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Samuel Myers

Kawasaki KLF220 Bayou issues

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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.

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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

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That’s my littlest guys.  9 years old rides like a champ.  

That bike as it sits cost me $450 including the parts to fix. 

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Wrong. I just looked I’m into it for $650 total.  Don’t know how I screwed that up.  

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Posted (edited)
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

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Posted (edited)

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

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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?

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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? 

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Posted (edited)
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

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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. 

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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.  

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So I was unable to get the starter in, but I have a bigger issue, I lost the banjo bolt for the oil line. Where could I get another one?

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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.

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So I managed to get the gear to line up but for some reason the starter bolts don't line up. Something isn't right.

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Following. Always curious to see how these restorations turn out. Hoping to do some work on my 220 soon, too- maybe I'll pick up some tips :)

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