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.

wrench66

1988 Bayou 220 lost spark

Recommended Posts

Hi all,

I recently acquired an old Bayou from a neighbor that I cleaned up a got running, then from nowhere a problem crops up where it refuses to start........ I pull the plug and it has no spark, pulled the plug cap off and laid the bare wire on the exhaust header and still nothing......once in a while though when I push the starter button but as I let off the button it might spark once. Now it did begin sparking normally just once and I plugged everything back in and it ran normally again until I turned the engine off. Next time I tried starting it we were back to no spark or the one spark deal.

I have tested the stator wires at 140 ohm, the pick up at 130 ohm (I can't seem to find a reliable number for these values online), I bought a new ignition coil and ignition switch on chance those may have been the problem but were not, not sure where to look from here......... does the starter relay switch have anything to do with the ignition on these? I know these older Bayou's are magneto type ignitions and do not need battery power to operate but I wonder if there are safety switches involved I may not be aware of. Also, can someone point me to a good wiring schematic for the magneto 220's? Pre 95 I believe.

thanks for any help!

-- Ray

Edited by wrench66

Share this post


Link to post
Share on other sites


The intermittent spark thing really sounds like a bad connection.  I would open the stator cover and check that there is no rust or corrosion on or around the stator/magneto.  Check all plugs and before you plug them back in add dielectric grease to the plugs. 

If the bike is cranking when you hit the starter then the starter safety relay circuit is working.   Easy way to test it to put the bike in gear and try to crank it. It should not crank.  

The stator coil should should read from wire to wire about the same ohms. And should NOT read anything from each wire to ground.  

I have to go back and look at the pick up coil and stator coil numbers to see where your at as far as readings.  

This should be your working diagram. Let me know if you need any clarification on the map.  

69924F40-12E2-4CF0-A575-F14C134BA830.jpeg

  • Like 1

Share this post


Link to post
Share on other sites
2 hours ago, Frank Angerano said:

The intermittent spark thing really sounds like a bad connection.  I would open the stator cover and check that there is no rust or corrosion on or around the stator/magneto.  Check all plugs and before you plug them back in add dielectric grease to the plugs. 

If the bike is cranking when you hit the starter then the starter safety relay circuit is working.   Easy way to test it to put the bike in gear and try to crank it. It should not crank.  

The stator coil should should read from wire to wire about the same ohms. And should NOT read anything from each wire to ground.  

I have to go back and look at the pick up coil and stator coil numbers to see where your at as far as readings.  

This should be your working diagram. Let me know if you need any clarification on the map.  

 

Thanks for the reply Frank, that diagram is just what I was after. Ok I will go through your questions one by one:

I was thinking about having a peak at the stator and pick up coils, is there oil behind that cover on the 220? I wanna be prepared with a new gasket.

Yes it does crank over fine and the neutral safety is working as it will only crank with the green light lit. 

When I tested the ohms from the stator coils (black-red wires into the cdi box from the engine) I did test for any reading to ground and found none. Like I mentioned I believe I read 140 + - was the target for the stator coils and 130 +- for the pick up, which both mine are reading.

Earlier today I did replace the ignition coil as well as the key switch with new items but neither had any effect on the problem (I had already ordered them prior to this).

One thing I failed to mention was that when pull starting I get zero sparks....not even the one intermittent ones like off the button. Before all this started I had this quad running very well (it had been stored for a number of years) and was very happy with it easy starting 2 pulls cold or just a quick punch of the starter button. I was riding around our pasture 20min before this began...so I'm certain it's a simple fix but electrical issues are tough.... lol.

thank you for the help!

-- Ray 

 

Share this post


Link to post
Share on other sites

Looking closer at that diagram Frank I think that's a later one that uses battery 12v power to fire the igniton, I don't see the two source coils near the stator and it looks like there is 12v going into the CDI box. My '88 has 2 yellow AC leads from the stator/altenator and 2 other black and red leads from the source coils in the stator like this pic shows.

81PwhNfkhgL._SL1500_.jpg

Share this post


Link to post
Share on other sites


Sure, I don't have the stator cover off but you can clearly see it's 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 pick up coil wires are blue & black and the last pic is the connectors at the CDI box...... 2 pair of 2 wire and a 3 wire.

thanks!

20190421_130844.jpg

20190421_130856.jpg

20190421_130950.jpg

Share this post


Link to post
Share on other sites

Are you positive of the year and size of the bike ? I’m looking at a few diagrams and I’m not seeing this wire configuration for some reason.  

Share this post


Link to post
Share on other sites

This is the machine I have, it's dark now so no pics but this the exact one from Google......... the registration reads date first sold '88 and the tenth digit in the vin is a J so yes it's an '88. Decal says 220 so I'm gonna go with that ;)

 

278863463_bayou220.jpg

Share this post


Link to post
Share on other sites

Thanks John, no continuity on the yellow/red wire coming from the CDI box to ground when off....... yes when switched on so it's working ok.

Found a service manual online with the correct wiring diagram from the early magneto type ignition (Bay-E download). Gonna separate the ignition from the rest of the wire harness to hopefully narrow down the players in this problem, by giving the cdi and ignition coil their own stand alone ground and eliminating the yellow red kill switch wire I can then see if the CDI, source, pick up and the ignition coils are working...... IF I STILL have no spark then it's only a matter of a couple of obvious parts, IF my spark returns then it's an easy job to one by one plug things back in until the culprit is found. We'll see ;)

220 Bayou wiring diagram 001.jpg

Edited by wrench66
  • Like 1

Share this post


Link to post
Share on other sites


13 minutes ago, wrench66 said:

Thanks John, no continuity on the yellow/red wire coming from the CDI box to ground when off....... yes when switched on so it's working ok.

Found a service manual online with the correct wiring diagram from the early magneto type ignition (Bay-E download). Gonna separate the ignition from the rest of the wire harness to hopefully narrow down the players in this problem, by giving the cdi and ignition coil their own stand alone ground and eliminating the yellow red kill switch wire I can then see if the CDI, source, pick up and the ignition coils are working...... IF I STILL have no spark then it's only a matter of a couple of obvious parts, IF my spark returns then it's an easy job to one by one plug things back in until the culprit is found. We'll see ;)

220 Bayou wiring diagram 001.jpg

@wrench66 can you add this manual to our downloads section? or PM me a link and I'll do it? It may help others since it seems we don't have the right manual available.

https://www.quadcrazy.com/files/category/6-kawasaki-atv/

Share this post


Link to post
Share on other sites

I cleaned it up a little bit for you as well as did some studying.  It’s a little different from my model but still pretty straight foreword.  Hope this helps.   A733EF4E-D55F-4BDE-A413-3386DE282672.thumb.jpeg.ebe68dc600dade8700ad23555146a5e3.jpeg  

If you have any questions let me know.   

If it’s not clear then private message me and I will email it to you.  

Share this post


Link to post
Share on other sites

Success!!

While following my plan of attack of separating the ignition from the rest of the quad's wiring I swapped out the CDI box with an inexpensive dirt cheap Chinese Ebay replacement just to see if a difference could be seen BEFORE springing for a proper OEM item and wonders of wonders I hit upon the defective part....... sparks a flyin :) lol.  So luckily what I ultimately ended up having to replace was the ignition switch and upper HT coil (which both were in dodgy condition to begin with) and the CDI box just mentioned. 

Going about it methodically and using the wiring diagram got this solved, thanks for the help fellas ;)

-- Ray 

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 Nick Gudex
      Hello I am new to this site and I havea problem. I have a 1987 big bear 4x4 that will not spark. I tested pick up coil per repair manual and I tested my new coil both ok. It puts out 9 volts at the coil but It is reversed polarity. So when I hook my meter up to it she shows -9 volts while cranking. When I put a test light  on it it flashes. Being an electric system this should tell me something but I don't know what its telling me. I have yet to meet one i could not fix but this old girl has me stumped. Any help would be awesome. Thanks to all.
      Nick
    • By Gary Mier
      1997 Yamaha 350 Warrior, should there be oil in the stator area? Have a no spark situation.
    • By Brock Kincaid
      Ok so just picked up an 02 ds 650 and the guy said he couldn't get it to start. He had a shop put new shims in it and I had them checked and they were ok now things I've done is new plugs even though guy had just put new plugs in it.. got new carb 42mm just like the one that was on it.. bought new intake manifold because the one that was on it someone got way to tweaked out and ported the shit out of it excuse my language but yeah so installed new intake manifold and it just won't start like its not getting enough fuel.  Timing seems to be right it does fire every now and again but just barely.. did a compression test today and it was at 90psi.. i know thats low but don't know where I'm losing compression.. valves we at .06 and .07 when checked im lost ive tried everything I know and can't figure it out
    • By Bebe
      Hey guys I'm new here. I have a 88 warrior that has intermittent spark. When I got the bike the guy said it needed a stator.  So I tested the stator and the Source coil has .310,  Trigger coil has .363 an .367,  Alternator side has .05 to .06 on the three. Which all seem in range. I did find that the ignition coil was bad and replaced it. After I  put the new coil on i got spark but only now and then. The bike won't spark while I'm holding the start button,  but as soon as I let off it will spark sometimes. I ended up unplugging the voltage regulator and it will spark every time I let off the start button, but still will not spark while I'm  holding it. What could this be?
       
    • By Gsk1500
      The clutch cover goes on and fits, but the little L chapped arm that has gear slots is concerning me.  It appears it goes to wear the clutch adjust bolts are on the cover. 
      Is there a specific way to tell how it mounts on the gears in relationship with the basket?
      I don't want to deal it up unless it's right 
  • 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
  • Recently Browsing   0 members

    No registered users viewing this page.


×
×
  • Create New...