1989 Kawasaki KLF300C Bayou Starting Problems

[Ben Lennon]

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 👍

[Frank Angerano]

Did you change the bendix on the starter? 

 

Welcome to Quadcrazy! 

[Ben Lennon]

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?

[davefrombc]

Double  check the sprag clutch to see if it  may be installed in reverse

[Ben Lennon]

hey Dave there is a clutch on the sprag gear aswell?

[davefrombc]

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 September 7, 2019 by davefrombc

[Ben Lennon]

Hey Dave did some research and my model doesn’t have a sprag clutch could the one way clutch bearing race be buggered?

[Ben Lennon]

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 👍

[Todd Michael]

im having issues with mine starting. just put in new carb but something in the wires is messed up now. fml

[Trent Pierce]

Turns out mine was missing the needle jet and spring, but I still have to sort out the wiring 

[Ben Lennon]

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