2008 Kawsaki 250 cc bayou I believe

germs · March 16

I have a 2008 250 bayou I got cheap. Real cheap. The guy said I just needed to remove and replace a couple stator rotor bolts that broke off when he was fixing it, not the case. I think he put it back together wrong and drove it. I'm new to this so not sure what all the parts are called or really even how or what has to be fixed. Any help would be greatly appreciated.

**Mech** · March 16

Look the parts up online and it will tell you what they are called, and the exploded pictures will show you where they go.

The exploded pictures in parts places are often a lot clearer about things than the photos in some manuals..

**Gwbarm** · March 16

Thats your rotor and pull start parts, what shape is the stator in .

germs · March 17

Gwbarm the stator looked ok has 1 slight scar or scuff on the contacts about 1/4 in long. My thing is that I like to fix stuff the right way preferably fixing or repairing it. Not Jerry rigged. I don't know crap about clutches or atv motors really.

**Gwbarm** · March 17

I know when to comes to these parts , you might get away with reusing, but I would replace the rotor and stator, can't really tell about the pull starter parts are they all there.

**Mech** · March 17

Are your pictures showing the starter's hub's been bolted inside the flywheel/rotor ? Bad one.

If that's not what haappened, you need to inspect the part that runs on that bit in the first picture, which is the starter's hub.. And that hub in the picture needs replacing. It's for the starter's one way clutch. The one way clutch has a lot of oval rollers that jamb one way, but they have to slide over that hub when the bike's running.. That hub needs to be smooth and polished around it's periphery. If I'm wrong about the hub being inside the flywheel then you also need to inspect(and probably replace) the sprag/oneway clutch.

I can't quite make out what that stuff it that's smeared on the inside of the flywheel/rotor, but if I could clean that off nicely, and the bolt holes are still ok, I might refit that part. It's not a wearing part, if the new starter hub bolts on flat and concentric on the back, and the bolts do up seated in their countersinks properly it will be ok as far as I can tell from a photo. I'd want to clean it up with a scraper though AND run my fingers over it feeling the surface was smooth and fit for the new parts to mate together..

**Mech** · March 17

Oh.. actually.. relooking at that first photo I notice it has it's ratchet pawls on the inside not the outside of it.. The outside doesn't need to be smooth and polished on that.

**Gwbarm** · March 17

Those ratchet pauls look pretty worn, but, I might try it out to see how it works before buying new parts

**Gwbarm** · March 18

I would try to salvage as much of the parts as possible, just looking at OEM parts, really expensive, 1000.00 for rotor and stator, hope the stator isn't damaged, rotor should cleanup all right , you can get the broken bolts out, clean up the ratchet Pauls, couldn't really tell by the photos what else might be damaged. I know you don't want to sink a lot of money into it, or you will have more in it than its worth, Im running into the same problem with my Big Bear im fixing.

**Mech** · March 18

Yup. I'd try to get it going cheap and have a ride and see if it doesn't perhaps any other problems.. well not too many anyway..

A lot of that stuff is non wearing and will be fine. If the windings are not damaged then perhaps new pawls and springs and new allen key bolts.

**Gwbarm** · March 18

You might try used on eBay if you absolutely need parts.

vagoscm · March 18

Did you disassemble these parts or they were already disassembled when you bought the atv? Did you find the bolt which was unscrewed and caused these screatches?