1990 Kawasaki Bayou 220 wiring issues

[neilroy87]

I have a 1990 Bayou 220 that runs pretty well for it's age--needs a new muffler, but sounds tough.    Have had to start with a pull cord since I got it, and recently started troubleshooting the start button.  Finding a lot of information on this issue in the forum, but haven't been able to chase it down yet.  Got a new battery, new starter solenoid, and going to replace the starter relay this week, but not convinced that's going to do the trick, since I can't get the neutral light on when turning the key on.  I can start it by jumping the solenoid, but the 2 black wires to the relay do not activate the starter.  Bad ground or a short somewhere?  Is there a good way to just test the ground?

[NRA4LIFE]

If you are not getting a neutral light, you can go to the starter circuit relay mounted on the plastic plate next to the battery. It is in a rubber boot and has a 4 prong connector attaching it to the main harness. The wire colors are light green (to neutral switch) brown (12 Volts with key on) the other two are black (one from the starter button and one to the starter relay). Essentially, the relay is hooking the two black wires together after it gets grounded from the neutral switch.  With the key on and the relay hooked up, ground the light green wire and see if the neutral light comes on. If doesn't I would still try the electric start as your neutral indicator bulb or circuit could have trouble. Another thought, I do know the black wires I mentioned are very light gauge and are prone to breakage. Recently I had a customer that had one broken. It may be a bit before I can get back to you as I am taking care of an ailing wife. 

[neilroy87]

I hope your wife is doing better!  Replaced the voltage regulator today, but didn’t help.  I’ll try your suggestions tomorrow—starting to wonder if the stator might be defective—would that cause the headlights and taillights to not be working either?  Thanks for the help!!

[Mech]

This should be the wiring diagram for the start circuit.. And there is the full wiring diagram as well.. Hope that helps..

I'd start by jumping the two black wires together at the start isolate relay, and then trying the start button. If that works, then the problem is in the neutral light circuit.. bad connection or broken wire somewhere. 

Wires mostly break where they get crimped into the metal terminal, and it can be detected by the way the insulation bends too easily. Handlebar switches also are not well protected and do get dirty contacts.. 

Bayou220Start.pdf output.pdf

[neilroy87]

Thanks!!  I’ll check it out tomorrow and keep you posted!

[neilroy87]

So the neutral light comes on when jumped to the positive terminal, but not to ground.  Do I have something backwards?  I’ll try to upload a few photos later this afternoon.  I appreciate all the help!

[neilroy87]

Cripes…starter solenoid was hooked up backwards.  Fixed that and now it seems to be working when jumping the black wires.  Neutral switch and relay may be bad, but I think I can get it from here.  Thanks all!

[Mech]

Ha..  That could do it alright..

So now the two black wires allow the start button to work you just need to figure why the neutral circuit isn't doing what it should. The power must be getting through the switches for it to be powering the start solenoid, so either the neutral switch or wire is crook. I'd disconnect the neutral switch and short the bike's switch wire to earth as my next test.