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Mitch gleed

1996 Kawasaki Bayou 220 CDI from 1995 Bayou

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Topic moved to Kawasaki ATV forum and topic title changed to include full ATV info and question. 😁

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  • Similar Topics

    • By Gsk1500
      The clutch cover goes on and fits, but the little L chapped arm that has gear slots is concerning me.  It appears it goes to wear the clutch adjust bolts are on the cover. 
      Is there a specific way to tell how it mounts on the gears in relationship with the basket?
      I don't want to deal it up unless it's right 
    • By oxidized_black
      View File 1988-2002 Kawasaki Bayou 220 Service Manual
      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.
      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.
      Chassis
      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.
      Size
      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.
      Basics
      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.
      Features
      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.
      Submitter oxidized_black Submitted 12/14/2016 Category Kawasaki ATV  
    • By Arizona
      Back again with another headache, maybe you guys can help me out. 
      Picked up a 87 Bayou 300 not running of course, all stator wires melted 
      on the motor and also no spark. I checked the pick up coil ohmed out good. 
      traced the wires and led to no cdi box, yes missing. So ordered it and while waited 
      fixed the stator wires, had to wire direct to harness. Get the cdi installed and after a lot
      of other things started it up. Battery dead so used a batt charger to start it. Now when i shut
      off the charger the motor died. So i check charging voltage...nada. I see voltage regulator is 
      old and catalist leaking so i replaced it. Same thing no charge. I check stator and no voltage 
      with it unpluged from harness while running. Soooooo i replace stator. Now Stator wires have
      23v and up to over 50v at higher rpms. So i know its charging now. Connect everything back up and 
      no charge voltage at battery! Still dies when i shut off charger. All 3 yellow stator wires have good voltage, checked
      harness from stator to regulator and is good. The white wire has battery voltage at regulator, the brown wire has battery 
      voltage at regulator when key on. The Black/yellow stripe has good ground. I get 3 volts at battery when i shut off charger. 
      If i connect old regulator i get 7 volts when i shut off charger. Do i have a defective new regulator? Im stumped. when i 
      figure this one out i have a big wiring problem on another one ill let you in on.  Az
    • By JCA
      I recently acquired 1994 Bayou 220 (leaks oil, leaks gas).  Beginning by cleaning carb.  When I took the float bowl off, the brass overflow tube is not straight (see image).  I am not sure if this is "right" or was damaged/modified at some point (although I can't image why).  I have looked for an image or drawing that would show this clearly with no luck.  Should this tube be straight vertical; and if so, should I attempt to straighten it, replace it, or leave it be (not sure if this would effect the required float level setting as the end of the tube sits just a little lower at the angle).  Prob putting too much thought into this, but any info would help!
      Thanks!!
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    • By Brent Mason
      IMG_4272.MOV Originally had my griz600 stop running and then wouldn’t start ! After testing all coils , valve lash , compression (115psi) and all tested ok I bought a used cdi . After cdi install it still wouldn’t start (no spark) ! So even though the stator , pulse/trigger and charge coils check within good range I decided to switch the stator etc ! It started but It is very unresponsive on throttle and acts like it is running in 2 Different spark timing ! With slight throttle it will take off good but instantly go into a very different running mode with no power like timing very retarded but it will switch back to running good for short period then bad again !  Since I replaced the stator and it started I then decided to install the cdi I replaced and it did the same thing ! Also I noticed the Used cdi I Took off had a capacitor that had swelled and extruded from the back of the cdi . I had always heard and I believed that when these CDIs go bad they machine will quit and will not run . Is that true ? I also checked the cam/valve timing and its ok ! Checked with timing light and it does fluctuate on idle ! I am thinking I have 2 bad CDIs . I also switched the trigger Coil wires and would not start then . Man , this thing ran good before and I am confused ! Video below may help !
      IMG_4272.MOV
    • By Brent Mason
      1998 Grizzly600 ! Slowly died then wouldn’t start ! All coils check good ohms ! Checked ac voltage from source coil get OL ! Is the source coil bad ? 
    • By Bryson Bailey
      Hey I have a Kawasaki buyou I put a new carburetor on it and a brand new spark plug coil and still firing up could you know what my problem is anyone please
    • By 1911Neil
      I had a quad fall in my lap a couple weeks ago. The only things I knew about it was it was a Kawasaki Bayou 220, was in pretty rough shape and was free. I couldn't say no to a fun little project. I've been looking a different ATV forums gathering quite a bit of info and decided this was the one I wanted to join.
      Thanks to this forum, I found the VIN under about an inch of mud and cross referenced it to be a '98. It had been sitting outside for at least 5 years and was told it ran when parked, but had no brakes. Squirrels or mice had been chewing on the handlebar controls and it's generally just kind of beat up.
      So far, I've gone through the carb (not near as bad as I expected), freed up the brakes (will probably need new cables), replaced the spark plug, air filter, petcock and put a new battery in it.
      The gas tank had been empty and looked clean so I put some fresh gas in it and tried to crank it today. I got a neutral light, but the starter button did nothing. I tried pull-starting it and it wouldn't fire. I checked the plug and wasn't getting a spark. I started digging and found some potential issues and some definite problems.
      I have a wiring diagram I found on here but it's just a picture or scan out of a book and hard to read. I don't see a reference to a black/yellow wire, which is my first problem.
      First, it that a factory crimp? One of those wired looks like it goes to the connector in the 2nd pic. Is that just a spade lug type connector? I pulled on it with some needle nose pliers but it didn't seem to want to come off. In the 3rd pic, should there be a fourth wire?
      I've read through and bookmarked the threads Andrew Baker and Arizona have going but I figured I needed to start with these obvious issues first. I have lots of pictures, so if there is something else you want to see, just ask. If I don't already have a pic, I'll take one.
       



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