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JamesD

1994 Kawasaki Bayou 300 ignition problem.

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Since  it you  have  replaced  everything  in the  spark  circuit ,  it   is time  to  start  checking  again  to  make  sure  none  of the  wires  and connections  are  broken  or corroded. 

Here  is  the  wiring diagram for  your  quad.

Bayou KLF 300 Bayou wiring 1986-2004.jpg

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Note  there  is  a   connection from the  starter  relay to the  CDI  box to   deliver  power from the relay to the  CDI when the  starter  is running . When the  starter  is not running   the  CDI  gets  its  power from the  ignition circuit.

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So are you say it's a broken wire, or you think the starter switchis bad on the handle bars,  or the starter solenoid by the cdi box is bad?

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Any one of them  could be the  problem.  That's  where it comes to  tracing  circuits  and wires  until  the  problem   is  found .  I  can't  point to  any  one   thing and say  "That's it" . All  I  can  do  is  suggest  places  to   look .

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Hey yall I have 3 bayou 300 and 1 rings great 1 has  same issue only start with pull start and last one died no spark all new cdi rectafire starter coil all selanoids and even replaced starter switch assy only get 1 little spark if I messed around with engine stop switch and starter button any ideas have stripped down to frame and cleaned every connection possible any help be great

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