New member looking to restore 85 klt110 and 81 klt200

[Fixerupper]

Good morning All,
I am looking to restore 2 trikes that I got for $115 delivered to my house. They have been sitting outside for awhile, but I am looking for the challenge. I am no stranger to restoring 4 wheelers (mostly Blasters) but this will be my first experience with 3 wheelers. Looking forward to meet new people and hopefully I can give back to the community on my learnings. Thanks

[Fixerupper]

So I have the KLT110 torn down to the frame. When I took the front forks off I had bearing balls fall out everywhere from the steering stem. Is this normal? Can I get new bearings or should I collect all the balls and put them back in the channels? Thanks

[barnett468]

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this is normal . . you can reuse the old balls or get new ones from any honda, kawi, or yammi shop or the hardware store.

clean the races, then use heavy old school wheel bearing grease, not the black moly or white grease to hold them in place for reassembly . . it looks like dark brown tar . . you can also use bel ray grease etc to hold them in place . . the bel ray is waterproof but the the wheel bearing grease is also fine . . you can get bel ray from amazon or any motorcycle shop . . you should disassemble the brake actuator and rear brake pivot and clean and grease those also.

spray some wd40 or 6 in 1 or some type of lube inside the cables using the long spray nozzle that comes with the lube . . this is a bit messy if you dont have the special tool but you dont need it, besides, the oil will made the outside of your cables look nice too after it gets all over them. :lol:

there should be no space between the balls . . if there is enough space for another ball, you are missing one.

[Fixerupper]

Thanks for the quick response and heads up!

[Fixerupper]

Some balls are large and some are small. Is there a special way to put them back in? Thanks again

[barnett468]

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also, make sure the shifter is tight on the klt110 . . use a grade 8 bolt in it and you will need check it after every ride.

also, look look closely at it after tightening the bolt . . if the two ends are mashed together, you will need to grind them to increase the gap.

i would also get new uni filters for both of them to avoid any problems from old plugged or decaying/deteriorating filters.

http://www.unifilter.com/atvs/kawasaki-atv/

you should also use foam filter oil instead of engine oil . . after applying it then squeezing it out, i set the filter with the big end down for around 15 minutes so any excess oil can go to the bottom then i squeeze it out again.

also, that 110 hauls a_s and it will lift the front wheel if you lean back when you speed shift . . it will also wheelie forever without ANY hesitation or burbling.

if the clutch slips at all when shifting, it is bad.

[barnett468]

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make sure the clutch is adjusted properly on the 110 . . they are sensitive to adjustment.
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[barnett468]

Some balls are large and some are small. Is there a special way to put them back in? Thanks again

ok, well then the small ones go in one end and the big ones go in another but i dont remember much about the balls on those so look at the radius/curve in the bearing races . . if one takes a different size, it will have a slightly different curve to it so try a big ball in each and look at how it fits the curve then try a small ball i each and see how it fits.

it is possible that both races take the same size balls and that someone lost some balls before and bought the wrong size and stuck them in there, but i will try to check for you and get back to you within 15 minutes.

the ball should fit the curve of the care perfectly

[barnett468]

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ok, the 110 uses 3/16" bearings in the top and the larger 1/4" bearings in the bottom.

http://www.partzilla.com/parts/search/Kawasaki/ATV/1985/KLT110-A2+KLT110/FRAME/parts.html

http://cdn.partzilla.com/diagram/kawasaki/08/0193/D-3.png

[barnett468]

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the 200 uses 23 of the 3/16 balls in the top and 19 of the 1/4 in the bottom.

http://www.xtremeusa.com/OEMpartfinder.htm#/Kawasaki/KLT200-A1_KLT200_%281981%29/FRAME%2f%2fFRAME_FITTINGS/KLT200-A1-1981/070021D-3

[Fixerupper]

Thanks guys for the help. I really apreciate it. She is ready for paint and start to put her back together. Excited as hell to ride her. I did find that the exciter coil is bad and have to get a stator. Oh well she only cost me about $57 to buy her LOL. Time to build her up back to life!

[barnett468]

Aren't the steel balls that hardware stores sell, just that; steel balls?

I'm thinking that what hardware stores normally sell are of such a low quality, they may not even be a graded bearing. I've even seen cheap bearings simply break in half, the balls actually split into multiple pieces.

Bicycle shops usually carry loose bearings and they're very, very inexpensive for grade 25 loose bearings. They come in many different sizes.

Well the bearings at industrial hardware stores will be hard . . The ones from places like home depot may very well come from china and be weak, however, the amount of load on each bearing is not that great due to the quantity of them, therefore, even if they are cheapos, they should still work fine in this app, however, I certainly wouldn't put cheapos in a motorcross bike etc.

[barnett468]

She is ready for paint and start to put her back together.

Which one of the two is "she".

[Fixerupper]

The 110 of course. Didnt get to the 200 yet.

[barnett468]

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yes, it is certainly best to get oem or other bearings whenever possible, but some people don't live near a shop that carries them and they don't wan to wait and neither of the bikes he has are they type that people will be doing double jumps on or any type of hard riding.

[barnett468]

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yes, "all balls" has tapered bearing kits for some models.

[Fixerupper]

So i got the frame painted and a couple other things. I will be starting to put things back together tomorrow. I found the exciter coil is bad and i am not getting spark. I tested the rest of the wiring harness and all is good there. Is there anything else to check why i am not getting spark? Thanks.

[barnett468]

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does the exciter coil show no continuity or no ohms?

you can check the spark plug coil too.

[Fixerupper]

It shows no ohms. The spark plug coil checks out good. Just dont get any ohms off the red wire coming out of the stator.

[barnett468]

It shows no ohms. The spark plug coil checks out good. Just dont get any ohms off the red wire coming out of the stator.

i would remove the stator cover and check it inside there then to the other end of the coil . . if its still not good you can remove the flywheel and check it on the coil . . might just be a loose connection.

[Fixerupper]

Thats the problem i cant get the flywheel off to check inside. Lol. I practically stripped out my puller trying to get it off and it wont release!

[Fixerupper]

So does the 110 have a clutch lever for manual shifting or just shift and go?

[barnett468]

So does the 110 have a clutch lever for manual shifting or just shift and go?

the 110 is odd in that it has the traditional automatic trans that can be shifted without the clutch lever but it also has a clutch lever than can be pulled in when the bike is in gear but ii dont know anyone that uses the clutch lever unless they use it to pop a wheelie with.

[Fixerupper]

Thanks! 1 less thing i have to buy and replace. Lol

[barnett468]

Thanks! 1 less thing i have to buy and replace. Lol

xlnt! http://www.mustang.org.au/forum/Smileys/smilies/hysterical.gif

[Fixerupper]

Got the forks back on to the tree with the bearings. I cleaned my whole dam garage because i was missing 1 of the 1/4" balls and found it outside the garage door in the driveway! Oh well at least the garage is cleaned up. Lol

[Fixerupper]

So i took the engine to local shop and had them pop off the flywheel. It looks like connections r tight but still not getting any reading from the meter. How do u replace the exciter coil? Thanks

[barnett468]

So i took the engine to local shop and had them pop off the flywheel. It looks like connections r tight but still not getting any reading from the meter. How do u replace the exciter coil? Thanks

one option is to send it to ricky stators at the link below and have him rewind it . . another option is to look for a stator assy on ebay but these bikes are pretty rare.

http://www.rickystator.com/
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[Fixerupper]

So i got a reading through my coil finally but im not sure what is supposed to read. Does anyone know by chance? Thanks

[Fixerupper]

How clean do the magnets on the flywheel have to be for good spark?

[roostersnubber]

just looking at your thread. i picked up an 81 klt200 and need a doner. any chance you still have it sitting outside?