Bayou 220 no power to starter, headlights, dash lights

[Acme54321]

I am trying to run down a problem with my Bayou 220.  I think it's a 96.

The battery has been dead for years.  Years and years.  It pull starts right away and I don't use it a ton so I hadn't bothered to put a new battery in until now.

I've got a new battery in it and now nothing works that should (and used to).  The starter, headlights, and dash lights are all inop.  I've looked at the wiring diagram and done a little messing around and haven't had any luck.

Fwiw the starter works when jumping the relay.  The 4 wheelers pull starts and runs fine.

Any ideas where to start?  

[Ajmboy]

Were you able to solve this? Sounds like maybe a fuse blew or something shorted on battery removal/install.

[Mech]

When you pull start it, and it's running, do the dash lights or headlights work then ?

And if you give the start button a quick push while it's running, does the starter work ?

[Acme54321]

It's a mess but I'm getting it sorted.  The ignition switch was bad which was the root of most issues.  I was going by a Bayou 250 manual that showed a two wire switch, not the 4 wire mine has.  So I wrongfully assumed the switch was fine but it wasn't.  The nuetral bulb did work but at some point in me messing with everything it blew out so that was the issue there.  Now I have everything good but the starter motor or solenoid is bad.  Ordered a new solenoid to eliminate that, comes tomorrow.  Once that's fixed it should be good to go.

[SilverLaker]

On 2/15/2023 at 9:45 PM, Acme54321 said:

I am trying to run down a problem with my Bayou 220.  I think it's a 96.

The battery has been dead for years.  Years and years.  It pull starts right away and I don't use it a ton so I hadn't bothered to put a new battery in until now.

I've got a new battery in it and now nothing works that should (and used to).  The starter, headlights, and dash lights are all inop.  I've looked at the wiring diagram and done a little messing around and haven't had any luck.

Fwiw the starter works when jumping the relay.  The 4 wheelers pull starts and runs fine.

Any ideas where to start?  

Hey Acme, so I had the same issue with a barn rescue 1990 220. 

There are a bunch of places to look, I ended up stripping the bike and going over everything as it is a father son project and my kids will be riding the bike, so I wanted it reliable. I found that my push start switch was intermittent, it was an easy take apart clean up contacts and re install. I also took put the neutral and reverse indicator switch cleaned contacts as well. I took all of the electrical parts and connectors apart and cleaned applied dielectric grease etc. Check the starter solenoid and the round starter relay too. By doing all of these things my system worked again. I need to replace my original starter solonoid as it is a bit crusty. If the lights for the neutral and reverse are not lit up it wont work, means power isnt getting there. The reverse switch involves removing the engine. I needed to do it. In the end I feel like going through the whole system was worth it on a 30+ year old bike. There is no easy answer but if you have the service manual and a multi meter you can check all of the components. My money is on startr relay and solenoid. Check that all of the switches ie ignition and engine stop run are working using a multi meter. It takes time but doing each component one by one you will find the problem. 

Mine is looking like a bit of a mess we plan on painting frame etc plastics and reassembly. Uploading a shop manual if you don't have it.

 

1988-2002 Kawasaki Bayou 220 Service Manual.pdf

[vagoscm]

@SilverLakerLooks and sounds like you made a very good job on your bike. Credits!