1997 Kawasaki Bayou 300 2x4 (klf300b) Runs Bad

[JacobSlabach]

in other words, something's locked up.

[Frank Angerano]

You didn’t put the timing chain back yet correct ? 

The timeomg chain should be held up with a piece of wire so it does not fall in the engine and jam up.  Is it psssble that the chain is kinked down in the engine ?

[JacobSlabach]

nope.  I was trying to turn the crank and piston to get the bottom end back in time and then connect the timing chain.

[Frank Angerano]

Bike in gear ? 

Did you drop anything in the engine ? 

[JacobSlabach]

checked that it was in neutral.  I kept the engine covered the whole time I was working on it and no I made sure I didnt drop any clips or anything when I had the cylinder off.

[Frank Angerano]

Your going to have to unbolt the cylinder and  see if the cylinder moves when you rotate the engine then you will know if the piston is locked up in the cylinder. 

[JacobSlabach]

ok.  I took the head off and losened the cylinder and pulled it up a little so the rings would still stay compressed.  The cylinder moved pretty freely up and down.

I also shined a light down the timing chain and around the crank.  no kinks.  

[Frank Angerano]

So the piston is jammed inside the cylinder it sounds.   I would back the piston out and see if that’s the problem. 

If the crank spins freely then the piston is jammed inside the head and that’s not good. You can scratch the cylinder walls.  Maybe a rings not compressed and sitting in the groove right.  

[JacobSlabach]

the cylinder is loose and it slides freely on the piston so I dont think thats the issue..?

[Frank Angerano]

Is the crank spinning ? Do you see the crank trying to rotate ?

I hate to say it but I would pull the head again and see if the crank spins. You have to be sure that nothings inside the engine.  

[JacobSlabach]

the head is off.  I dont see anything trying to spin in there.  Its like its frozen or something...

[Frank Angerano]

I hate to say it but I would pull the head again and see if the crank spins. You have to be sure that nothings inside the engine.  

Habs you tried to spin it both directions.  I feel like it would have to be the timing chain. Be sure it’s all the way up and not kinked down below.  

[JacobSlabach]

how do I spin it backwards?

[Frank Angerano]

Grab the piston and try to rotate it or put it in  gear and spin the wheels 

But be gentle. 

[JacobSlabach]

before i saw your reply, I took the pullcard off and turned the flywheel backwards and now its free.  was a kink I didnt see in the timing chain.

[JacobSlabach]

got the timing chain back in the top end and in time (the 'T' mark at the bottom and the marks on the sprocket parallel to the cylinder)

do you know what the valve clearance specs are on my klf300b?

[Frank Angerano]

It should be in the manual and if I’m not mistaken it should be 0.010mm but not sure. I will check later when I get home. 

[JacobSlabach]

Ok, looked it up, for the forum:  In:   .10-15mm

                                                    Ex:   .20-25mm

I got it as close as I could- the valve clearance tool I bought didn't go that small...  just down to .20mm so I just tightened it farther on it to try and get down to .15mm.  If Its running bad, I'll get a different set and get it exact.  Any tips as I put it back together?  

[Frank Angerano]

So timing and valves are good ? 

If so just re tighten everything good and spray a drop of wd-40 into the cylinder and spin the engine a few times to get the piston up and down the cylinder. 

Did you put the new rubber rings in the valve cover caps.  I like to use a drop of high heat scilicone on the edge of them caps. They leak oil for some reason.  

lastly  after it’s all back together I like to  press the start button with no spark plug in to cycle the engine a few times to pump oil up into the head before it fires up so it does not scorch the cam. 

 

[JacobSlabach]

ok.  yes I replaced the gaskets in the caps.  will do.

[Frank Angerano]

Any pics to share ?

[JacobSlabach]

Just put it back together..  It fires but wont stay running...  I also didnt put the rear part of the muffler on- does that matter?

i dont have any more pics rn..

[JacobSlabach]

It seems as if its flooding.

[Frank Angerano]

What makes you think it’s flooding? 

[JacobSlabach]

There is gas coming out of the vent hose coming out the bottom of the carb

[Frank Angerano]

I would do a quick clean on the carb just to make sure it’s giod to go and nothing’s in any of the jets.  It has happened before.  

1-3/4 turns out on the fuel air mixture screw from a snug position. 

Put the air filter back on before you dial it in with the final adjustment. 

Floats prob stuck. 

You can try to tap it with the back side of a screwdriver to maybe free it up. 

[JacobSlabach]

I had the air screw out 1-1/2 turn-  the manual said to have it at 2-1/4 turns?

I cleaned the carb good already- (its the new(old stock) one I bought of ebay)

[Frank Angerano]

Ok so it might just be a stuck float. That’s the only thing that would cause an over flow condition. Float not coming up to close off fuel. 

[JacobSlabach]

The float was free when I took the carb apart.

sp was wet when I took it out.  I'm gonna check compression to rule out the valves.

[JacobSlabach]

compression is at 170psi

so do I have the valve clearance wrong or what?