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By 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 👍
By 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.
Got a good deal on an 89 bayou 300. Couple questions. First is in the picture I have posted. Note the two wires at the bottom of the pic (white and black/yellow). They were not hooked up to anything and Im not sure if they are supposed to go to the battery or somewhere else and what they are for.
Second question is I had the carb apart for a cleaning. The vaccum operated slide has a spring under the cap with a plastic clip that goes inside the spring. Is there a proper location inside the spring for that clip. Right now it is just below half way inside the spring.
It runs alright but keeps fouling the plug. Pulled the plug off, cleaned it and dried it off and it starts back up but not sure how long before itll do it again, last time it was about 20 minutes of riding and it bogged out and wouldnt start.
these are what i have in my collection ... always looking for more
1981 - 2008 ATV HISTORY
1986 - 2006 Kawasaki KLF300 Bayou Service Manual
1988 - 2002 Kawasaki Bayou 220 Service Manual
1994 Kawasaki Bayou 220 Owner's Manual
1997 - 2002 Kawasaki Prairie 400 Service Manual
2003 - 2005 Kawasaki KLF250 Bayou Service Manual
2003 Kawasaki KVF360 Prairie Service Manual
2004 Kawasaki KFX700 V Force Service Manual
2004 Kawasaki KVF700 Service Manual
2005 Kawasaki KVF750 Brute Force Service Manual
2005 Kawasaki KVF750 Brute Force Service Manual
2006 Kawasaki KFX80 Specs
2008 - 2009 Kawasaki KVF750 Parts Manual
2008 Kawasaki KFX450R Service Manual
2008 Kawasaki KVF750 Brute Force Service Manual
I am in need of a manual for my KLF 300 Bayou 4x2 . I've found others on here for the 4x4 model, but was wondering if I need a separate 4x2 manual. Does anyone know?
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By Chris Simpson
Got a 99 or 2000 bayou 220. Its started making alot of noise, then the starter would spin freely. Took it apart and determined the three bolts in the starter clutch had sheared. Installed the new starter clutch and in the process, not realizing that Japanese motors turn counterclockwise, I turned the crankshaft clockwise about a half revolution so that the key holes would be on top of the crankshaft for easier installation of starter clutch. I get everything back together and try it. The pressure is so great that its very hard to pull with the pull start, the electric starter turns it over but it struggles greatly. A key issue could be this. When I engage the choke the starter will barely turn it over and you can't pull start at all because there's so much pressure. Like the back pressure cant be released once the carburetor is choked. I'm pretty sure by turning the crankshaft clockwise I screwed something up but I cannot figure out what it is. If there's anyone that can give some advice it will be greatly appreciated.
By Daniel Gibson
Working on a bayou 220 that has been ran extremely hard it's whole life. Literally had almost an inch thick dirt/oil covering the motor. Yeah that bad. Surprisingly it runs though. I cleaned the carb and tank multiple times. They're clean enough to eat off of. Readjusted valve lash and set timing. Was about 3 teeth off. It cranks good and runs good only problem is I have to cover the carb intake basically choking the hell out of it for it to start. The com choke works fine. It does this each time I start it regardless of temperature both ambient or motor. Wth? Compression is at 115psi I get 130s if I put a little oil in the piston chamber. Please help. Thanks
By Dwight Williams
Hey everyone, I've been scratching my head over this for most of the day. I bought a couple of Bayou 220's, got them running (they've both been sitting), and started tweaking and fixing small things. One of them is mostly done, the other had an aftermarket carb on it and I've been trying to sort that out.
Anyway, while adjusting the carb it died a few times, I restarted and moved on until it died and wouldn't restart. I figured maybe I'd flooded it or something - after further attempts I realized I had no spark. Since I have two identical machines I have many parts at my disposal. I've swapped the CDI, spark plug and coil with no luck. I have good resistance readings from the stator and pick up (135 and 110 respectively), I don't have a peak voltage meter but I measure around 53VAC on the stator when cranking. I have a 4 wire stator, not an alternator like the newer ones. Grounds look good, I've checked the kill switch by verifying that it and the ignition switch grounds the black/yellow wire to the CDI. I can turn the engine slowly and see the pickup short the meter as well, seems normal right? So far everything I've checked looks the same on both machines. I've got the service manual and wiring diagrams. Do these readings make any sense? I'm obviously missing something but I'm stumped. thanks!
Let me start with I have about 30 years of ATC experience, but not much with stuff made after 1988. Some, but I'm mechanically inclined so it's all good. I"m rehabbing a 1997 Bayou 220 to send back into the wild and the mechanicals are now all good, just working on making the electrical system...electric. Right now, I have no power on the white wire as tested directly on the plug at the starter solenoid. I'm assuming that wire is supposed to be hot any time it's attached to a battery? The genius that had it before snipped a couple wires and inserted a fairly heavy push button for electric start bypassing the electrical system. I think i've corrected everything north of the solenoid but the white wire has me stumped. Is my assumption that this should always be hot with a hot battery correct? Does this indicate a broken circuit in the starter solenoid? Relay was also bad and wired incorrectly, but that's resolved and I can make the relay click bypassing the solenoid and connector, directly giving the white wire 12V. Thoughts?
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