What sparkplug does a Kawi KLT 200 trike take???

[kormos_93]

Just wondering what spark plug to use in a KLT 200. I just picked one up & it had no plug when I got it, not sure on the year. The parts stores say that all the 200s require an NKG B7ES or BR7ES. I picked up the Br7es because that's all they had but it is way too small (just pushes into the head. I can see the threads on the trike are in good shape & not stripped, just that the plug is too small). So what plug do I need? I can post pictures if necessary. I searched for a different plug but kept getting the same number. I'm beginning to think someone swapped the motor........no Idea where the engine size is stamped on the motor either.

[rg97]

this may be able to help... on my X the engine size was stamped into the lower back of the cylinder, right below the cooling fins. on my banshee, its right on the side of the jugs, it says 347cc (which isnt exactly true anymore ) I'm not a kawi guy, but thats the best info I got...

[MRSOUND]

Looks like you need the B7ES.....http://www.partzilla.com/parts/detail/kawasaki/KP-B7ES.html

[kormos_93]

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[kormos_93]

Looks like you need the B7ES.....http://www.partzilla.com/parts/detail/kawasaki/KP-B7ES.html Did you read my post? The B7ES/BR7ES doesn't fit.

[rg97]

the "0.198L" on the bottom of the cylinder mean .198 Liters, or 198cc, so it is a 200... Does the plug barely not fit or is it waaay too small?

[MRSOUND]

I read your post and you bought the BR7ES and I was just showing you what part store says... B7ES. I don't know if if threads are different or not. Either way I had another suggestion for ya but since you need to be a wise crack I'll just keep it to myself. good luck

[rg97]

I read your post and you bought the BR7ES and I was just showing you what part store says... B7ES. I don't know if if threads are different or not. Either way I had another suggestion for ya but since you need to be a wise crack I'll just keep it to myself. good luck
The threads arent different. the "R" just means it has a resistor

[kormos_93]

Hey Mrsound, sorry about the wisecrack but it didn't seem like you read the post as I assumed that you knew they both have the same thread. And rg97, it's waay too small, just slides in & pulls out without even attempting to screw it in.

[kormos_93]

Update: the plug is the right diameter, just too short. When I removed the crush washer it starts to screw in. Just barely.

[rg97]

I edited my old post out... It was wrong anyways
I dont know if NGK make a long version plug

[90guy]

The Diameter of the B7ES is correct (14mm I believe). When I remove the crush washer, the plug screws in, but just barely. So it's just too short...if the hole was re-threaded, the head still remained the same thickness, so I don't think it has been re-threaded if the recommended plug is the right diameter & thread. But it's confusing why it would be at least 1/3 inch too short.
I was thinking they drilled it out replaced it with one of those spark plug cylinder fix kits I have seen now and then. Just to find out its to long for the spark plug. The plug whole looks strange to me.

[kormos_93]

I was thinking they drilled it out replaced it with one of those spark plug cylinder fix kits I have seen now and then. Just to find out its to long for the spark plug. The plug whole looks strange to me.

Not a fix kit. the threads appear to be stock when I look closely, just that they start fairly close to the bottom. I wouldn't have any idea if hole looks strange compared to other klts because this it the first Kawasaki trike I've ever owned. That's why I need more people with experience to help out.

[Yamaha_Rules69]

It may have had the heli coil fix gone wrong. Do the threds start at the last 1/4 of the hole? Thats what it looks like in the pic. Can you put a wire in the hole and feel if the threads stick down into the hole? That would mean they threaded it in too far on the installation or did it incorrectly.

[briano]

That is definitely a repaired hole. It's not a helicoil, it looks like a threaded insert that is used in a Ford Triton engine after a spark plug blows out

[kormos_93]

It may have had the heli coil fix gone wrong. Do the threds start at the last 1/4 of the hole? Thats what it looks like in the pic. Can you put a wire in the hole and feel if the threads stick down into the hole? That would mean they threaded it in too far on the installation or did it incorrectly.

The threads start about 2/3 of the way down the hole. & the threads don't extend past the bottom of the hole into the combustion chamber

[kormos_93]

That is definitely a repaired hole. It's not a helicoil, it looks like a threaded insert that is used in a Ford Triton engine after a spark plug blows out

I didn't know there were such things... Have you ever seen an original KLT plug hole to compare it to?? I guess this would make the most sense as to why the plug doesn't fit properly. Maybe I'll just buy a new head for it if that's the case.

[kormos_93]

Thank you for your help briano (& everyone else of course). Problem Solved. I looked at an original head on ebay & the plug hole is flush. Mine is raised up from the head, which would indicate that it has in fact been repaired (crappily) with some sort of sleeve at some point & makes the plug sit too high to thread in.

[barnett468]

Hello Kormos_93


Hello I actually did all the testing on these when I ran the ATV R and D dept for Kawi so I’m kind of fond of them.

Your photo is blurry so here’s what I suggest, I have done many of these. To determine if it is an insert do the following.


1. Take a magnet and see if it sticks. All inserts are steel and your head is aluminum. A magnet will only stick to steel.

2. If it does not stick remove head and install timesert, hole looks is too worn for helicoil. If it sticks proceed to next step if you want to repair without removing head..

3. Buy spiral tip screw extractor of proper size. They are available at industrial hardware supply stores maybe home depot tool section.

4. Simply screw extractor into hole and while applying slight downward pressure slowly turn counter clockwise. If extractor spins freely in hole then you must remove head to properly repair.

5. If insert removes then take small thin rubber hose as large as will fit through hole, tape it to a vacuum then vacuum any metal debris out that might have gotten in from removing it.

6. Get right size timesert and installation tool and install.


Scroll down to screw extractor to see what they look like.

http://www.timesert.com/html/usefultools.html


Hope this info helps.

[90guy]

That is definitely a repaired hole. It's not a helicoil, it looks like a threaded insert that is used in a Ford Triton engine after a spark plug blows out
There we go that's where I have seen it!!!

[barnett468]

Hello


I forgot to mention "you can replace it with a timesert providing the timesert threads match the existing ones once the existing insert is removed if there is one". If they don't match you may be able to get a "thick wall" timesert or just reweld and timesert or helicoil it. Either one will require head removal.

I have no edit button.


Hope this info helps