2001 Kawasaki Bayou 220 KLF220A Ignition Switch

[TravisM]

2001 bayou 220 KLF220A

Need some help putting a new ignition switch on this thing. I'm not finding homes for all the wires. I can hook up the white wire and brown wire, But the switch has a B/W and Solid Yellow wire i can't find a home for, and there aren't any more wires in the vicinity from the harness that match this, except one red wire with a double female end crimped on, and a few B/Y grounds. None of the wiring diagrams i've founder or have been given match.

I'm also wondering if i have the wrong switch? some switches appear to have 4 wires and other just 2, the Brown wire and a White wire.

I'm at a loss here. Thanks.

 

[Mech]

This is what my book shows for the 2000-2002, but the older models in the book are the same.. Just two wires.

output.ps

The book shows a four wire switch up to 1995...

[TravisM]

That download isn't working for me, for some reason. but it does stand to reason i may need a 2 wire switch, as all i have is a white and brown available on the harness.

[Admin]

@TravisM I converted that .ps file to a .jpg and added it to the post. You should be able to view now.

@Mech .ps files aren't easy to open for most, without a program. I edited your post and added the converted file. I used https://convertio.co/ps-jpg/

[Mech]

Oh thanks, sorry about that. I thought it had saved as PDF.

 

[TravisM]

That wiring diagram looks like alot more like what i have on the machine. THANK YOU!

[TravisM]

Replaced the key switch, CDI box, and igniter, WE HAVE SPARK! just need to slap a carburetor on this sucker,and some new fuel line and tires.

What do y'all recommend for crankcase oil? assuming it has a Wet Clutch, so probably Valvoine ATV 10w40 will be my choice.

ju

Edited October 5, 2023 by TravisM

[Gwbarm]

Valvoline is good oil, i have never used their ATV oil, i have been using Yamalube mineral oil, it has the best rating and is not that much more expensive than any other, i have also used Suzuki Ecstar in my Suzukis no issues. I have also used Rotella and Castrol no issues with any of them.   

[TravisM]

Well since i got spark, before i put a new carb on and all that, i figured i'd see if it'd pop over on some starting fluid.. gave it a squirt through the carb.. no go. made sure i had spark. i have spark. put a new plug in. Gave it a shot in the plug hole. no fire.

What gives?  I know i have fuel (since im introducing it directly), i have spark, a new NGK plug...

[TravisM]

Well, it seems now i have no spark.... rechecked it.....

How can i go from having no spark, New CDI, Igniter and Switch, get spark. leave it alone for a day, come back. no spark.

[Gwbarm]

Thats Bad, I think the first thing i would do is check all my connections and make sure they are good and tight. Im sure you have done that already. Does everything else seem to be working correctly, just no spark.

[Mech]

Some of the starting fluids have something like kerosene in them, and it may have drowned the spark plug. I'd try another plug.

[Gwbarm]

Kerosene, well that doesnt burn very well, i thought ours are  mostly ethyr, maybe wrong, i dont use it much.

[TravisM]

https://www.oreillyauto.com/detail/c/valvoline/valvoline-starting-fluid/valc/602373/v/a/106196/atv-utv-atv-utv-2001-kawasaki-klf220-bayou?q=valvoline+starting+fluid&pos=0

this what i was using. But, i have no spark anyway.... i'll double check all my connections again.

[Mech]

Check the kill switch too..

[Gwbarm]

Wow! That stuffs really gone up, i think the last i bought was maybe 1.99 a can

[neilroy87]

How often do the starter switches go bad on these things?  I can jump from solenoid, but nothing at the start button--also don't have neutral light or headlights/taillights...chasing some odd electrical