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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 Erik Plug
Picked up my first Brute Force yesterday. What should have been an awesome afternoon of riding turn a bit into a deception. As I was unable to really take it out for a test drive at the shop, I decided to buy it and agreed that I would take the test drive at home.
When giving full throttle I noticed that the Brute was choking and lost all of its powers. Faulty fuel pump most likely.
Called the shop and the are coming to pick it up and repair it and bring it back. Good service. Nevertheless feels a bit sour in the mouth as I was told it was a 100% good.
Need to have some patience I now before I can really start riding.
By Dra O
posted a while back - it was running at one point - I have all the plastic shroud off - it's down to frame and engine now
-fuel pump: when line from petcock is attached, no fuel comes out other side to carb; the line to the carb is open (can blow through it); I thought when I cranked engine that the pump would spit out fuel on other side but it does not; I removed fuel pump and opened it up - diaphragm looks good - but internal areas had lotsa calcification build up - I cleaned this out and dried it good - the clear plastic pieces (?diaphragms) aren't broken - the spring w/ steel ball on end moves freely; am putting it back on tomorrow; but can anyone answer about the pump? isn't it supposed to pump fuel through it... to other side... to carb? puzzling
-along with fuel pump: I replaced petcock 3 weeks ago (gas tank had rusty fuel in bottom - cleaned it out prior to new petcock); when I turn petcock arrow NOT to on or reserve, fuel comes out of line; when I turn it to on or reserve, fuel doesn't come out; puzzling
-I don't know what's on back of fuel pump - it's a valve that has a hose coming out of it - looks like it goes to engine/carb - I haven't traced this out yet - what is it?
-can squirt gas on air filter and engine will run for 2-3 seconds then stop - fuel in top of carb (under diaphragm) does same
-it likely needs carb rebuild - will get to this - but something isn't allowing fuel to get from fuel pump to carb
-I THINK it has a mikuni model x carb - diaphragm is ID 26mm OD 68mm - hard to find inexpensive diaphragm, I guess because it's a model x
-last thing - I replaced solenoid due to old one clicking; I HAVE to be charging the battery or it won't start/turn over - battery just goes dead; but if charging, it'll turn over nicely; i'm guessing it's a bad battery
-any help appreciated - I've never owned an ATV before - inherited this beast from grandparent in-law
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