Bought a lemon.

Hi,

My name is Kieran and I live in Melbourne Australia. I own a 1980 KZ200 A3.

I bought it early 2009ish? and well I still haven't fixed it. It's sat in my back yard a few years, the engine was rebuilt kinda... And then for another few months a friend offered to work on it. I decided to get it running again as it's just a waste of space otherwise.

A bit more detail:
I took it in for a roadworthy and was given a long list of things to repair already having spent too much for it in the first place...

After seeing the list of problems I decided I could fix most of them with my brothers help.
We've replaced the bearings. front hub, rear hub and swing arm. Changed the tail light over and done a few other things. It constantly fouled the plugs and I was told the motor had to be rebuilt to fix it. So I've had the cylinder bored out and a new piston installed along with a new gasket kit for the top end. And well since then we've never been able to get it started.

I saw there are a few other KZ200 owners on here so I decided to join here to get some advice.

So yeah that's about it.

Cheers,
Kieran

Here's a pic back from 2009 after a few things had been fixed. (before the motor was rebuilt)

First things to check:

Spark
Compression
Fuel

You need all 3.

Welcome to z-jungle

:laugh: I think lemon is more common on new vehicles. Your KZ200 is just old and needs love

OldSchoolZ wrote: :laugh: I think lemon is more common on new vehicles. Your KZ200 is just old and needs love

+1

Not to mention, every time I hear "bored out" that usually means it's time for a replacement cylinder. lol

Kuro, stick with it, it'll be worth your while in satisfaction. You at least had a great start by keeping it in the house.

welcome...as mentioned...does it have a spark...is it getting fuel......does it have compression .....these in that order go BOOM boom Boom....

nice enough little bike...all there....why quit now...you will get it

be very specific on the question/problem ...and folks here can help you for sure

welcome

Anything done to the head? Valve job, or anything? Is the valve clearance and cam timing set correctly? Definitely check compression first, make sure that its within service limits.

Patton always says when life hands you a lemon bring it over to his place,he always has plenty of this on hand!

And make a party of it! :woohoo:

No eBay APP ID and/or Cert ID defined in Kunena configurationNo eBay APP ID and/or Cert ID defined in Kunena configurationThanks everyone for your comments sorry for the belated reply.

Kidkawie wrote: First things to check:

Spark
Compression
Fuel

You need all 3.

Motor Head wrote: Anything done to the head? Valve job, or anything? Is the valve clearance and cam timing set correctly? Definitely check compression first, make sure that its within service limits.

Spark: The SLA battery I have is flat I'm looking at chargers atm. The contacts have been changed along with a new lead for the plug.
Compression: The compression is good now. I tested it before and after the rebuild, now it is within factory limits.
Fuel: It's a bit iffy... I'm trying to source parts for a carb rebuild it's quite hard to find NOS or NRP items for it. I think I might have a work around for some of the parts just need conformation from some of you guys that it will work.
Valves and timing: I tested the valves with the petrol leak test in the upturned head method they seemed to be fine. As for timing I'm not too sure I believe the cam chain was replaced by my brother one evening while I was away during the rebuild.

wireman wrote: Welcome to z-jungle

Thanks mate

OldSchoolZ wrote: :laugh: I think lemon is more common on new vehicles. Your KZ200 is just old and needs love

Kidkawie wrote:

OldSchoolZ wrote: :laugh: I think lemon is more common on new vehicles. Your KZ200 is just old and needs love

+1

Not to mention, every time I hear "bored out" that usually means it's time for a replacement cylinder. lol

Yes quite right it's a TLC project for sure. I bought it "as working" cough cough. And I hope it'd doesn't need to be taken apart again. I'll change the title to Re: Bought a [strike]lemon[/strike] TLC project.

Bozo wrote: Kuro, stick with it, it'll be worth your while in satisfaction. You at least had a great start by keeping it in the house.

Ha yes I know, nice and warm in winter. I left a few suspicious cracks in the tiles. :whistle:

trianglelaguna wrote: welcome...as mentioned...does it have a spark...is it getting fuel......does it have compression .....these in that order go BOOM boom Boom....

nice enough little bike...all there....why quit now...you will get it

be very specific on the question/problem ...and folks here can help you for sure

welcome

I'm not going to quit on it now. It's worth shit all now, I may as well get it running and ride it for a while. I'll try to be as specific as I can be. I'm a kinda noob at all of this.

wireman wrote: Patton always says when life hands you a lemon bring it over to his place,he always has plenty of this on hand!

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And make a party of it! :woohoo:

Ha yeah, I'm sure I'll have a few once I get this running.





Okay this is what I've done recently. I've take apart and ultrasonic clean the carb. It's got a bit of the dirt and grime out of it but I really need a new float bowl seal as the old one has deformed into the bowl chamber and interferes with the travel of the float. I've found this kit for the earlier KZ200 model A1/A2 but I have a post 1979 model 1980 KZ200 A3. Apparently Keyster isn't making the kit for the A3 anymore.

Now I've managed to get a scan of the parts for the KZ200 carbs for both models (See attached images) and the only differences I can find between them is the pilot jet sizing, spring, jet needle and the valve. Is this correct? or am I missing something? So I could just order the kit and use the other parts correct?

And I'm looking at chargers online on eBay I currently have a small SLA batter but I'd like to get a charger that could be compatible with a Lithium battery in the future. Any suggestions? I'd like to spend around $100USD. Any recommendations?

1.
2.

After I get the carb working and the battery charger I'll test the spark again and I'll check the timing if I can remember how. :side:

Cheers,
Kieran

Free service manual download:
www.kzrider.com/forum/13-bike-related/47...test-download#472613

When recently downloading this manual, screen stayed completely blank for almost 8 minutes, as if nothing at all was happening, then the manual suddenly appeared out of nowhere on the screen.

A KZ200 isn't listed at kawasaki.com

en.wikipedia.org/wiki/Kawasaki_KZ200

www.kzrider.com/gallery/kz-200

www.google.com/url?sa=t&rct=j&q=1980%20k...xlR9fqpY-WA9yLdiFRfg

If not already done, there's a plethora of sites to be found by Googling KZ200.

Is the carb a manual slide or CV?

Is the ignition points or electronic?

Good Fortune!

did'nt those 200's come with pedals