Kawasaki KLT 100/160/200/250 Service Manual Repair 1981-1985

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Typ: Motorcycle

Anbieter:

Art.-Nr: 97389

Stichworte: 1981 1982 1983 1984 1985 ATV Kawasaki KLT 100 KLT 160 KLT 200 KLT 250 KLT Models Motorcycle Powersports

Produktvarianten

Beschreibung

This manual covers the KLT Series Trikes, including the KLT110, KLT160, KLT200, and KLT250 models produced between 1981 and 1985. These three-wheeled all-terrain vehicles are known for their robust engineering and were designed for both utility and recreation. With a heritage of producing capable off-road vehicles, the KLT series was introduced to meet the growing demand in the ATV market, offering a range of displacements and features that defined early off-road riding experiences. This comprehensive 187-page repair and service manual provides detailed information for maintaining and repairing your KLT Series Trike. It covers all major systems, including the engine, transmission, drivetrain, suspension, brakes, and electrical system, with specific guidance on carburetor adjustments, valve clearance, and common issues such as potential corrosion or drive shaft wear. The manual is designed for both DIY enthusiasts and professional mechanics, offering clear illustrations, torque specifications, and troubleshooting guides to ensure optimal performance and longevity of your vehicle.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLT Series Trikes

Covered Models:

KLT110, KLT160, KLT200, KLT250

Production Years Covered:

1981-1985

Codes

Model Codes:

KLT110, KLT160, KLT200, KLT250

👋 Introduction

Market Position

Market Position:

Targeted at owners and mechanics of early 1980s Kawasaki KLT all-terrain vehicles, a niche market for enthusiasts and restorers.

Competitive Analysis

Competitive Analysis:

This manual fills a critical gap for owners of these vintage Kawasaki trikes, offering detailed repair information often scarce for older, off-road vehicles. Unlike factory manuals which can be prohibitively expensive or hard to find, this digital resource provides accessible, comprehensive guidance.

Key Features

Key Features:

187 pages of detailed repair and maintenance information, clear illustrations and diagrams, torque specifications, troubleshooting guides, and a user-friendly digital format with clickable chapters and search functionality.

Seller Offering

Seller Offering:

Free replacement of the manual if lost by the buyer.

📋 Manual Details

Coverage Areas

Systems Covered:

Engine, Transmission, Drivetrain, Suspension, Brakes, Electrical System, Fuel System, Cooling System, Chassis, Body Panels, Controls, Lighting.

Page Count

Page Count:

Manual Type

Manual Type:

Repair Manual / Service Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Internal Components:

Cylinder head, piston, conrod, crankshaft, camshaft, valves, valve clearance, lubrication system, cylinder bore.

Fuel System:

Carburetor (main jet, pilot jet, slow jet, mixture screw, idle adjustment), fuel pump, fuel tank, fuel lines.

Ignition System:

Stator, flywheel, magneto, ignition coil, spark plug, electronic ignition system.

Transmission Drivetrain:

Gearbox, transmission gears, clutch operation, drive shaft, rear axle, reverse gear.

Electrical System:

Starter motor, battery, charging system (rectifier, regulator), lights (headlight, taillight), switches, fuses.

Braking System:

Brake pads, rotors, brake fluid, brake lines, brake adjustment.

Suspension Steering:

Front forks, rear swingarm, suspension linkage, steering mechanism, handle bars.

Bodywork Plastics:

Removal and installation of body panels, plastics, seat, fenders.

Procedures Included

Major Procedures:

Complete tear down and rebuild, engine overhaul, transmission overhaul, carburetor rebuilding, clutch adjustment, valve adjustment, brake system service.

Maintenance Tasks:

Routine maintenance, fluid changes (engine oil, coolant), lubrication schedule, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Diagnosing common problems, 'no spark' issues, starting problems, engine performance issues, electrical faults.

Diagnostics:

Troubleshooting guides, error code identification (if applicable, though unlikely for this era/type of vehicle), diagnostic charts.

Part Identification:

Part diagrams, component illustrations for identification and assembly reference.

Technical Depth

Technical Depth:

Comprehensive repair and maintenance information suitable for DIY enthusiasts and professional mechanics. Covers detailed procedures, specifications, and troubleshooting for all major systems.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

Printable and savable. No restrictions.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Features

Searchability:

Yes, text is searchable within the PDF.

Navigation:

Clickable chapters for easy navigation.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, air-cooled

Engine Displacement Range:

110cc to 250cc (specifics vary by model: KLT110, KLT160, KLT200, KLT250)

Valve Configuration:

Overhead Valve (OHV) or Single Overhead Cam (SOHC), depending on specific model. Manual covers adjustments and maintenance.

Performance

Compression Ratio:

Specifications provided per model (e.g., KLT200/KLT250 typically around 9.0:1 to 10.0:1). Manual includes checking and adjustment.

Fuel System

Fuel Delivery:

Carburetor

Carburetor Details:

Manual covers adjustment of idle speed, mixture screw, pilot jet, main jet, and throttle cable for optimal performance.

Engine Ancillaries

Cooling System:

Air-cooled. Manual includes checks and maintenance related to airflow and heat dissipation.

Lubrication System:

Wet sump. Manual specifies oil type, capacity, and change intervals. Includes oil pump and filter maintenance.

🔧 Transmission

Standard

Transmission Type:

Manual, foot-shifted

Number Of Gears:

Typically 5-speed or 6-speed depending on the model (e.g., KLT250 often 6-speed). Manual details gear ratios and shift mechanism.

Features

Reverse Gear:

Included on most KLT models. Manual covers operation and maintenance.

Clutch Type:

Wet, multi-plate. Manual provides procedures for adjustment and replacement.

Drive Train

Final Drive:

Shaft drive to rear axle. Manual covers maintenance and lubrication of the drive shaft and rear differential components.

📐 Dimensions

Exterior

Vehicle Type:

Three-wheeled all-terrain vehicle (trike)

Weights

Dry Weight Range:

Approximately 150-200 kg (330-440 lbs) depending on model. Manual may provide specific weights.

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable for ATVs of this era in the same way as modern vehicles. Safety information pertains to proper operation and maintenance.

Active Features

Active Safety:

Braking system (discs and drums), stable chassis design for its time.

Passive Features

Passive Safety:

Handlebar controls for steering and braking, foot pegs, seating position.

💡 Technology Features

Infotainment

Infotainment System:

N/A (basic recreational vehicle of the era)

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 1,000-2,000 km or annually. Manual will specify exact interval and oil type.

Valve Adjustment:

Recommended at initial break-in and then periodically (e.g., every 4,000-6,000 km). Manual provides precise intervals and procedures.

Spark Plug Maintenance:

Inspection and cleaning/replacement at regular intervals (e.g., every 2,000-4,000 km). Manual specifies gap and type.

Fluid Specifications

Engine Oil Type:

API SE or SF classification, SAE 10W-40 or 20W-50 recommended. Manual will confirm exact specification and viscosity.

Transmission Oil Type:

Gear oil, typically SAE 80 or 90. Manual will confirm specific type and capacity for the gearbox.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid. Manual will specify required type and bleeding procedures.

Known Issues

Known Issues:

Carburetor gumming due to infrequent use, clutch wear, potential electrical connector corrosion, drive shaft spline wear.

Common Repairs:

Carburetor cleaning and rebuilding, clutch adjustment, brake caliper service, fork seal replacement, electrical system diagnostics.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Kawasaki has a long history of producing robust and capable off-road vehicles, including motorcycles and ATVs.

Model Evolution

Model Evolution:

The KLT series represented Kawasaki's entry into the growing ATV market in the early 1980s, evolving from smaller displacement models (KLT110/160) to more powerful options (KLT200/250) to meet consumer demand for utility and recreation.

Production

Production Period:

1981-1985

🏆 Awards & Recognition

Recognitions

Recognitions: