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.

viper0906

2001 Kawasaki Bayou 220 Engine Locked Up

Recommended Posts

That primary is gone! The ruts wil prob show that its within spec maybe because the high points in the ruts.  It’s not supposed to look like that.  It has to be replaced. 

Share this post


Link to post
Share on other sites


haha thats prolly what my bayou clutch looked like- had to adjust it wayyy tight to run and not slip- I couldn't have done anything about it tho cause any more money I sunk into it was money I lost...

Share this post


Link to post
Share on other sites

Prob best thing you did was move that bike along to a new owner @JacobSlabach.  That clutch housing on this bike is in bad shape.  When that clutch looks like that It’s basically the same thing as letting your brake pads on a car run down to the metal.  It destroys the rotor and metal shavings get everywhere.  That primary housing should have some meat on the inside for the clutch to grab.  The secondary is prob ok but the metallic shavings need to be cleaned out.  

Share this post


Link to post
Share on other sites


@Frank Angerano So pulled the secondary down and found also two things.  First is the new clutches I put in are right at the service limit.  These were after market clutch disc bought on amazon.  The next thing is the question of the two washers on the secondary clutch.  I have information in the clymer manual that does not match each other.  Which one goes on first? The special note at the top of page 212 says the outer washer 20 is thinner than the inner washer 17.

Then the diagram on 212 calls 20 the inner washer and 17 the inner washer.  but pictures on 213 figure 54 and 57 seem to go with thin first then thick?  Does anyone know which way is correct?

 

washers1.jpg

washers2.jpg

washers.jpg

Share this post


Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.


  • Similar Topics

    • By John Brucato
      Hi all new to the sight haven a problem with my 1988 kawasaki bayou 220 it ran then just died when out one day get gas but no spark any info will help I'm new to the ATV got it used and ran like a champ but don't know where to start when it comes to this
    • 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 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 Ross
      http://www.off-road.com/atv/tech/2003-kawasaki-bayou-300-atv-29516.html
      I can't find the serial number or a specific manual for this atv. It sounds like the same one in the link above. It says Kawasaki Bayou 300 Dual Mode Differential. And it has a handle lever attachment for shifting, fuel gauge, and a small storage compartment. Can anyone find me a manual? Pictures attached
       




    • 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.
       



  • Similar Tagged Content

    • 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.
       



    • By Mike Strayhorn
      last year I bought led lights when I was riding my 4 wheeler the lights started getting dim shut off
      now my 4 wheeler will not start the battery is hot everything is dead I checked the fuse and its good 
      would there be another fuse I am missing I'm took the led bulbs out and replaced them with the ones that was in there 
      wonder what meh problem is
       
    • By EoNe Frost Vortex
      Hello i was wondering if someone could help me out iv recently got a Kawasaki klf 220 it needed big end bearing changing so i rebuilt the engine and the bike has compression starts first time every time but after i have been riding for about 10 minutes oil starts to leak from the head just below the exhaust so i replaced the gasket still done it so i took it to a shop he done the same and it is still doing it any information would be great thank you
    • By oxidized_black
      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.
  • Recently Browsing   0 members

    No registered users viewing this page.


×
×
  • Create New...