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I have read many forum topics on this matter but have never found a similar problem. So i bought a cheap ass quad thats got all sorts of parts on it. It's a 1997(if you look the date on frame) Kawasaki KLF(Bayou) 300 EUROPEAN Model (atleast I think, since I'm from Europe), the engine is 1988 if I'm not mistaken and the CDI is 1995.-2006. ( 21119-1447, 6pin ). My problem is that I don't have spark. I would diagnose the issue but connectors from CDI to wiring harness have almost all different colors and I'm not sure if they are connected correctly (pictures below). Pickup coil is putting out around 400 ohms and is pulsing. CDI is being fed 12v by one y/r wire that is coming to connector and with 12v to one gray wire which is coming from ignition switch ( quad actually doesn't have ignition switch so I'm not sure if gray should be supplying power or not). Stator looks good cause when crancking all three yellow wires put out around 5v AC. Neutral light is also on which means the switch should be ok, if it even matters. I know it's not the ignition coil since I get no power nor any kind of pulsing to G/W wire that is coming to it ( and I even put another one on there just to check an it ended with the same result). I'm nowhere near proffesional around this type of stuff so any help would be amazing.
Hello, I am restoring a bayou 220 here in Brazil, I have a question regarding the rear brake activated by the lever on the left side. The ex-owner connected it in place of the reverse cable and as this is incorrect, could someone show me through pictures where I correctly connect the rear brake cable? Another thing, every time you reverse, is it necessary to activate the reverse key?
Hey there all,
First off thanks for the board. My Bayou 220 has survived 3 teenagers and is on its 4th now. Up until recently it has been a virtual tank....until I decided to fix it;)
Noticed some smoking from the engine block (not exhaust) so figured it was time for a quick top end rebuild. Now that I have it all back together, it fails to start. I've pulled the starter rope until my arm is tired.
So I will be as detailed as possible and hopefully get some help.
-New Head gasket
-New Valve seals
-New piston (standard)
-New rings (standard)
-All new seals
-Cleaned up head and valves (didn't do any resurfacing, as it all cleaned up pretty easy)
-All torqued to spec
-Piston ring gaps all checked out
-Valve clearances (Intake: .18mm, Exhaust .20mm). Not too tight, not too loose.
-Engine IS making decent compression
-DO have spark
-Will fire for a split second if I drop some gas in the spark plug hole and pull start. Will NOT from carb and or intake valve.
So I followed the guide of: TDC
-Flywheel aligns on the “T” mark on the engine site hole
-Cam gear mark aligned with the cover mark
Seeing as this is my first time doing a top end rebuild on an ATV. Here are my questions and concerns:
-I didn't realize (dummy me) that there are 2 TDC's. 1- Compression, 1-Exhaust.
How do I know if I'm on the right one?
-Does the cam need to be aligned a certain way when put back in? I just aligned the cam gear dimple with the cam and put it in. No alignment.
Thanks ahead of time. I feel like I'm 90% there, but I'm missing an important step for completion.
By Brent Mason
I have worked about 4 weeks on my Griz600 and have burnt 2 CDIs up ! I added a wire harness and stator and It starts but runs erratically like spark timing is off ! So I would like to try another CDI but I don’t want to Pay an arm n leg ! Anybody have one ? Thanks
By Brent Mason
I have been trying to get my Griz600 running right for 3 weeks ! Grandsons used it and it quit running , no spark ! New stator etc and started but ran terrible ! Found a burnt capacitor on cdi . Installed used cdi and burnt it also but ran same as other cdi . Came to conclusion wire harness had short so stripped it and found some bad spots fixed and another cdi ran terrible again ! Bought another harness and same rough running ! Checked spark timing with light (put tdc mark on case and on pull start hub) and when it starts timing right on but will jump 25+° retard ! When timing is on tdc marks it has no power ! The stator is new but I am wondering if the pickup coil is triggering incorrectly ? Also had top end apart when I first started having trouble and although rings were good I installed new rings . Also new timing chain and check the valves , they were good also . It kind of seems to boil down to the last stator I installed new ? I have done trouble shooting on quite a few cars , trucks , dirt bikes and ATVs but this is frustrating me ! Just wondering if anyone has any ideas ? Carb was new last yr and I checked it ! I
The front wheels of my quad have a ton of slop. Its the spindle as shown in the picture. There appears to be an outer plastic bushing of some sort and then an inner metal hollow rod that the attaching bolt goes through. The slop in between the inner attaching bolt and the hollow rod going through the plastic bushings. I see kits for bushings for sale, but I have not found just the spindle parts. The length of the spindle where this bushing goes through is about 80mm. Does anyone have a source for these parts that you could point me to?
Just thought I'd start a new thread for newbies to the site!
If you're new here, tell us who you are, where you're from and what you ride!!!
Lets get to know each other a little better shall we?
I'm not new to the site, obviously, but...
I'm Kristin from Denver!!! I ride a 2008 Yamaha Rhino. She's my muddy baby!!!!!! Several aftermarket parts on her. She's good to me! We try and ride every weekend. This weekend we're off to MOAB! :woot:
Heres my story. Kinda long. I guess I was a late bloomer when it comes to quads. I had never ridden a quad in my life. Rode Dirt Bikes as a kid growing up. Back in Oct of '06 I found a Mustang on craigslist. Took it for a test drive one morning before work. Fast car. 351 Cleveland. I had planned on meeting the guy again after work. For some strange reason thats still to this day beyond me, I stopped in Hillsboro MotoSports on the way home from work. I had 6 Grand on me. There was a left over '05 sitting by the front door. It was on sale for $4999. It was $5499 OTD. I didnt even look at anything else. I knew nothing about quads accept I thought it really looked coool and I had the money in my pocket to buy it. I was sitting on it when the salesman walked up and asked... "Can I help you?" Without hestitation I pulled 60 Ben Franklins outta my front pocket and said "I want this Quad. Load it up in my truck." It was just about dark by the time I drove away from the shop. BTW, I didnt bother to ask my ol lady if I could buy it. LOL. Anyway, I took it by the house and showed her. She was kinda stunned but not mad. We drove over to a friend of mines house and unloaded it. I took it to the field across the street from his house. HOLY CHIT!!!!! I was surprised by the power. I had it for about 2 weeks and took it to Sand Lake. I was there a few hours and rolled it on a banked turn at the top of the bowl right before you get to the one-ways. When it rolled, I flew off and landed on my belly. The quad came bouncing and landed on my back. For a month I couldnt even walk. I was scared of it. I considered trading it for a 250EX. Went back to the shop. The salesman said..."Dude!!! You dont want a 250EX!!! Trust me. Just get used to it" I still wasnt convinced. I put it on craigslist for $4000. Calls were coming in. I had a guy that wanted to come look at it that evening. I decided to take it for one last ride at Browns Camp before I sold it. I was still afraid of it. After about 5 minutes I started feeling comfortable on it again. I decided right then, I loved my Honda 450 and would learn how to ride it instead of selling it. That was late Nov of '06. Work was slow for a Painter in Oregon. My new job everyday? Going to Browns Camp and ridding my Quad. I bought my Girl Friend an '02 Blaster. I rode my 450 for 4-6 hours almost every single day for 3 months. And yes, I know my way around Browns Camp pretty well. LOL. In March I bought her an '06 TRX250EX (Thank God I didnt trade my 450 for one of those) LOL Since then, I have become totally addicted to quads. I love them. Couldnt imagine not owning at least one quad. Luckily I have two. My "07 was $6500 OTD in July of '07. Bought it for my Girlfriend. Traded in her 250 EX. A month later we broke up. So, I wound up with two Honda 450's.
these are what i have in my collection ... always looking for more
1985 - 1995 Polaris All Models Service Manual
1996 - 1998 Polaris All Models Service Manual
1996 - 2003 Polaris Sportsman & Xplorer 500 Service Manual
1996 - 2003 Sportsman 400 & 500 ~ Xplorer 500 Service Manual
1999 - 2000 Polaris All Models Service Manual
2001 Polaris 90 Service Manual
2001 Polaris Scrambler 50 ~ 90 Sportsman Service Manual
2001 Polaris Sportsman 500HO Parts Manual
2001 Polaris Sportsman 500 Parts Manual
2002 - 2003 Polaris Sportsman 600 & 700 Servive Manual
2002 Polaris Sportsman 700 Service Manual
2003 - 2005 Polaris Magnum 330 Service Manual
2003 Polaris Predator 500 Service Manual
2003 Polaris Predator Parts Manual
2003 Polaris Trail Blazer 250 Service Manual
2003 Polaris Trail Boss 330 Service Manual Part I
2003 Polaris Trail Boss 330 Service Manual Part II
2003 Polaris Trail Boss 330 Service Manual Part III
2004 Polaris Predator 500 Owner's Manual
2004 Polaris Sportsman Owner's Manual
2005 Polaris 400 & 500 Sportsman Service Manual
2005 Polaris 700EFI Owner's Manual
2005 Polaris 800EFI Owner's Manual
2005 Polaris Sportsman 400 Parts Manual
2005 Polaris Sportsman 500 Parts Manual
2005 Polaris Sportsman 6x6 Owner's Manual
2005 Polaris Sportsman 700EFI & 800EFI Service Manual
2005 Polaris Sportsman 800 Twin EFI Parts Manual
2006 - 2007 Polaris Outlaw 500 Service Manual
2007 Polaris 700 800 800x2 EFI Service Manual
2007 Polaris Ranger 700EFI 6x6 Parts Manual2007 Polaris Ranger 700 4x4 & 6x6 Service Manual
2007 Polaris Ranger XP 4x4 Service Manual
2007 Polaris Sportsman 450 & 500EFI - 500X2EFI Service Manual
2007 Polaris Sportsman 700 800 - 800EFI Service Manual
2008 Polaris Sportsman 500EFI & 500x2 Service Manual
2008 Polaris Ranger 6x6 700EFI Parts Manual
2008 Polaris 800 RZR Service Manual
2008 Polaris Sportsman 700x2 - 800EFI - 800 Touring Service Manual
2009 Polaris 850HD EPS Service Manual
2009 Polaris Outlaw 450 & 525 Service Manual
2009 Polaris Outlaw 90 Service Manual
2009 Polaris Predator 50 Service Manual
2009 Polaris Ranger 2x4 Service Manual
2009 Polaris Ranger 4x4 Crew Service Manual
2009 Polaris Ranger 500 2x4 Service Manual
2009 Polaris Ranger 500EFI 4x4 Service Manual
2009 Polaris Ranger 500EFI 4x4 Service Manual
2009 Polaris Ranger 700 4x4 Crew Service Manual
2009 Polaris Ranger 700 4x4 Service Manual
2009 Polaris Ranger INTL Service Manual
2009 Polaris Ranger RZR 170 Service Manual
2009 Polaris Scramber 500 Service Manual
2009 Polaris Sportsman 300 & 400HO Service Manual
2009 Polaris Sportsman 450 & 500X2 Service Manual
2009 Polaris Sportsman 500 Service Manual
2009 Polaris Sportsman 6x6 800 Service Manual
2009 Polaris Sportsman 800EFI & 800EFI Service Manual
2009 Polaris Sportsman 550XP Service Manual
2009 Polaris Sportsman 850XP Service Manual
2009 Polaris Trail Boss - Trailblazer 330 Service Manual
2010 Polaris Ranger RZR S Service Manual
2011 Polaris Ranger RZR S Service Manual
2011 Polaris Ranger RZR SW Service Manual
2012 Polaris Sportsman 400 Service Manual
Visit the Polaris Service Manual Section: https://www.quadcrazy.com/files/category/7-polaris-atv/
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