My first build. 1978 Kz200.

[mrtracy1990]

So this is my first bike/build. I bought the little piece of $#!t for $450. It ran at the time but died after a semester of college. The bike looked horrible but I painted her tank and side covers and replaced many parts before I left for the second semester of college (James Madison University). I don't plan on getting her into ultimate DTT approved bike of the month quality, since this is my first bike and need to get used to riding. Here are photos from the first restoration.
As posted on Craigslist, Kansas City:

From:

To:

To: (Spray painted with "Dupli-Color" Dark Toreador $7 cans) (Pinstriped with 3M Scotch Plastic "pinstripe" Tape)

Parts:

The reason why she was not running before which later took quite a bite out of my wallet:

This is how I got her looking before the second year of college and before she died again:

 

[mrtracy1990]

Alright so that was my first attempt at making something look pretty. Now here is my current build. Many many issues have been found along the difficult process of taking her apart but she's all stripped now.
Beginning:

Parts:

The engine waiting to be tinkered on: (198cc)

Where I want the battery to be:

Cut off the side cover tabs and battery tray tabs:

The workshop: (Parents garage..needs to be cleaned before the next hail storm so cars can fill it up)

Newly painted frame: (Engine enamel spray..don't really know if I should have used that but oh well. She's getting a clear coat)

Newly painted parts: (same engine enamel spray)

Started to paint the wheels. From:

To:

To: (again I'm using engine enamel)

Again more painting:

Alright yall, this is my issue. The head and the cam are ruined. Apparently the chain was too tight around the camshaft causing the cam to spin on the top of the head cam thing causing both to strip. Now I'm waiting on parts both the head and camshaft (ebay for $90 for the both from a used KLT200..hopefully it'll fit).
Here are the photos:

Quite badly stripped:

The cam:

Quite stripped:

 

[go!]

78 kz200.. fun little bike! why'd the bike stop running, or have you not figured that out yet? did it always seem to be running lean? how far into the motor were you planning on going? yes, those questions are leading up to something

welcome to the board!

 

[mrtracy1990]

78 kz200.. fun little bike! why'd the bike stop running, or have you not figured that out yet? did it always seem to be running lean? how far into the motor were you planning on going? yes, those questions are leading up to something

welcome to the board!

Thank you. Well the bike stopped running because of the cam and the head and the rectifier. I'm just going to switch the screws with allen screws and throw some engine enamel onto the head. I'm getting Josh Alvarez to build me a battery box to hide all the guts of the bike. Also I'm going to redo all the paint that I threw onto the tires and all parts since engine enamel apparently is the wrong paint. So she's been mostly a pain in the rear end for me.

 

[mrtracy1990]

So this is what I want to do paint job wise. A tri-colour scheme with Red White and Blue but nothing too patriotic looking. I'll add some style to it with pin stripping. Just check out this link:
http://cgi.ebay.com/1978-Ducati-860GTS-Tri-Color-Cafe-Racer-/160456901093?cmd=ViewItem&pt=AU_Motorcycles&hash=item255bfa01e5#ht_690wt_930

 

[bikeboy]

78 kz200.. fun little bike!

Hmmm. If that's the motor I'm thinking of, oil-supply to the cam bearings was a real issue, and failures such as yours were common. I hope you manage to find a good head and cam, but make sure you get detailed pictures before you pony up.

Still, it looks like a good project you've got going there. Have fun with it.

cheers
ian

 

[mrtracy1990]

HELP! Alright so I just got a KLT200 head and cam today but there is no tachometer meter and the carb boot intake is larger than that of the Kz200. So now I'm stuck with a non running bike and don't know where to go. I've looked everywhere for a head and cam but to no avail. Would anyone know where to find both for not too expensive of a price? I just want to ride. HELP!

 

[dakine_surf]

Tracy, start calling around to salvage yards. I still think not having the tach is no big issue on a small cc thumper like you have, you will really be able to feel when you need to shift. But check your local (and interstate) salvage yards... most of them want you to email them with what you need and they will get back to you if they have it.

Cheers,
Micah

 

[mrtracy1990]

Alright yall. So I kept the head and cam from the KLT200. I will be lacking a tach and will have to buy a new carb intake boot. But who the heck cares..at least I'm riding right?
Here's what I got:

Here is where they angled the the intake boot mounts differently and widened them.

I couldn't resist he was lying next to my room.

Here are bearings around the camshaft...GENIUS!!! No more shredding!!

Here are some new parts that I keep in my room to keep things more organized than how they are in my garage. Head, cables, spray cans, bulbs, allen screws, gaskets, etc. Yes I did stripped the wheels of engine enamel.

\

Hopefully I'll make her happen by the end of this week. Keep your fingers crossed.

 

[sebatron]

ooh i feel a bit guilty for putting you onto the KLT head given it doesn't have tach output :/

could you run a universal using a pickup on your spark boot? that's what i'll be doin...

 

[mrtracy1990]

ooh i feel a bit guilty for putting you onto the KLT head given it doesn't have tach output :/

could you run a universal using a pickup on your spark boot? that's what i'll be doin...

Sorry mate I have no clue to what that last sentence means. Could you explain that and what I'd be needing for that? But no...really thank you for showing me the KLT head. I had doubts at first but its the only head that will actually make her run! You done me a favor!
-Thanks.

 

[hurley209]

this is going to be a rad bike man! love it! youve done awesome so far, i bet its going to look killer!
keep up the good work and keep posting pix, were all like a buncha first graders, we looooove pictures hahaha

 

[mrtracy1990]

BAD NEWS: Well there has been a huge halt in this project. The KLT200 head will not work for my bike. It does not have room for points and the camshaft will not hold them. Engines on three wheelers after the 70's did not use points but CDI boxes so thats kind of an issue. So I'm stuck WITHOUT AN ENGINE!!!! All I need is the head and cam. But I've been told that I should just buy a new engine. I would like to but I don't know where to look and I'm leaving for college in about a month with bills. Can anyone help!!!????? AAAAHHHHHHHAHAHAHAH!!!

 

[sebatron]

might sound like a massive undertaking, but what about converting to cdi then?
you'd never need to adjust the points again at least.

what i meant about the tacho - what about using a universal one that uses an electronic pickup? rather than cable driven like the original.

 

[mrtracy1990]

might sound like a massive undertaking, but what about converting to cdi then?
you'd never need to adjust the points again at least.

what i meant about the tacho - what about using a universal one that uses an electronic pickup? rather than cable driven like the original.

CDI is just to much of a pain in the ass. I don't have all this time. School begins in less than a month. I could use that tacho idea if I find another head without a tacho meter. Good idea. Thanks.

 

[mrtracy1990]

Alright..its been quite a while since I've added to this post and there is a reason. Kawasaki Kz200's suck. Thats it..nothing other than they suck. Alright maybe they don't suck but they are sure a pain in rear end. Let me defend myself. Finding parts for these little buggers is not easy..plus people charge a lot due to how difficult they are to find. Also their heads were made crapishly..since they wear down quite quickly. Its been too long since I've ridden a motorbike so I'm getting quite frustrated.
Alright enough of the negativity...and now for the pics.

The current workspace after I move my project bicycles.

The head that I bought on the right..the original on the left. The one I got off craigslist that cost $80 I was told is in great shape and that I will love the purchase. The guy reassured me that its in awesome condition by saying it only has around 3000 miles. He said everything was good to go. So I took his word. I learned something that day.

Never trust anyone. Always ask for photos. Always look on ebay for cheaper prices and compare prices. Never pay shipping costs over half the price of what the item is worth.

This doesn't look too bad..just needs a nice cleaning.

Alright maybe a chip out of the fin but thats alright..

Okay..maybe another chip..but I can deal with that..

Valves are in horrible condition..but thats alright I can replace them with my originals..

Okay the spark plug feels lose. WTF..I can pull it out with my bare hands. DAMN IT!!!! Worthless head. Can't get compression due to spark plug having stripped the head. I would have returned it but I would have only gotten $20 back. Thats a $60 loss. But now an $80. But I do have the camshaft from the dude...

The camshaft. Can it be used?????

Took the engine apart to see if the oil pump was clogged. Nope..seems to be fine.

I did find a bunch of build up. Most likely from the original camshaft having been stripped so badly. Should I be worried?

A while back I got this awesome battery box made from Hurley29 (Josh). Paid an excellent price for what it is. Thanks man. This will one day contain the guts (electronics) of the bike. I may paint it to match the tank. Now how to fasten it to the bike???

Yes that was a bunny in the background of these photos. Will rabbit hair mess up the engine??

 

[bikeboy]

Alright..its been quite a while since I've added to this post and there is a reason. Kawasaki Kz200's suck. Thats it..nothing other than they suck. Alright maybe they don't suck but they are sure a pain in rear end. L

yeah. That's kinda what I was eluding to in my first post, but I didn't want to dampen your enthusiasm. You still seem to be keen to see this through, and I hope you do, but I'm afraid these bikes were a bit of a dud. Perhaps there's another model motor that will fit??

ian

 

[mrtracy1990]

So this is the final shape of the bike for this summer. I'm leaving for James Madison University in 2 days so I need to put everything back together..even if not done (like the bloody engine). I wish I could somehow incorporate the speedo into the headlight so it would keep its low riding shape. Anyone know how or wanna help?? Thanks guys for the help throughout the summer. I may post parts that I purchase..if/when I purchase with the money I don't have.
Here are the pics..

Oh and that gastank is the old one. I'll be painting a different one next summer. So basically the whole summer was half-assing this whole project. AAAHHHH WEEEELLLL it'll work out, hopefully.

 

[Manic Mechanic]

I just got hold of one of these. Thought id look at the state of the engine before I do any work on it.
The engine has turned out to be in exactly the same condition as yours. The cam is badly shredded and the piston skirt also has a crack.

I too am now looking for a head and a camshaft and a piston.......... :

I might just bin the whole thing :-\

 

[crazypj]

You can Helicoil (or 'Recoil') spark plug hole, complete kit is about $35.00 for four inserts and all the stuff you need (PepBoys, et.al.)
You need to check clearances of the oil pump you posted pictures of, it looks like body is worn out (burrs on top left?)