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.

Samuel Myers

Kawasaki KLF220 Bayou issues

Recommended Posts

So, I've been having issues with my Bayou 220. It's gotten to the point where it was parked for 4 years just because of the issues.

Issue 1, Grabby clutch: The clutch is adjusted incorrectly and grabs when shifting from neutral to 1st. It grabs before the engine has a chance to rev, which stalls it.

Issue 2, Starter clutch blown out: The starter clutch is busted and spins free both directions.

Issue 3, bad shocks: The springs or shocks are bad and the quad leans hard when getting on.

Share this post


Link to post
Share on other sites

Shocks you can pick up on eBay relatively cheap as well as the starter clutch.  

The drive clutch issue could be an adjustment or just may need a new one all together.  Just need to figure out if it’s the primary or not.  But that’s easy enough to figure out.   The bayou I picked up also sat for about 5 years. Owner was getting up there in age and he said the electrical crapped out.  It was the neutral safety switch that was bad but man the amount of water and the elements this bike was exposed to.  I had to drain it down and flush everything out and wash the heck out of it. Grease and oil all fittings and she was good as new.   Over all I think it’s a great bike.  C8F61B79-F3E7-4DFD-AFE2-F2999304AF67.thumb.jpeg.c156d7752734bdf90ed4b953e483c7c6.jpeg

  • Like 1

Share this post


Link to post
Share on other sites


On 4/12/2019 at 11:33 AM, Frank Angerano said:

Shocks you can pick up on eBay relatively cheap as well as the starter clutch.  

The drive clutch issue could be an adjustment or just may need a new one all together.  Just need to figure out if it’s the primary or not.

The clutch issue is an adjustment issue. My brother attempted to adjust it but forgot the second step of loosening it until you feel resistance again. He just tightened it all the way in and tightened the locking nut.

One long term plan is to pull all the plastic off and repaint it. My brother repainted it in this awful green.

20170417_143458.jpg

Edited by Shadow soul60

Share this post


Link to post
Share on other sites

So yesterday I pulled the side of the case to investigate the broken electric start. I struggled with the pull start cup but got that off, and then struggled with the stator for an hour and a half, but got that off, too. If you look before you can see I mentioned that supposedly the starter was bad? Yeah, that was a lie. It was actually the fact that the starter clutch bolts are broken.

 

Explanation: The starter gear just slips into the starter clutch and free floats on the shaft. The starter clutch is anchored to the stator, which is keyed onto the shaft. When you hit the start button, the starter turns the starter gear, which engages the starter clutch and turns the motor.

 

Basically that means that with my situation is when you hit the starter, it turns the clutch on the shaft, so it does engage but it doesn't engage the shaft.

Edited by Shadow soul60

Share this post


Link to post
Share on other sites

Ugh, I tried putting the starter in but of course the freaking thing won't go in. I can seem to get the thing the whole way in. Any tips?

Also, I lost the banjo bolt for the oil line. Where could I find a new one?

Share this post


Link to post
Share on other sites

The banjo bolt eBay I think I have one but mine was from a 400 not sure if it’s going to fit. 

The starter should not give you any trouble going in.  Something has to be holding it up. Have you tried to spin the gear as you slide it in? 

Share this post


Link to post
Share on other sites


1 hour ago, Frank Angerano said:

On the starter ? 

On the starter and in the case. Not that they don't turn, they do, but I can't pull the starter back out to spin the gear.

Edited by Shadow soul60

Share this post


Link to post
Share on other sites

Have you measured and compared the two starters old to new and checked that the gear is not longer on the new starter as well as everything matching? Something does not sound right. The starter is an easy install. 

Share this post


Link to post
Share on other sites

Your going to have to try to spin the motor slightly and slowly and push the starter in at the same time.   I don’t see why it should not slip right in.  

Share this post


Link to post
Share on other sites

So, I was planning on adding on LED headlights and wiring them up to the headlight's high beams. I have bulbs but the stupid things are already broken, and the connectors are really bad, so you have to punch the fender to get the one headlight to work.

Any issues I would encounter? I'm just going to cut out the left side (from seat, looking toward front) connector and splice in the LED wires.

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 Tagged Content

    • By yugnats
      Hi all, I was gifted this Bayou but she's been sitting quite some time. It won't crank using the factory start button but when I jumper the starter solenoid it cranks but there is no spark. The key has power coming in on the white wire and when turned on supplies power to the brown wire coming out.

      I guess I should start with testing the pickup? I heard I may be able to jumper the wires coming from the pickup with an LED bulb and it will flash? I noticed in the manual that it should have around 110 ohms resistance so I'll check that as well. One thing I noticed was that the starter circuit relay has power on one of the black wires with the key on- this doesn't seem normal as I'm assuming the black wires are grounds? I think one of them comes from the start switch, travels through the starter circuit relay and then grounds the starter relay?
      Mine is a 1991 so it has the 7 wire CDI (ignitor) and a 2 yellow wire alternator ( as opposed to the later 3 wire type ) with another 2 wires for the source coils (black & red wires ). The pickup wires are blue and black I do believe. Any help appreciated and yes I will test the pickup ASAP.

      I'm trying to understand how the system works and I don't understand what the yellow / red wire from the kill switch does- I assume it gets grounded when the kill switch is "on" and therefore grounds the CDI so it can't activate the ignition coil? I noticed in the diagram that that yellow / red wire looks like it may be grounded by the ignition key switch when in the "off" position?
      I also don't have 12v power at any of the wires going into the CDI- doesn't the CDI need to be powered? I also read on this forum that someone used a GM HEI module in place of the factory CDI just to test it for spark- does anyone have any info on that?

      I hope I'm not missing something simple!
      Here is a link to the diagram for my bike (which was posted by another user): https://www.quadcrazy.com/atvforum/topic/13742-1988-bayou-220-lost-spark/?tab=comments#comment-101193

      Any help appreciated!
       
    • 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 tnhomestead
      Just was given a 220 bayou, turns over and was wired by a crazy mouse on drugs helped by a committee of politicians taking advice from lil green folk from Mars! This is going to be fun. Claimed the stator was bad. My other project is an old lakota, died driving with no spark and has sat for a bit due to building a house n life! In other words,I may need lots of advice!
    • By Brother Buddy Gardner
      Hello everyone! I recently purchased this quad for a mere 300.00 and it is pretty clean for the year. I bought it from a guy who bought it in a storage unit. He didn’t know anything about it. I got it home and noticed it did not have an ignition coil for the spark plug. I bought the ignition coil, a new battery, new CDI box, new starter relay, new safety neutral relay, new carb and so on... I got it to turn over, but when I pull the plug and check for spark I have nothing.. it has a non factory starter button that works when I push it and turns the engine over no matter if the key or stop switch is on or off..not sure what that’s all about, but it does turn over..just no spark at the plug. Any help would be greatly appreciated! Thanks!
  • Similar Topics

    • By VikingTrad3r
      picked up my third timberwolf 250 for my daughters.  these are great light weight little quads.
       
      have a strange one for you.  the quad will NOT start in neutral.  it will start in first. 
      if i lift up on the gear selector just enough to hear the little click (its not loud, sounds like a contact clicking, perhaps the neutral safety switch?) the light will go out, but it won't yet be in first either.  that is how i have shown my daughter to start it and she can.
       
      id like to carry out whatever repair is needed.  i have the pdf of the shop manual but it doesn't really have a flow through diagram.
       
      any help appreciated!  thank you.
      i need to add something.  it feels like i can switch into another gear BELOW neutral.  
      so if i switch to neutral, i can keep pushing the gear selector, and it has another click below the neutral.  the light stays on, and when i pull up into first it kind of feels like it has two positions it moves through to arrive at first.
    • By Ailll1
      I’m working on a Kawasaki Bayou KLF400 for a family member that doesn’t have spark. I’ve already replace the ignition switch and the stator which were defective. The stator had a melted connector and one of the phase had low resistance and low VAC output. 
      What I’ve figured out so far is that I’m not getting 12V to the ignition coil when I turn the key to the ON position. From what I understand, the 12V should come from the CDI. I’ve resistance tested both wires going from the CDI to the ignition coil (Green/white and black/yellow). They are fine. The only 12V coming from the ECU is on the yellow/red wire.
      I don’t have the wiring diagram for the 400 but I’m working with the one for the Bayou 300 which looks pretty similar except for the wire color between the CDI and ignition coil. On the 300 diagram, the yellow/red wire goes to the ignition coil, not the black/yellow… All the other wires color match except for this one. Not sure if that’s normal?
      Thanks!
    • By yugnats
      Hi all, I was gifted this Bayou but she's been sitting quite some time. It won't crank using the factory start button but when I jumper the starter solenoid it cranks but there is no spark. The key has power coming in on the white wire and when turned on supplies power to the brown wire coming out.

      I guess I should start with testing the pickup? I heard I may be able to jumper the wires coming from the pickup with an LED bulb and it will flash? I noticed in the manual that it should have around 110 ohms resistance so I'll check that as well. One thing I noticed was that the starter circuit relay has power on one of the black wires with the key on- this doesn't seem normal as I'm assuming the black wires are grounds? I think one of them comes from the start switch, travels through the starter circuit relay and then grounds the starter relay?
      Mine is a 1991 so it has the 7 wire CDI (ignitor) and a 2 yellow wire alternator ( as opposed to the later 3 wire type ) with another 2 wires for the source coils (black & red wires ). The pickup wires are blue and black I do believe. Any help appreciated and yes I will test the pickup ASAP.

      I'm trying to understand how the system works and I don't understand what the yellow / red wire from the kill switch does- I assume it gets grounded when the kill switch is "on" and therefore grounds the CDI so it can't activate the ignition coil? I noticed in the diagram that that yellow / red wire looks like it may be grounded by the ignition key switch when in the "off" position?
      I also don't have 12v power at any of the wires going into the CDI- doesn't the CDI need to be powered? I also read on this forum that someone used a GM HEI module in place of the factory CDI just to test it for spark- does anyone have any info on that?

      I hope I'm not missing something simple!
      Here is a link to the diagram for my bike (which was posted by another user): https://www.quadcrazy.com/atvforum/topic/13742-1988-bayou-220-lost-spark/?tab=comments#comment-101193

      Any help appreciated!
       
    • 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 KDawgFPC
      I have a 2004  Kawasaki KLF300. I’m not sure What is the black/yellow, brown, and red wire wrapped together in the wire hornets of a klf300. I got it used and notice some wires not connected. They are located in the front area 

      The reason why I am asking because I’m having issues with it firing up. I cleaned the carb put new spark plugs and gas. 
  • Recently Browsing   0 members

    No registered users viewing this page.


×
×
  • Create New...