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2000 Kawasaki Bayou 220 - Bad Cylinder?

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Well this is my first time tearing down an ATV. Have done a little work on 2 stroke's in the past, but not much. I'm needing some help. I've got a Bayou that has lost compression. I tested it, and it was like at 40psi. I had already set the timing on it, and it does have spark fuel, etc...

My question is about the cylinder. To me it looks pretty toasted, but need some help in determining. It is a 2000 Kawasaki Bayou 220. I bought it not running, just to see if I can get it running so it has not ran since I bought it. This question is about the cylinder, and part 2 I have will be about the CAM.

Any advice / help is greatly appreciated.

Inside sleeve a line(left line) runs the length that I can feel with my fingernail. The line on the right I can't feel.



Some rust it looks like on these two pictures.




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  • Michael Rogers changed the title to 2000 Bayou 220 - Bad Cylinder?
4 hours ago, gillies_robert said:

looks pretty polished with little to no crosshatch left, measure your clearances, chances are it will need to be bored oversize. are there signs of burning oil or was it just low compression?

What signs would I look for on burning oil? I bought it not running and the guy said he didn't know anything about it. I wanted a challenge and it was a good one to start with.  Thanks for the help

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That rust line looks like its below the rings so it should be ok. It's pretty worn so you might want to check it with a bore gauge. 40 psi was probably due to a ring stuck on the piston bc thats pitiful compression. If it's in tolerance hone it a bit to give it a good crosshatch, set of good rings and I bet you get compression back. 

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assuming the valves are sealing too ;)

2 hours ago, Michael Rogers said:

What signs would I look for on burning oil? I bought it not running and the guy said he didn't know anything about it. I wanted a challenge and it was a good one to start with.  Thanks for the help

heavy carbon buildup on plug, and exhaust valve and port. post some pictures of piston and rod will tell a little more of what happened with this engine.

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  • 4 months later...

Sorry it took so long to update this, I am getting lazier as I get older...

This bike was bought with the owner saying it had jumped timing. With the awesome help on here this is what I found and did to fix it.

No compression. Due to the timing jump it bent the intake valve and the rings were worn out.

Replaced valve, honed cylinder and installed new rings.

No spark issue, replaced CDI box and ignition coil.Installed new spark plug.

Other items replaced as identified. Starter solenoid, could jump across the terminals to start. Carburetor replace DC,  tried cleaning the old one but still didn't work right.

$23 carb

$7 ignition coil

$23 cdi

$7 starter solenoid 

$3 spark plug

$ 40 ring and gasket kit

$16 valve

$10 stator cover gasket (nothing wrong just opened it up to see what was in there)

$20 oil change.

Rounded up on the prices. Hope this might help someone. And, I appreciate the help.


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