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Ben Lennon

1989 Kawasaki KLF300C Bayou Starting Problems

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Hi guys new to this forum and thought I’d jump on as I’ve just bought my first quad a Kawasaki bayou klf300c 89 model. It had starting issues when I bought it so I’ve gone thru and replaced the cdi, voltage regulator and starter solenoid aswell as rebuilt the starter motor after all this it was still free spinning on electric start so I pulled the stator cover off to find the fly wheel wasn’t spinning so replaced the one way clutch bearing put it all back together and still not engaging at all. I’m at a loss and looking for some ideas on we’re to look next to solve the problem

cheers Ben 👍

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Hey frank I didn’t replace the bendix just put a brush kit thru it. And looking again last night the starter sprag gear and chain from starter is spinning  it’s just not engaging the fly wheel. Could it be that the bearing race on the fly wheel for the one way starter bearing is worn and that’s why it won’t engage?

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The  sprag is a clutch.. It  is a special assembly that  locks up in one direction and free wheels in the  other. I don't know about your machine  but on many the sprag  can be  put in  wrong side out  so the starter can't  lock it up to  turn the motor over. They are built  with   rollers  that  are made to lay  flat when spun  on way  and   rotate  to  lock to the  outer  part when  spun the other..  Search on "sprag clutch"  to  see what I mean.

Edited by davefrombc

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Hey Dave turns out the bearing race on the one way clutch was worn so after replacing that and reassembly it started working the way it should thanks for your help and advice 👍

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Yeah mines turning over and has spark so I’m moving to the carby next to see if that’s the problem although I’ve cleaned it twice 

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