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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 Tom Pavlak
Hi Everyone - Need some help.
Got a nice little 220...clean machine. wiring is a mess. I have a diagram however, the one I have has 4 wires coming from the ignition switch not 2 like mine. So, I cant trace wires properly.
There is a white one that runs to the Solenoid, and a brown wire...from the Ignition...I dont know where its supposed to go. Also, on the Solenoid, there are 3 wires..W to ignition, B to start relay and B/Y runs up to the front of the machine...and is not plugged into anything...and there isnt a "Mate" missing it. How do they plug into the 4 open shovels by the 20A fuse?
I'm pretty sure my Lights and start switch/Lights are correct.
Problem I cant get anything...new battery...cant get the start button to work, cant get any power to the lights or switches...so I know something is not grounded or..
Any advice would be greatly appreciated.
By colin james
View File 2018/2019 Polaris Sportsman XP 850/1000 Service Manual
This is the factory service manual for the 2018/2019 Polaris Sportsman XP 850/1000
Submitter colin james Submitted 08/01/2019 Category Polaris ATV
By colin james
View File 2017-2019 sportsman 450/570 with eps factory service manual
This is the factory service manual for the 2017-2019 factory service manual for the sportsman 450/570 with electronic power steering
Submitter colin james Submitted 09/06/2018 Category Polaris ATV
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