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1911Neil

1998 Kawasaki Bayou 220 project

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@Michael Rogers If you're putting in a new valve, don't forget to lap it.  The chances of the angle on the new valve matching the old head is about 0%.  Might as well lap the other valve while you have it apart.

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15 hours ago, Michael Rogers said:

Glad to hear of your success. I'm waiting on my valve to arrive today to see if mine will start once I put it all back together.

Thanks. I got lucky with my motor. With everything else going on with mine, I probably would have scrapped it if I had engine trouble too :)

@MarkinAR 's advice on lapping the valves sounds like a good plan. I hope it works out. I'm assuming this is in reference to your 2000 220 Bayou cam, valves, timing thread. I'll be watching that thread for updates.

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I got the new exhaust studs and nuts today. I should have my new lefty drills/extractors tomorrow. The intact stud came out really easy even being bent quite a bit. Glad I bought a set. I hope the broken stud comes out as easy.

I changed the oil and filter. The oil was very dirty. I changed the rear diff lube again. It was still pretty dirty . I'll keep changing it pretty regularly until it starts to stay clean. I also put slime in the front tires and pulled a nail out of one of the rear tires and plugged it. All are still holding air after a few days.

I pulled the rear wheels again. I originally thought I could live without replacing the bearings but I'm going to have to add that to the list. Both sides are pretty sloppy and the seal on the right side is shot, which trashed the brake shoe. Guess I'll go ahead and replace the brake shoes all around. They're cheap enough. Hopefully I can salvage the brake cables.

After all that, I'll start on the front end. The kingpins are shot and the alignment is off. This free 4 wheeler is getting kinda spendy. ;) 

 

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You may never get the rear diff to look clear because bearings and even the dry upper 75% of the ring gear tend to rust if they sit long.  I'd just ride it a while and come back later and change it.  Chances of the bearings getting a bit loose are high too if it sat for long so you may need to go back into it with new bearings and seals after it's ridden a while.

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