1988 Kawasaki Bayou 220 No Spark

[John Brucato]

Hi all new to the sight haven a problem with my 1988 kawasaki bayou 220 it ran then just died when out one day get gas but no spark any info will help I'm new to the ATV got it used and ran like a champ but don't know where to start when it comes to this

Edited December 24, 2019 by Ajmboy
Added issue to topic title

[Ajmboy]

Welcome to QUADCRAZY! Does the starter crank fine, just no spark? Have you taken out the plug to test? How did you test for no spark?

[John Brucato]

It cranks over no problem has no spark tested it alongside the head it's a brand new spark plug trying to pull start it same thing

[Frank Angerano]

Maybe do a little simple testing on the kill switch, ignition switch and  stator coil. Could be something  simple. First start at the kill switch by opening it up to make sure there is no water inside. Second wiggle the ignition key and see if that works, sometimes the contacts inside wear away a bit so wiggling may show spark hence a new ignition may be needed. If not lastly you have to do a test on the stator coil and ignition coils.  
All of the above testing needs to be done with a tester so of your somewhat familiar a tester it should be no problem.  

[John Brucato]

So when trying to start bike today I found a bunch of the wiring harness was burnt all together I called my local bike shop and just my luck they can't get me the wiring for it they can get everything else but that so my new problem is the wiring spent hrs up and down the net looking for a wire diagram with no luck so if some one can help me out with that this would be great

[Frank Angerano]

Well that's kinda good that at least you found the problem. Is it localized to one area that you can just cut out the bad stuff and splice in new ? In addition to that you have to also fond out why it happened in the first place.   
I have a few diagrams for that atv but there are a few different models.  What area of tye harness is burnt up ? Maybe post a few pics.

[John Brucato]

At this point I just wanna start off all fresh with the wire I started to test the wires and there is no point trying to Mickey mouse by cut and replace just go all new only thing I can still use is the connections

[Frank Angerano]

Its a 88 not 98 correct? Sorry to ask again but I was half asleep this am when i read this.  I agree with putting all new wiring in but if you cant find one then you have to make due.  There were other kawasaki atvs that the harnesses were the same. Maybe the lakota.   

[John Brucato]

It's a 88 klf 220

[Frank Angerano]

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F402002537146
 

[John Brucato]

Thank you I found that one too but it seems like it was beating hard and put away wet if I pay that much money it's not guaranteeing that that wiring harness is still good

[Frank Angerano]

Listen its a wire harness. Its not rocket science. Its dirty at worst. Plus the seller has a 100% positive reviews page.  
 

A spray can of contact cleaner on the plugs, fresh tape and dialectric grease on all plugs after its all re wrapped in tape and its a new harness.  As long as its not burnt up its fine and by the pics and the sellers history he knows what a burnt harness looks like. 
Even if you were to build your own and i have on many which worked great and felt great to actually build one but, the time spent (2 days minimum), effort and roughly about $50 bucks in material it would be cheaper to put the oem harness on.   Not trying to push this on you just trying to let you know I've been down the path before and what worked out the best.   
 

[D3monic6]

Hey guys it's been a while but trying to take a crack back at the wiring of my kawasaki bayou 220 just don't know what gauge wire I should be using I'm starting from scratch and don't wanna go to big bit don't wanna go to small with wiring as I don't wanna have to go through this again

[Arizona]

All the harness repairs i do i use 14 gauge, if i was making a harness from scratch

i would probably use 12 gauge. I just redid a bayou 220 with melted wiring, missing

the starter relay, the ign relay mostly all wiring was gone was just left with 5 strands

of wire out of the main harness, Just get a diagram take your time. I used a sharpie 

to hi light the circuits i was working on, makes it a little easier. Good luck Az

[D3monic6]

Thanks I found on Amazon 16 gauge wire color coded to the book and should be good next thing for me is have to get a new shifter shaft and put that in got all new seals for when I do it just have to get some money up and the time to do it will keep posting on the progress