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By Steven Urban
First time using this forum. Owned a Kawasaki dirt bike once, had no issues. But I picked up this 4 wheeler at an auction. They stated it ran, but only needed a battery. Well I do not believe that was all true.
Some pictures are attached. Not sure why, but the whole air filter stuff was removed. They had some small thing inserted as a make shift air filter.
I purchased a battery to try this all out. Waiting to return it and get the proper size, as it was too big for the battery box. But here is my issue I had while the battery was connected.
1 - The lights on the steering column did not come on. Not sure if they work or not.
2 - The starter solenoid seems to be bad. I have a new one on order.
3 - In the pick, there is another rusted part. Not sure what that part is or what it is used for.
4 - What is the 12v rectifier? square bodied part.
So when I hooked the battery up. Pushing the start button did nothing. Pulling the cord to try and pull start, it turned, but would never fire. I have put in a new spark plug as well, it looked worn out. With electric start, I crossed over the posts on the start solenoid, it turned over, but would never fire and start.
I have read a few other threads and it stated something about needed the neutral light on. SOmething about a kill switch.
Any help would be appreciated.
Hey I have a 97 bayou 300 2x4 (klf300b) that i bought for 1000 last June and sunk another 1000 into it already. When i went to look at it, the seller had warmed it up before hand (he was riding it when I got there). it ran good so i bought it and took it home that evening... next morning it wouldn't hardly start. I discovered the carb was clogged, there was chunks of rust in the fuel valve, the choke lever was missing and other things. I have since cleaned the carb and replaced the fuel valve and gas lines and cleaned out the gas tank and cap.
Enough background on it, the problem is this: It floods if i push it past half throttle in 4th and 5th gear even going downhill and shifting correctly. It also has to idle and warm up when you first start it which is really annoying now that its cold... It also smokes blue smoke for about 15 seconds when started cold- does not smoke at all once warm but the exhaust still smells like burnt metal. A friend told me that it didn't have enough compression. I also found out that the valves are a common cause for low compression on Kawasakis.. I have never adjusted valves before- the most I've ever got into a engine was a head gasket on a riding mower so I'm new to this. My goal is to get this bike running and starting cold like a top- should i tear down and rebuild the top end? What should i try first? I tore the carb apart and rebuilt it and fiddled with the air screw and nothing changed. I also ordered a compression test kit that should be coming in soon.
Ive also considered just selling it for like $500 and taking the hit- Id rather not sink too much more into this machine.. lol
got that 220 I'm 'servicing'.......... well it turned into a guts and oil job.... I cleaned the carb and it wont idle cold, but idles too fast when warm. also misfires and burns rich cold (white smoke out of the exhaust) I'm going to order a new carb since the old one is leaking and beat up (some one was tinkering) I'm wondering about the valve clearance and timing...? Maybe a factor? What should the clearance be on the valves? How should I check the timing on this bike? (this is a mid 90s bayou 220 2x4)
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1988-2002 Kawasaki Bayou 220 Service Manual
The Kawasaki Bayou 220 is one of the most common all-terrain vehicles on off-road trails that is geared toward novice riders and families. It’s also one of the smallest and most inexpensive ATVs on the market, with a retail price under $3,500, as of 2010. The Bayou 220 is Kawasaki’s only ATV of its size. The 220’s sibling is the larger Bayou 250 equipped with a 228cc engine.
The Bayou 220’s engine is a 215cc, four-stroke, shaft-driven, air-cooled model. Its bore measures 2.6 inches and the stroke is 2.4 inches. It features a relatively high 9.3:1 compression ratio with fuel delivered through a Mikuni VM24SS carburetor. The electronic ignition is Kawasaki’s DC-CDI. It also features a recoil backup as a starting system. The clutch is an automatic wet multidisc model with power delivered to the wheels via a five-speed transmission, according to ATV Source.
The steel frame supports a front suspension with single A-arms and twin shock absorbers, with the rear suspension a Quad-Link system with two shocks. Front wheel travel is 4.5 inches, while the rear wheel travel measures at 4.9 inches. Front and rear brakes are drums.
The front tire size is AT21X8-9 with the rear tires measuring AT22X10-10. The ATV’s wheelbase is 43.9 inches, with an overall length of 68.7 inches. Ground clearance is 6.1 inches with the seat height measuring 28.7 inches. It weighs 403 lbs. and can tow up to 450 lbs. Its fuel tank can carry 2.6 gallons.
The Kawasaki Bayou 220 is not the fastest ATV on the market, but one reason the Bayou 220 has kept its price low is the lack of amenities. It features a brake light and dual headlamps with high/low beam. There is an auxiliary lighting terminal inside the front cover of the ATV and electrical accessory terminals under the seat. The instrument cluster atop the fuel tank features a fuel gauge, but not much else. There are no speedometer, odometer, hourmeter, tripmeter, high-beam indication or high-temperature light. It does have a reverse/neutral indicator light. The Bayou comes in two colors: hunter green and firecracker red.
The front A-arm, twin shock and rear Quad-Link twin-shock suspension system is not a true fully independent system, but it allows for a comfortable ride over rough terrain without employing a complex and expensive, fully independent suspension system. The ATV features front and rear steel cargo racks. The ATV is rider-friendly with a limited adjustable throttle to help novices practice their riding skills without twisting the throttle too far and losing control of the vehicle.
By Mike Johnson
Does anyone know what the 3rd item is behind the battery on this ATV ? I know 1 is the, solenoid1 is the CDI box, what is the 3rd.
By Andrew Baker
I need help with wiring on a 1998 (I think, 10th digit of the VIN was W) Bayou. I'm not getting spark, I'm pretty sure it is due to grounds being off because the harness is pretty hacked as far as the electric start and charging system goes. I'm needing a good wiring schematic. I found one online and there are a few things that don't add up on it so I'm skeptical that it is really for my year and model. Any help would be appreciated. Thanks.
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