, its the culprit with your cam failure, its a common issue with the 250's