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I had a quad fall in my lap a couple weeks ago. The only things I knew about it was it was a Kawasaki Bayou 220, was in pretty rough shape and was free. I couldn't say no to a fun little project. I've been looking a different ATV forums gathering quite a bit of info and decided this was the one I wanted to join.
Thanks to this forum, I found the VIN under about an inch of mud and cross referenced it to be a '98. It had been sitting outside for at least 5 years and was told it ran when parked, but had no brakes. Squirrels or mice had been chewing on the handlebar controls and it's generally just kind of beat up.
So far, I've gone through the carb (not near as bad as I expected), freed up the brakes (will probably need new cables), replaced the spark plug, air filter, petcock and put a new battery in it.
The gas tank had been empty and looked clean so I put some fresh gas in it and tried to crank it today. I got a neutral light, but the starter button did nothing. I tried pull-starting it and it wouldn't fire. I checked the plug and wasn't getting a spark. I started digging and found some potential issues and some definite problems.
I have a wiring diagram I found on here but it's just a picture or scan out of a book and hard to read. I don't see a reference to a black/yellow wire, which is my first problem.
First, it that a factory crimp? One of those wired looks like it goes to the connector in the 2nd pic. Is that just a spade lug type connector? I pulled on it with some needle nose pliers but it didn't seem to want to come off. In the 3rd pic, should there be a fourth wire?
I've read through and bookmarked the threads Andrew Baker and Arizona have going but I figured I needed to start with these obvious issues first. I have lots of pictures, so if there is something else you want to see, just ask. If I don't already have a pic, I'll take one.
By colin james
View File 2018/2019 Polaris Sportsman XP 850/1000 Service Manual
This is the factory service manual for the 2018/2019 Polaris Sportsman XP 850/1000
Submitter colin james Submitted 08/01/2019 Category Polaris ATV
By Jeremy Morris
If you're getting that pesky leaky seal on the pinion of your front differential and the pinion has allot of play, polaris won't sell the bushing needed to repair it properly without having to shell out big bucks for the complete ring and pinion kit.
I have a kit with an upgraded bushing, Japanese made bearing and USmade seal
50 shipped in the US and 55 to Canada
By Chase Cook
I have a Polaris sportsman 500 and I just replace the piston in rings and head gaskets on it and I made sure the timing was exactly right it's getting gas and fire but it still won't start. It sounds like it has low compression but at the same time it sucks in air pretty good from the intake. Also the valves are adjusted to spec. It did start the first time I installed the Piston and Rings but it only stayed running for 5 seconds with starting fluid and then it shut off and then I tried to turn on the next day and it didn't do nothing and I've been going at it for three weekends now and it still ain't doing nothing. I wonder if i set the timing off a little or a lot if it would start up, because I inline the crankshaft sprocket with the crankcase timing line like it said in a manual and the two points on top of the cam sprocket to top dead center of the piston. I even took the spark plug out and stuck a camera light in there to make sure it was top dead center and it still won't do anything. AlsoI drain the carburetor some and shut d fuel petcock off to see if it was getting too much gas and that still isn't the problem. And where I live all the darn mechanics that work on Polaris ATVs are booked for two weeks which sucks and I need hope immediately or I'm just going to set the ATV on fire because I'm getting very frustrated with this crappy brand. Every other name brand ATV I worked on I got it running right and I replace the piston, rings and everything etc, and they started up fine. But this is starting to get very frustrated and I don't know who to talk to who had this problem before, who "don't have to come look at it". Cuz when they say that that means you're not going to come look at it until 2-4 Weeks later because there booked, which I don't have time for. Living in northern part of Florida sucks.
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