Quantcast
Jump to content

  • Do you own an ATV? Join our Forum!

    As a member, you can post in our forums, upload your photos and videos, use and contribute to our downloads, create your own member page, add your ATV events, and even start your own ATV club to host your own club forum and gallery.  Registration is fast and you can even login with social network accounts to sync your profiles and content.

Squirrel

Cleaning/sealing electrical

Recommended Posts

Thought I'd throw this one in the club section to help raise the lack of activity here. I'm fixing up a '00 Bayou 220 that I picked up last weekend; needs the carb rebuilt, at least that's all I was hoping it needed. Anyways, decided to check the battery, starter, spark, all that jazz so I was good to go when I got the carb fixed.. and that's when I found an intermittent short in the start switch as well as the headlight switch. So I removed the switch housing from the handlebar to find this:

20181125_141415s.jpg.22e77529245160af26eb05984eb3514b.jpg

I dismantled the entire assembly, blew it all out with compressed air, cleaned everything including the corroded contacts, and then reassembled it all making sure to put dielectric grease on all the exposed electrical. It looks 1000x better than before and everything works as it should (though I think I installed the kill switch backwards lol). 

My question is this: Is that good enough? As a former auto mechanic, I'd always seal any external electronics to prevent dirt, moisture, etc from getting in. However, the design of the housing doesn't really make this possible. I'm not trying to make this thing 100% submersible, but with the switch being old/original I'd like to know it won't fail on me if I get caught in a downpour or something.

Share this post


Link to post
Share on other sites



  • 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 Brent Wright
      Can I check the compression just by pulling the pull start even if it doesnt start?
    • 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
  • Recently Browsing   0 members

    No registered users viewing this page.


×
×
  • Create New...