2000 Kawasaki Bayou 300 Occasional Misfire

[Lance Workman]

Bayou 300 has an occasional missfire. I can pull the plug and it’ll spark every once and a while. I’ve read the service manual but don’t understand the testing of the excited. Here is the wire I have coming from the stator area. Also primary winding resistance is high. Thanks guys!

Also it a 2000 year model

[Frank Angerano]

Hey @Lance Workman welcome to Quadcrazy. Do some testing and check the readings on the stator and pick up coil to see where they are.  Do you have the acceptable ranges listed in the manual ?

I would also check your readings on the rectifier/regulator and the  ignition coil feeding the spark plug. 

Also while the engine is running wiggle the wires going into the stator cover to see if any worn areas of the wire are possibly rubbing agains the engine causing a momentary short.   Continue to wiggle wires along the frame as well as it could be a short somewhere along the harness.  
 

Lastly does this happen during wet weather or going through puddles or any particular time like after the engine gets hot?

[Lance Workman]

Engine will not run. They are ohm readings in the manual but I’m not understanding where it’s wanting it checked at.

[Frank Angerano]

Ok so the first pic is your stator wires.  3 of them. Each one is called a phase and they come from the engine side.  Not on the harness side.   

Take a tester and set it to ohms, test the wires (each phase to phase). Call them A,B,C.  So put the test leads on each of the wires one in A and touch B and check your reading and then touch C and see your readings and then B and C. Your numbers between all of the phases should be about the same and that number should be within the range listed in the manual. 

Test each of the phases to ground also.  Phase A one test lead the other to ground on the frame. You should not get a reading. Do that with B and C as well. Any readings from a phase to ground is a bad stator coil. 

The second pic should be your pick up coil.  Two wires.  
Put your test leads on the two wires in that plug and check your readings. The number should be within the range shown in the manual. 

 

[Lance Workman]

That’s what I needed! Thanks! Any idea what the green and red are?

[Frank Angerano]

Neutral safety switch.  They should run down into the left side of the engine? 

[Lance Workman]

Ah yea possibly. So if I’m reading this correctly pickup coil should be 30-300? What exactly is it meaning by that? I know it says 1k ohms. I think I’m mis understanding what my reading should be....

[Frank Angerano]

Your looking on the wrong page. It should show you a stator coil page with a number reading from (example) 0.30 to 0.65 as  a range and if you tested and it came back as 0.55 then its within range. These numbers are only for example 

 

Now the pick up coil should show you the same type of table but a much higher number like 189 to 330 for instance. Try and locate those pages. 
The page your showing me looks like a regulator/rectifier table.

 

 

[Lance Workman]

I’ve went through the manual til I’m cross eyed. That is the only thing I can find. I already have the info for the ignition coil. Which is reading high on the primary winding. But I now need to check the pickup. I’m not concerned with the charging portion of the stator just yet. Does the 30-300 mean 300 +-30 across the bk/w and bl wires? That would be the wires coming straight from the pickup inside the stator assembly. Isn’t the ignition coil ignitor same term as the ignition coil pickup?

[Frank Angerano]

These should be the numbers/pages your looking for.  

[Lance Workman]

What manual did you use to find that? The manual I have from here for the Bayou 300 does not have these pages? Also mine is a 2000 so not in the supplements section.

[Frank Angerano]

My apologies. That was from the 220. Here are the 300 numbers.   I pulled these out for you. 

Should be good with these numbers.

[Lance Workman]

Awesome! Thanks Frank!

[Frank Angerano]

Your welcome!

[Lance Workman]

I still don’t see numbers for the pulse coil?

[Frank Angerano]

Im sorry I didn't see your reply. Pick ip coil should be 390 to 590 range ohms if I'm not mistaken. What color wires are you testing, should be blue and black or blue and black with a stripe?

[Lance Workman]

I got it, pickup coil was fine. Ended up being the CDI box hopefully. Ordered one, so we will see.

[Frank Angerano]

Wow good news.  Expensive but good. 

[MarkinAR]

@Lance Workman I assume it will occasionally spark when using the electric start?  And I bet there is no sign of spark if you rip the pull start?  Occasional spark, especially when letting off the push start button generally indicates bad CDI as the spark is actually spare voltage leaking off from the battery when you let off the push start button.  I've seen quite a few Honda 300's with spark only when letting off the start button as I described.  Wonder if the Bayou will do that too....

[Lance Workman]

The CDI box had no resistance between any to pins. It was totally dead.

[Lance Workman]

Parts finally arrived. Will update whether it fixed it or not!

[Frank Angerano]

Cant wait to see how this goes.  Definitely post some pics and keep us posted.  

[Lance Workman]

Was fixing for a buddy. It started but smokes. Super bad.... and has engine noise. I think he’s gonna cut his loses and quit sinking money into it. Even has some engine noise.