1996 Kawasaki Bayou 220 no spark HELP PLEASE!

[Brother Buddy Gardner]

Hello everyone! I recently purchased this quad for a mere 300.00 and it is pretty clean for the year. I bought it from a guy who bought it in a storage unit. He didn’t know anything about it. I got it home and noticed it did not have an ignition coil for the spark plug. I bought the ignition coil, a new battery, new CDI box, new starter relay, new safety neutral relay, new carb and so on... I got it to turn over, but when I pull the plug and check for spark I have nothing.. it has a non factory starter button that works when I push it and turns the engine over no matter if the key or stop switch is on or off..not sure what that’s all about, but it does turn over..just no spark at the plug. Any help would be greatly appreciated! Thanks!

[MarkinAR]

Sounds like wiring gremlins.  The starter button would only work regardless of key position if it were wired around the key.  If key was off and button still worked it would likely not have any spark.  I would put the original CDI back on because I am assuming you bought a $30 chinese one?  Those only work about 10% of the time.  My first step would be try original CDI and then move on to a wiring diagram and work through each wire.  Those are really simple bikes to work on, I've had several. 

This is a youtube video but has the clearest wiring diagram I can find.  Just pause it and screenshot.

 

[Brother Buddy Gardner]

I appreciate the advise, and yes I bought a Chinese CDI so I will put the original back on and go from there. Thanks again!

[Brother Buddy Gardner]

I put the original CDI on and still no spark. My push button that the previous owner put on is wired directly to the starter solenoid, one wire on each side.

i do have a question tho...the ignition coil that goes to the spark plug that I bought has 2 terminals..one has a green marker at the bottom..I assumed that the green and white wire goes there and the black and yellow goes to the other. Is this correct? I consider myself somewhat mechanically inclined, but a 4 wheeler mechanic I am not 😬so pardon me if I ask stupid questions but I have tried all I k ow to do at this point..

[MarkinAR]

I would think so but not sure without seeing it.  Normally the black wire is closer to the outside if memory serves correctly.  The fact that the push button is directly wired is odd, that means some parts are taken out of the normal flow.  I'd run it down with the wiring diagram and put it back to normal before doing too much digging with the no spark.  It might be that the CDI is simply bypassed since there has been some wiring changes.

[Brother Buddy Gardner]

Thanks I really appreciate it.. so I guess just start at the front one wire at a time and work my way back correct? Just look for breaks in the wires and re-wire it back to factory specs and see what happens huh?

[MarkinAR]

Pretty much. I usually start at the battery though and work forwards. 

[Brother Buddy Gardner]

Thanks Mark, you da man..I’ll keep you posted! 👍🏼👊🏼

[D3monic6]

Hey brother buddy Gardner if you want I am having the same problem with my bayou I went and got the book on it I can send you the wiring schematic so you can print out and go from there

[Michael Kastanis]

Ok

[Brother Buddy Gardner]

My brother D that would be awesome and I would appreciate that

[BillyRey]

Did you ever get the no spark fixed?