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1986 Bayou 300 - Fixing It Up

HelpMyQuad

By HelpMyQuad
in Kawasaki ATV Forum

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HelpMyQuad Rookie

HelpMyQuad

Posted
Posted

This post is just an FYI. Im fixing up the subject quad. Problems and solutions found so far:

1) The ignition switch would not complete the circuit. Fortunately, you can take this ignition switch apart. I cleaned the corrosion off the contacts and lubricated it with WD40. It works well now.

2) The lights did not work. I took the switch apart and found a broken wire where it solders onto the switch. I also cleaned the switch with WD40. The lights now work.

3) Fuel tank was full of rust. I had cleaned it up a year or two ago, but it was rusted so bad I could hardly get the cap off. I bought a plastic after market tank from Clarke. They are bit expensive, but it fits well and seems to work.

4) Cleaned out carb to rid it of rust.

The quad fired right up after 2 or 3 seconds of cranking.

Remaining work may include new muffler and piping. Im wondering if I have problems with the alternator too. The front brakes also need work. Beyond that, I think everything is working OK.

oxidized_black Grand Master

oxidized_black

Posted
Posted

nice you were able to salvage the electrical parts.

front brakes ... drum? yah they are special for sure LOL.

why are you thinking alternator? the bikes have stators and if you are getting good spark, it is ok ,,, are you having problems with lights dimming or battery not holding a charge?

HelpMyQuad Rookie

HelpMyQuad

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Posted

Sorry, wrong terminology (shows my ignorance). The spark is good. I don't have a battery in it yet, so Im not sure if it will hold a charge. My post immediately before this one explains why I was concerned about the stator, but based on your response it sounds like my concerns might not be founded.

The front brakes are hydraulic, but I haven't even looked to see if they are drum or disc. Im betting drum. Ive never worked on hydraulic brakes of any kind before, so this will be a learning experience. Is there any point in working on them? I had an old Yamaha with cable brakes, and the front weren't worth fixing because they never lasted for long.

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