KLT 200 info - directly from the book
The book covers the 83 KLT200B and the KLT200C, i will post info for just the klt200c, the klt200b uses a nearly identical setup, just no differential in the back.
Dimensions:
Overall Length 68.1in
Overall Width 40.4 in
Overall Height 38 in
Wheelbase 45.1 in
Wheel Track 28.5 in
Ground Clearance 4.7 in
Dry weight 322lb
Fuel Tank Capacity 3.2 us gal
Performance:
Maximum Torque 1.5kg-m (10.8 ft-lbs) at 6000 RPM
Minimum Turning Radius 59.1 in
Engine:
Type 4-stroke, OHC single Cylinder, Air cooled
Bore and stroke 66mm x 58mm(2.60in x 2.28in)
Displacement 198cc
Compression Ratio 9.0:1
Valve Timing:
...Inlet open 32 degrees BTDC
...............Close 60 degrees ABDC
...............Duration 272 degrees
....Exhaust Open 67 degrees BBDC
...............Close 25 degrees ATDC
...............Duration 272 degrees
...Overlap 57 degrees
Carburetor Keihin PW26
Lubrication System Forced Lubrication (wet sump)
Engine Oil:
...Grade SE Class
...Viscosity SAE 10w40, 10w50, 20w40, 20w50
...Capacity 1.4l(1.5 US quart)
Starting System Electric Start
Ignition System Transistor Controlled Breaker-less Ignition
Ignition Timing 10 degrees @ 1300RPM to 40 degrees @ 4000 RPM
Timing Advancer Electronic Advance
Spark Plug NGK b7es or ND W22ES-U
Drive Train:
Primary reduction:
Type Gear
Ratio 3.285(69/21)
Clutch Type - Manual, Wet, Multi-Disc
Transmission:
.....Type 5-speed, constant mesh, return shift
......Gear Ratios 1st 3.400(34/10)
.....................2nd 2.077 (27/13)
.....................3rd 1.444 (26/18)
.....................4th 10.050 (21/20)
.....................5th 0.833 (20/24)
Final Drive:
...Type O-ring, Endless, Chain
...Reduction Ratio 3.846 (50/13)
...Overall Ratio (top gear) 10.531
Electrical Equipment:
Alternator:
...Type Single Phase, AC
...Maximum Output 141W @ 10,000 RPM
Voltage Regulator Short Circuit type
Battery 12v, 12AH
Headlight:
...Type Sealed Beam
...Bulb 12v, 35W
Tail Light 12v, 8W
Fuel Pump 12v 15W
Main Fuse 20A
Auxiliary Electrical Accessory
...Terminal Fuses 10A
.................................................. .........................................
Carburetor Specifications:
Type PW26
ID Mark 1811
Main Jet #105
Pilot Jet #42
Pilot screw(turns out) 2
Jet Needle NO4E
...Clip Position 3
throttle Valve Cutaway 3.0
Fuel Level 1.5mm
Float Level 20mm
Fast Idle Link-to-Cam 2-2.5mm
Fuel Required - 91 Octane
Fuel Pump pressure - 1-21 psi(service limit.7psi)
Fuel Pump output(per minute) 350cc(12oz) (service limit 300cc-10oz)
Air Cleaner Element Oil - SE Class, SAE 30 or aftermarket air filter oil
.................................................. .................................................
Top End
Cylinder Head:
Cylinder Head Warp *Service limit 0.05mm
Combustion Chamber Volume 28.8 to 29.6 cc
Valves, Guides, Seats, Springs, Seals
Valve Clearance
.....Intake 0.008 to 0.13mm
.....Exhaust 0.17 to 0.22mm
Valve Head Thickness .80 to 1.20mm
Valve Stem Bend under 0.01mm *Service limit 0.05mm
Valve Stem Diameter:
.....Intake 6.965 to 6.980mm *Service Limit 6.90mm
.....Exhaust 6.959 to 6.970mm *Service Limit 6.90mm
Valve Guide Inside diameter 7.000 to 7.015mm *Service Limit 7.08mm
Valve Guide/Stem Wobble:
.....Intake 0.049 to 0.123mm *Service Limit 0.25mm
.....Exhaust 0.076 to 0.166mm *Service Limit 0.26mm
Valve Seat Width 0.5 to 1.0mm
Valve Seating Surface Diameter:
.....Intake 35.7 to 36.3mm
.....Exhaust 29.7 to 30.3mm
Valve Seat Angles 60, 45, 30 degrees
Valve Stem Grinding: "A" *Service Limit 4.9mm
Valve Spring Tension
.....Inner 28.5 to 31.5Kg @ 22.2mm *Service Limit 27.3 Kg
.....Outer 53.2 to 58.8Kg @ 25.7mm *Service Limit 51.4Kg
Valve Spring Squareness Within 1.0mm *Service Limit 1.5mm
Camshaft
Cam Height 40.642 to 40.783 *Service Limit 40.55mm
Camshaft Journal Diameter 21.959 to 21.980mm *Service Limit 21.92mm
Camshaft Bearing Inside Diameter 22.000 to 22.021mm *Service Limit 22.06mm
Rocker Arms, Shafts
Rocker Arm Inside Diameter 13.000-13.018mm *Service Limit 13.05
Rocker Shaft Diameter 12.976 to 12.994mm *Service Limit 12.95mm
Camshaft Chain Length/20 links 160 to 160.2mm *Service Limit 162.4mm
Camshaft Chain Guide Groove Depth
....Front *Service Limit 2.00mm
....Rear *Service Limit 1.5mm
Camshaft Chain Tension Spring Free Length 75mm *Service Limit 71.3mm
Cylinder, Piston, Rings
Compression Pressure 892 to 1275 kPa(129-185psi)
Piston/Cylinder Clearance 0.035 to 0.058mm
Piston Diameter 65.950 to 65.965mm *Service Limit 65.80mm
Cylinder Bore 66 to 66.008(less than 0.01dif) *Service Limit 66.10(more than 0.05 dif)
.................................................. .................................................. .............................
Valve timing:
Lubricate and carefully push the camshaft into the cylinder head with cam lobes "down."
Install bearing retainer, Tighten screws securely
Check to see the T mark on the Alternator rotor aligns with the point(timing cover on left side of crank case)
Fit the sprocket under the chain and slip it over the shoulder on the camshaft so that the KL250, KZ250W mark on the sprocket aligns with the pointer on the cylinder head. (yes the kl250, not the klt200 or kz200)
The projection on the back of the sprocket must fit in the hole on the end of the camshaft.
Tighten camshaft sprocket bolt to 30ft lb
Install the chain tensioner - compression the chain tensioner, then screw bolt in on rear of tensioner to lock it into place
Install chain tensioner on engine, release locking bolt near rear of tensioner.
Last edited by RubberSalt; 03-17-2011 at 05:17 AM.
Reason: Added Valve timing
I just wanna go fast. If your not first, your last!!
Reproducing the Tecate CDI. Contact me if you need one. I'm most accessible on FaceBook. You can find me on the 1984-1987 Kawasaki Tecate KXT250 Group.
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