Kawasaki KLT 200 GURU's Help Needed

[Rollingmenace]

i have what i believe its a 84 klt200 that im working on .. i have a few issues... and was wondering does anyone have a manual for one of these these.....would really help the troubleshooting
And on to a few questions
#1 The bike has no spark.. i made all the necessiary repairs and reconnections on the harness... i can get the bike to crank.. but no spark...(my first thought is the cdi because the case is all broke to crap) but need some guidance checking the coil and stator outputs i want to check all these before i move to replace cdi

#2 what options do i have for a cdi.. im sure finding a stock unit that works for a decent price is a rarity .. would a aftermarket cdi say for like a 200cc lifan or chinese bike work in place of the stocker or would the timing curve be way off.... ( im just looking for alternatives here)

#3 can anyone tell me about the fuel pump it looks like some sort of hybrid between a vacumn and electrical pump... in the event this craps out what are my replacement alternatives

[Rollingmenace]

anybody willing to help me out here?

[squirrel1182]

With the fuel pump if its electric and it dies, just go to napa and ask them for a low pressure electric fuel pump and make sure it has a 1/4 inlet and outlet. As for the spark the only thing ive figured out how to test was the pulse generator.( the red and green wire coming out of the case on the left side) put an ohms tester on it. If its not reading anything or reading really low its bad. I don't remember what my good one was reading but i had a bad one that wasn't reading anything.

[MonroeMike]

Check out this thread.
http://www.3wheelerworld.com/showthr...0-Service-Data

[Rollingmenace]

thanks mike that is some helpfull info there

[spywell]

i have what i believe its a 84 klt200 that im working on .. i have a few issues... and was wondering does anyone have a manual for one of these these.....would really help the troubleshooting
And on to a few questions
#1 The bike has no spark.. i made all the necessiary repairs and reconnections on the harness... i can get the bike to crank.. but no spark...(my first thought is the cdi because the case is all broke to crap) but need some guidance checking the coil and stator outputs i want to check all these before i move to replace cdi

#2 what options do i have for a cdi.. im sure finding a stock unit that works for a decent price is a rarity .. would a aftermarket cdi say for like a 200cc lifan or chinese bike work in place of the stocker or would the timing curve be way off.... ( im just looking for alternatives here)

#3 can anyone tell me about the fuel pump it looks like some sort of hybrid between a vacumn and electrical pump... in the event this craps out what are my replacement alternatives

The user Rubbersalt has a manual.
Issue 1: Check the CDI they are falty Kawi garbage and can get water inside them and wreck havok. Most likely your issue is with the CDI, Gabe (Rubbersalt) can tell you how to check. He has replaced his twice now and he coated his with a quarter inch of silicone to keep his good one safe. Check the ground on the coil, it rusts there really easily and keeps the coil from grounding and working. Gabe can ohm his coil and tell you the correct ohm's if you need to find an aftermarket coil.

Issue 2: Spend like $160 for a working cdi on ebay thats what we had to do. We looked for alternatives but no luck.

Issue 3: The fuel pump is required for this bike to run since the carburetor is above the gas tank. When you start the bike you have to wait for the fuel pump's clicking to slow down which means you have fuel in the carb. Ours occasionaly craps out on us but a few taps at the side of it gets it going again.

Good luck!

[atc500x]

I have every shop manual for all model of kawasaki 3 wheeler.....ask if you need some spec.

[RubberSalt]

http://www.3wheelerworld.com/showthr...ook&highlight= Theres a little info for you.

The main issue I've seen is the coil having a bad ground. It tends to rust right under it and then no spark.

Wish i had my book with me right now.

Check things in this order:
Coil grounds. Also check the wires going to the coil., they can get dirty and need cleaned.

Pulsing coil power. The pulsing coil is the 2 wires coming out of the front left of the engine. These should produce a little AC voltage when cranking the engine over. Just hook a volt meter to it. volts=good, no volts =scroll to the bottom of this post lol

CDI, make sure the wires going from the pulsing coil and plugged in securely and they are not corroded. Then trace the wires going to the CDI and make sure they are not corroded.

Plug wire. Make sure your spark plug wire isn't broke and is screwed on to the coil. They twist in and screw on.

Plug, make sure you have a b8es or a b7es(book calls).

If the battery is dead, or not fully charged, the engine will never start. It takes to much power for the starter leaving none for the ignition system.

After replacing my CDI, i found out it was a bad coil ground. I've got my original as a spare but haven't tested it since I've replaced it. I found an aftermarket 1 that is WAY WAY better quality(and i swear gave more power). It's from RMstator, made for the KLT200 - bout $140.


If the pulsing coil isn't putting out any voltage, you need to pull the stator cover off. This is easy stuff. drain the oil or tilt the trike on it's side. Unplug the green/yellow wires for the stator, and unplug the pulsing coil wires. Remove the cover. The cover will want to stay on, it's got the flywheel magnetically pulling it together, just pull it hard. At this point, you need to wipe down your flywheel, stator, and pulsing coil. Over time, the magnets pull in metal particles not allowing the engine to produce spark/electricity. Make sure you wipe the inside and outside of the flywheel. There is a magnet on the outside for the pulsing coil.

[Dallas101]

I have every shop manual for all model of kawasaki 3 wheeler.....ask if you need some spec.

I have what I think is a klt200. Trike and need help where does the coil get grounded to get the spark needed??

[dcolbyh]

https://threewheelermanuals.com/kawazaki