KLF300 A bit Nungary

[Mattyc]

I just got a cheap quad to tow stuff around home, the bike is fairly sweet but its a bit nungary once you get up in the rev range, Im unsure if its camtrain noise, piston slap or the big end..

Anyone know if these things have common faults like above? Model is a KLF300b 2wd - about 1990

[Mattyc]

May have found a possible solution that I thought id share. Spoke to a great guy at Mr Motorcycles workshop this morning, He reckons a common fault with this quad is the voltage regulator shits itself and the magneto (think its a magneto) overcharges, which then plays havoc with the CDI and causes the timing to be all out of whack, This fits the symptoms so im going to check the voltage tonight and if its overcharging will source a new rectifier

SWEET!

[Mattyc]

gayballs...

wasn't the problem

[crazyxr250rider]

If the 2wd motor is anythin like the 4wd motor its likely to be the timing chain is at the end of its life or the tensioner is gummed up, chuck it on tdc and whip the tensioner out (only 2x 10mm bolts ) and make shure the shaft moves freely and
the locking bearing isnt buggered...

[Mattyc]

Cheers dude, will take a look this weekend.

Do you know where the timing marks hide?

[crazyxr250rider]

easier to get maori tdc (turn motor over with a screw driver down the spark plug hole and stop when its at tdc,shure you can work it out lol)
but from memory theyre under a cover on the side of the head(Been a while)
can be done without putting on tdc but you risk the chain jumping a tooth or two
might be an idea to check the valve clearances while you muckin round with it too

[Mattyc]

yeah was planning to reset the tappets too. will have a good tutu on the weekend. Will grab an oil filter tomorrow too, are they a common filter ?

[T.W.R]

Oil filter is a HF123 (Hifiltro)
valve clearances are 0.15mm (.0059) for both inlet & exhaust

Timing marks are simple; under the cam sprocket plate there's a nib on the top end that lines up with mark on the sprocket. under a inspection window (20mm screw cap) on the engine casing there's an indent that you line up the timing mark on the flywheel ( mark with a T beside it).

don't go the screwdriver down the plughole trick as the angle of the hole puts the tip of the screwdriver right at the lip of the piston and can wedge and score the bore.

The ignition system is ultra simple and very weak and a sparkplug with a bit of age to it can easily cause a lot of issues (they have an appitite for plugs).

They wearout carbs needles & seats easily too, and the filter system is primitive and easily lets crap into the carb including water

[Mattyc]

Saweet TWR thanks for that

Got the owners manual downloaded from kawasaki.com, which has valve clearances, but no info on timing marks, Yeah as much as sticking a screwdriver in there will find tdc, id rather preserve that area of the motor as much as I can.

Went to Mr Motorcycles and bought a genuine filter, only $13 so pretty good.

So an external filter might not be a silly idea ?

[T.W.R]

So an external filter might not be a silly idea ?

I was meaning the air filter it's just a mesh frame with a foam sleeve and that sits on a plastic frame with a metal end cap....piss poor design. Just have to be particular about keeping the service intervals up with them because even though they're a simple motor they breath heavily and are delicate in their fuelling; and that's where a lot of problems come from with them.

Apart from that they're a simple robust design as a overall machine, the only real weak link is the brakes or brake design....they let a lot water in and sieze up very easily.

[Mattyc]

Blinged it out with a k&n that was sitting in the shed, sounds a bit throatier too...