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JamesD

1994 Kawasaki Bayou 300 ignition problem.

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I am having what I think is ignition problems. My 1994 Bayou 300 seems to flood very easy when starting. At first I thought it was a carb problem but while testing the spart I noticed that there is no spark while the engine is turning over. When you let off of the ignition swith there is one spark. But only when you let off of the ignition switch. It has a new coil, plug wire, and plug. Any ideas? I dont know if it is the ignition box, or maybe the ignition switch. Any help would be appreciated

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I am having what I think is ignition problems. My 1994 Bayou 300 seems to flood very easy when starting. At first I thought it was a carb problem but while testing the spart I noticed that there is no spark while the engine is turning over. When you let off of the ignition swith there is one spark. But only when you let off of the ignition switch. It has a new coil, plug wire, and plug. Any ideas? I dont know if it is the ignition box, or maybe the ignition switch. Any help would be appreciated

Did you find out the problem with your Bayou? The one spark when you let off the starter button? Please let me know as I have the same problem.

Thanks,

Edward

Edited by DirtDemon
member posted same addition in his next post

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It sounds like a faulty cdi box.

* Adjusted thread title.

I too adjusted the thread title, it sounds like an ignition problem not a flooding issue.

On that note, I think the problem is in the primary starting curcuit, maybe a short that is rendering the primary ignition system inoperable while engaging the starter. First try jumping the solenoid, if it works, then you know that every thing between the solenoid and starter is ok, and there is probably an issue between the start button and solenoid. Might try checkin the battery cables and connections too, just because. If that doesn't work, try pull starting it. If either of those things works, then you know that there aren't any problems in the secondary ignition.

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I am having what I think is ignition problems. My 1990 Bayou 300 seems to flood very easy when starting. At first I thought it was a carb problem but while testing the spark I noticed that there is no spark while the engine is turning over. When you let off of the ignition switch there is one spark. But only when you let off of the ignition switch. It has a new coil, plug wire, and plug. Any ideas? I don't know if it is the ignition box, or maybe the ignition switch. Any help would be appreciated

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Wow, this seems to be a regular problem with these machines. The previoust poster, Edward67, fixed the same problem by replacing the pulsing coil. It is what generates the ignition signal from the rotor portion of the stator assembly. Click this link and look at part #59026. You may want to shop around a bit for a better price, you may find a better price on Ebay.

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i have the solution

change your oil and clean your stator with break cleaner and inside of your flywheel, put new oil and bingo

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Ok, I just bought a 1994 bayou 300 2x4. The guy said he put everything new (used) on it except for the coil and the atv only fires sometimes. He said that the ignition coil is bad but I dont think that is the problem. I took it to the Kawasaki dealer and he said that its more than likely the cdi box or stator. Does anyone know what the deal is? I havent been able to get it to fire. I've heard it hit a few times but not fire up. Thanks

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well it has been my experience that a cdi box will either work or it won't. there is no itermittent with an ignition cdi. i would check for a bad wire between the cdi and the coil. if that is ok then i would probably put the coil on it. i have seen alot more coils do what you are describing than anything else.if everything else is new then i would put a coil on it then you know all of your components are new.

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yeah the same thing happens to mine sometimes but when it dose i take my knife or a wrench and tap on it or wiggle the wires then it usually fires up

hope it helps let me know if it dose

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if you guys disconnect the plug and tighten the connectors in the plug (female side) and then clean them and put them together it might completely eliminate your problems. i was always taught in automotive school to always check your connector/conections first. they usually cause approx 70% of all electrical problems.

your friendly neighbourhood mechanic

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If you get a repair manual, it will have directions and specs for some direct resistance tests for the coil and the stator, and possibly other ignition parts. If you can find a problem with a part, or rule as many possibilities out, you will be left with a better idea of what could be wrong. As far as CDI boxes go, the fail in many different ways. Sometimes they work and stop working when they get warmed up. Sometimes they just work intermittently. Sometimes they work consistently, but it won't let the motor rev past a ceartain RPM. The can be very fickle devices. Rule out as much as you can, by testing what you can and go from there. Used igniton parts are always a bad idea IMO. You never know what you are going to get.

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I have the same problem with my 2000 . I have a repair manual and I have been doing

resistant checks and so far the ohms I am getting dont match the ones in the manual for the CDI. The pickup coil shows in range it that it should. 419 ohms. I am starting to think the CDI is the problem. Will find out more tomorrow when I go to KAW. shop.

Dave

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Well I contacted kawasaki today and that was a waist of time. I asked them if they could check my cdi box and they said they didnt have away too. They told me I would have to buy another new box for $380.00 and there is no returns on electrical componence.

That SUCKS.....

Is there any after market boxes that would work.????

Dave

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I don't know that there will be too many aftermarket CDI boxes for your machine, if any at all. I do know that you can get that same OEM unit from an online retailer for considerably less. Try, these sites and compare prices. ServiceHonda.com, Babbitsonline.com, and Bikebandit.com. All of these should have better prices than the dealer, most around 30% less, but all have better prices than one another on different parts, so it would be beneficial to check all three and maybe a few others that you find. If all the other parts check out, and you know your plug is good, and you have made sure all your switches and wiring is intact and working properly, then I think it would be somewhat safe to conclude that your CDI is the problem. I would not recommend buying a used one, there is usually no guarantee that it will work, and even if it does and first, you never know for how long. New is the only way to go with electrical components IMO. Good luck.

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hey DirtDemon,

By chance would you know what the average AC voltage should be that the pick up coil

puts out. I am getting .90 of a volt on the my pickup coil while the engine is cranked over.

The Clymer doesn't give that only what the ohms should be and they are fine.

Dave

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