1988 Kawasaki Bayou 220 Issues

[nwr161282]

Evening folks

I have a 1988 bayou 220 quad that has a damaged stator and been lying about for a few years. Recently I got the chance of a 1996 bayou 220 that had also been sitting for a few years so I decided I would try and make 1 good bike out of the 2. The 96 frame was rotten so I decided to use my original 88. I swapped the magneto and stator over from the 96 bike but then noticed that the magneto and stator wiring was slightly different so I decided best thing to do would be to change the wiring loom over. Having done this I ran into issues connecting my original run stop switch and push button start. The 96 loon had a connector with 6 wires where as the 88 had a 4 wire connector and a 3 wire connector. I sorted this by making up a conversion harness using the 2 looms but still the push button start would not work. I have now solved this by using some of the spare wires left beside the ignition key connectors and a relay. So now I have the engine turning over with the starter button. But sadly I have no spark.

On checking the Cdi unit I have found that I have 6 wires going into the cdi unit but all the wiring diagrams I've seen only show 5 for the 96 model. The extra wire I have is a grey wire which has a loose unattached end beside the ignition switch. Does anyone know where this grey wire needs to be attached. 

Thank you to anyone who has read this sorry it's so long but wanted to try and give the full story.

[Stephen Nelson]

Having similar issue. Old ignition switch is 4 wire, new bike only has 2.