1998 Kawasaki Bayou wiring help

[Andrew Baker]

I need help with wiring on a 1998 (I think, 10th digit of the VIN was W) Bayou. I'm not getting spark, I'm pretty sure it is due to grounds being off because the harness is pretty hacked as far as the electric start and charging system goes. I'm needing a good wiring schematic. I found one online and there are a few things that don't add up on it so I'm skeptical that it is really for my year and model. Any help would be appreciated. Thanks. 

 

[Frank Angerano]

Hey @Andrew Baker welcome to Quadcrazy. So what’s going on with the harness you said it’s hacked up pretty good.  Do you know whats missing or disconnected etc ? I can help you out but need to know what’s left of the harness and where you need help. If you can, post a few pics of the areas that are hacked up and in the meantime I will get you a diagram to help you along so you can figure out what’s going on.   

[Andrew Baker]

22 minutes ago, Frank Angerano said:

Hey @Andrew Baker welcome to Quadcrazy. So what’s going on with the harness you said it’s hacked up pretty good.  Do you know whats missing or disconnected etc ? I can help you out but need to know what’s left of the harness and where you need help. If you can, post a few pics of the areas that are hacked up and in the meantime I will get you a diagram to help you along so you can figure out what’s going on.   

Thanks. So, the wiring that goes to the starter solenoid and the battery is snipped. It seems that the red feeds the lights and the Black/Yellow is ground. I know that one Black/Yellow, White, and Black will go to the solenoid, and IF the Red feeds the rear lights then that leaves 2 Black/Yellows. Is that the ground for the rear lights? I guess my main question is, would not having all the grounds prevent me from getting spark? I thought the spark would be generated directly from the flywheel trigger. But then again, most of my experience with this stuff is on cars and not ATVs. Especially non Chinese ones. 

 

Edited November 10, 2019 by Andrew Baker

[Frank Angerano]

Is it a 220, or a 300? Both are pretty much the same diagrams but I would like to be sure which one is for your bike because of the red wire for the lights.  

First things first do you have your dash lights and neutral lights working? If so great then let’s move on to the solenoid. 

On that solenoid there are three wires; white (comes from ignition key switch), Black (comes from the start circuit relay) that’s the relay that allows the bike to only start when it’s in neutral, and then the black/yellow stripe (general ground) 

Depending on what model the bike is the small red wire comes from the battery or from the switch on the handle bar. Either way it’s for the rear  lights.

Front lights are red with a yellow stripe if I remember correctly.  If you have a red wire near the battery then It goes to the positive terminal and should have an in-line fuse. 

I would have a tester or test light ready and turn the key on, put a tester on the white wire at the solenoid and see if it’s 12v+ If not then you have to go to the back of the ignition switch. 

The black/yellow stripe runs through the harness and is the general ground for everything on the bike including lights. 

Keep in mind that the start solenoid has a fuse on it also so double check that’s good before you do this and have an extra fuse or two. 

I’m heading upstate for the day but start there I will try to get back to you with a diagram once I know what size the bike is.  


 

[Andrew Baker]

Thanks. It's a 220. I don't have the ignition because it was taken off. However I have the brown and white wire connected to each other to complete the circuit. I do not have the starter relay yet. It is on order. I'll check back in once I have the stuff. 

[Frank Angerano]

Ok great. I’ll have a highlighted diagram to take you through it. Btw amazon has that ignition switch if you need it. It’s like $15 bucks.  

[Andrew Baker]

Still no spark. I know I have the wiring right. Coil maybe?

[Andrew Baker]

Actually there is one other thing. I have seen a few diagrams and they all have 5 wire CDIs. My has 6 wires. I have a grey wire that has been cut. What is this wire for?

[Frank Angerano]

That grey wire goes from the cdi to the ignition switch.   

[Andrew Baker]

2 hours ago, Frank Angerano said:

That grey wire goes from the cdi to the ignition switch.   

I don't see that wire in any diagram. Also, my ignition was only 2 wires. A white and a brown. Also, I have a 1999 Bayou 250 as a parts bike and it doesn't even have that wire. Can that wire be deleted?

[Andrew Baker]

Also, I am not getting continuity between my two pickup coil wires.

[Frank Angerano]

Here’s the diagram 

[Andrew Baker]

Thank you. But could you please explain the ignition wires? I have a brown and white wire. when I hook up the ignition, the neutral light comes on like it is supposed to. Also my other quad does not have that wire. Thanks. 

[Frank Angerano]

I just realized that diagram is the Europe model. Hang on a sec 

[Frank Angerano]

This is the US diagram. Sorry about that mix up. You might have them wrong cdi if that’s what you purchased or that atv is the Europe model which I doubt.   

[Andrew Baker]

This is even more confusing. On top of the fact that my ignition is 2 wires and not 4. My CDI box doesn't even have a 7 pin plug. Only 6. 

[Frank Angerano]

it will be fine. Just need to figure out what diagram fits your atv. Can you post sole pics of the cdi and the ignition. Make sure there aren’t any wires that your  not seeing that may be disconnected?

Edited November 17, 2019 by Frank Angerano

[Andrew Baker]

Ok try to walk me through this. First of the CDI from my 250 had the same numbers on them as this 220. The 250 has no grey wire in the harness and the 220 does. My ignition that came from my 220 had/has a brown wire and a white wire. Now when I wire the brown and white together to complete the circuit, my neutral light comes on as intended. So it seems to me that this is correct. Also, that diagrams shows a yellow/red wire going to the ignition and I do not have a Yellow/Red wire up front. It's not even in the legend call out in that diagram either. Is the KLF different than the Bayou? 

Edited November 17, 2019 by Andrew Baker

[Andrew Baker]

This is the ignition switch that was on it. 

[Frank Angerano]

Ok I’m looking now 

[Andrew Baker]

Should I be getting continuity between the 2 pickup wires? I do on all my other vehicles but not this one. Maybe bad pickup?

 

[Frank Angerano]

If it’s new it should be fine. What you should get is a reading on ohms setting, if not then there is a problem. 

I am looking at diagrams for you.  I will be in touch.   

[Andrew Baker]

It is not new. If fact, I think it is the original 1998 coil. I'm getting no more that 15.8 ohms of resistance. Should it not be more like 130 to 150? That's what it is on my buggy. But that is a1 50cc GY6.

[Frank Angerano]

Sorry it took so long I’m up hunting and it’s hard to get a good signal up here and the time to look. 
Attached is a page for the ranges of all the coils etc.   Also all the diagrams I could find. It’s about 6 of them and because you don’t know exactly what bike it is yours is then your going to have to compare each diagram until you find a match.   
Can you see the vin number clearly ? If so then post it. Maybe we can find out more.  

[Andrew Baker]

Thank you for your help. So far I have it wired correctly but still no spark.  I know the pick up coil to be bad so I replaced it and yet still no spark. I have pretty much replace everything except the stator. Would a bad stator cause a no spark issue?

 

[Frank Angerano]

Absolutely 

The new stator will or should come with the pick up coil as well.   
Stators go bad from a few different things but mainly from trying to jump the bike with a car or welding on the frame without disconnecting the stator and installing the battery wires backwards.  

[Andrew Baker]

Thank you for your help. So far I have it wired correctly but still no spark.  I know the pick up coil to be bad so I replaced it and yet still no spark. I have pretty much replace everything except the stator. Would a bad stator cause a no spark issue? I'm getting 0.7 ohms of resistance between the yellow wires from the stator. 

 

[Frank Angerano]

Check each wire from the stator to the ground on continuity and see if you get a reading. One lead of the tester on one of the yellow wires and the the other lead of the tester to a good ground.  If you get any kind of a reading on continuity or ohms then there is a problem with the stator.  As far as the 0.7 I would have to see what the specifications for that atv call for. But do that test first and see what happens.  

[Andrew Baker]

All open line and no continuity. I'm so stumped. Now I will say that I do not have the starter relay on it. It is still in the mail. But I do have the white wire that goes to the relay hooked straight to the positive side of the battery

 

[Frank Angerano]

That white wire on the positive should send voltage to the harness.  Have you checked that it’s going through the ignition and feeding the brown ?