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viper0906

2001 Kawasaki Bayou 220 Engine Locked Up

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Need help with teardown of 2001 Bayou 220.  New to atv's but not to mechanical work.  I was given this ATV and went to turn engine over by pull rope and the engine is locked up.  Pulled spark plug no change.  Was going to tear down top end.  Any suggestions or tricks before I proceed?

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Greetings! New to atvs as well (and a bayou 220). Don't know how much help I'll be but does the electric start not work? or missing? Only ask cause mine turns over with tons of compression with the start button, but the pull start only comes out about 6-8" before stopping completely. I thought mine was seized as well until I got the start switch working. Just a thought. Good luck!

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Welcome to Quadcrazy. I would pull the plug @viper0906 and spray some wd-40  or some penetration oil inside the cylinder head and let it sit for a day or so then warm the head up with a heat gun and try to spin the engine with the plug out.  

Hopefully the head frees up and it’s not seized.  

Also @Squirrel keep in mind that the cylinder head on the top right side has a compression relief lever that should be used when pull starting. Press the lever down and it should stay until you pull the engine cord.  

It will automatically reset it self so be sure to push it again before pulling the cord or your shoulder will be sorry! 

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@Frank Angerano I got the Head and Cylinder off  and the cylinder off.  The piston was rusted in place to the cylinder wall.  The rings are stuck in also.  I guess I can try to hone the cylinder or should I send it to a machine shop?  Looks like I might get away with a top end kit and maybe a new sleeve?

bayou cylinder.jpg

bayou piston.jpg

piston 2.jpg

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Oil the shit out of the piston and rings. Unless you just want to change it bc it’s torn down already. Buy a honer from the auto parts store and pop it in the drill and go to town on the cylinder. New gaskets, slap it back together with a fresh plug and fire it up!  Change the oil as well.

i just ordered a complete gasket set for that same bike $38 on amazon.

the only thing I would recommend is to change the valve seals since it’s all apart and they come with the gaskets anyway. 

great pics

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So I have not had a chance to hone the cylinder yet but I did soak it over night in simple green and almost all of the rust came off the cylinder walls.  I will post some pictures later.  The second piston ring has freed up a little but the top ring still will not loosen up.  Any tricks on removing the stuck rings other than soaking in oil?

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I have in the past put the piston in a pot of boiling water for a few minutes, taken it out and repeated the steps.  Then soak it in penetrating oil. The heat and cooling makes the metal expand and contract loosening the rings.  You can use a small torch but be careful not to keep the flame to close for to long.   

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I just picked up a non-running 220 that I can get to fire and will run for a few seconds and then locks up. It came that way and I turned the crank reverse a full turn or so and then pulled the rope and it fired a few times and locked again. I got it in my shop now, stripped down the bike and gonna pull the motor and have a peek in it tonight

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