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Hi, I have an EU '94 KLF300 Bayou with ignition issues. I got it last summer and used it for about 20 hours, then one sunny day we used it for about an hour, parked it, and then it didn't want to start again. It has a *really* weak spark, I've only been able to see it once while testing.
I'm just getting started on this, I'm going to go through all the weak/no spark trouble shootings from the manual. Since I've already invested like 10 hours digesting the manual and forum threads that I possibly can, I thought that it would be nice to create a thread like this in case I come up with a solution that can help someone else.
So far I've replaced the spark plug, I will replace the spark plug cap with a NGK VD05F (5kOhm resistance). I'm going to check the resistance in the pickup coil, stator coil and ignition coil next. I have tried two CDIs, right now I mounted the original CDI which actually gave the most output to the spark plug out of the two
A question for you, is it possible to make any assumptions about the CDI by measuring the resistance like in the manual? There's a "resistance table" that you can refer to when measuring between the different connections. I'm asking because I haven't yet seen anyone in the forums that has mentioned that they've measured the CDI resistances and made any conclusions from that.
I'll attach a photo of my Bayou
Hi everyone This little monster came to me as a non runner and to sort it for a friend. Had it in bits thrown the service bits at it but nothing, it struggles to turn over unless you put your hand over the intake then it spins like a demon. The valves are adjusted correctly and I am just lost where to go next.
Still working on the 2000 Big Bear with a no spark issue. A lot of this has been covered in an older thread, but I will summarize.
Bought it with the previous owner telling me it needed a new wiring harness, but the wiring harness was in tact and seemed to be fine, except starter solenoid and coil was missing, also the engine was stuck, and no spark plug. Got the engine free and rotating, checked compression, it was 130, not great, but good enough to run. Hooked up a battery, nothing , went through all the wiring and found starter cutout relay bad, replaced that, now I have it rotating with starter. Pulled the plug checked, no spark. Checked start/stop switch, working like it should, reverse relay was bad ,replaced that. Checked continuity from coil to CDI, good, checked pickup coil resistance, within specs, checked anti kickback coil resistance, within specs. What am I missing.
I'm currently pulling my hair out over a customers 98 bayou 2x4 KLF300b. I've changed every electrical component on it twice and in a couple instances three times. Still no spark, I am baffled. Initially customer brought it to me complaining of a hard start no start situation and in fact, it wouldn't start. I changed the starter relay, spark plug, CDI box, and starter circuit relay after which it fired right up ran very well but then started having issues with the neutral switch/light where it wouldn't come on and wouldn't allow it start or even turn over. I found in the wiring harness a loose connection, I got it taken care of and secured and that solved the problem. So now that it would crank up again and run fine I called the customer over to test it out see what he thought as I've never heard it run before and I wanted to get his opinion on how it was running. Customer ride it around a little bit pulled it back on my carport and turned the key off and said it was great, and had never ran better or started so easily, then we set up a time for him to come pick it up the following day and he left. Well where he pulled it on my carport and shut it off was in the middle of the carport so I jumped back on it to park it off to the side, crank it up no problems put it in reverse went about maybe 18 inches and it stalled and ever since that point it has not had spark or run. I replaced the CDI box again with a better brand, I replaced the ignition coil twice put another starter relay on it and I've also changed out the stater and the pick up coil (pick up coil twice) and I'm just I'm lost I don't know what else to do to it. I've had this customers four wheeler for four months now whereas he's a patient guy I need to get it out of here so I can move on to something else. I've seen dozens of threads across different sites for off-road, 4 wheelers, ATVs, UTV's, whatever and they are all experiencing the same sort of issue but they never ever post hear the problem was or the fix. So I'm hoping somebody here has a little bit of knowledge on this particular issue sent since it seems to be so widespread. Thanks in advance for any help or suggestions.
Hi! I'm new to the forums I'm working on my klf300 that isn't starting anymore. I accidentally ripped apart the spark plug cap, and I'm curious to know the resistance of the original part, it's not mentioned in the manuals. If anyone with a KLF300 could measure their OEM or known working replacement spark plug cap I would be very happy NGK for example has spark caps with resistances 0, 5, 10, 15 ohms so it seems to be something that I would like to match as close as possible with the original part.
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