Reviving a 2000 Big Bear From Storage

[Claytonsdad]

I have a 2000 Big Bear 400 4x2 that has been sitting since about 2005. It has been inside, so it still looks very good. Bike was low hours and ran great before it was parked. I plan to change the engine oil and filter, differential oil, battery, fuel lines, fuel filter, drain and clean the fuel tank and rebuild the carburetor before I even try to start it. Is there anything else I should do? I don't want to cause any damage before I even get the thing running again. Thanks.

 

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[Claytonsdad]

I will also replace the spark plug and the air filter and check/clean engine ground connection as well.

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[dtoots1]

i have a question for all the gurus on this site.....just about that very question....i too have a 4 wheeler that has set a while...i went thru it and checked and cleaned everything on it...started right up and idled fine, before i could even try any adjustments it died...did that 3 different times and final time locked the engine up!!!  it is a kawasaki bayou 220 dated 2000...

the question i have of the gurus is...is there a way to oil these from the top end, since they have been setting, and the oil surely has all drained out of top end and would that oil sufficiently to prevent issues once engine going??????

Thanks,

dtoots1

[Claytonsdad]

May be a silly question, but you did remember to put oil back in it, didn't you? I don't know if you can access the top end easily on that particular machine. Is there a way to manually turn the engine over without the starter to see how much resistance there is? I don't like using the starter because the torque they put out can break stuck rings.

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[dtoots1]

just exactly had the proper amount of oil in it....have pull starter off and cannot turn over by hand nor with a short bar. so tis locked.

[Claytonsdad]

That sounds strange. Hopefully one of the experts will be along shortly with a possible solution. Did it get hot at all while it was running? Have you checked to make sure the starter isn't stuck in the engaged position and keeping the engine from turning?

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[dtoots1]

not sure if starter sticking will lock engine...and no did not get hot...warm but not hot.

[Claytonsdad]

If the starter stays engaged to the flywheel, it can eventually seize and shut the engine down. This will cause the symptoms you describe.

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[Claytonsdad]

The engine won't be able to turn because the starter is locked up to the flywheel, preventing it from turning. If the flywheel can't turn, neither can the crankshaft.

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[dtoots1]

not sure if starter sticking will lock engine...and no did not get hot...warm but not hot.

 

odd to have to add here...

so i have to pull the starter to see if free?

[Claytonsdad]

I'm not familiar with your machine, but you might. Something is preventing the engine from turning and I wouldn't think no longer than you ran it, it would be the crank. Then again I'm only a jakeleg redneck and I didn't even stay at a Holiday Inn Express last night. [emoji16]

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[dtoots1]

not sure if starter sticking will lock engine...and no did not get hot...warm but not hot.

 

odd to have to add here...

so i have to pull the starter to see if free?

will try it and see...shop wants $80 just to see it!

[Claytonsdad]

I'd pull it to save $80. From what Google says, it's pretty straight forward, albeit a but tight to get to. You might wait to see if someone more qualified comes along in a bit.

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[1987Moto4YFM350]

@Claytonsdad How do you clean the fuel tank?

[Claytonsdad]

For plastic tanks, I remove the tank, empty it out, and plug all but the filler hole. I then rinse it with hot soapy water the best I can and check it with a flashlight. If there is still buildup present, I put a little aquarium gravel and hot soapy water in the tank and shake it to agitate the gravel, which usually loosens anything stuck to the tank. Once I'm satisfied it's clean, I remove the soapy water and gravel and rinse with hot water. Let it dry and inspect with a flashlight for cleanliness and to make certain there isn't a pebble stuck somewhere. That's about it. You can use solvents and such, but I don't like to. Metal tanks can be cleaned in a similar fashion, but if you have rust it gets exponentially more complicated. There are many videos out there on cleaning and coating metal tanks. You can get about as elaborate with that as your patience can stand.

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