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Showing content with the highest reputation on 11/08/2023 in all areas

  1. Version 1.0.0

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    Also available on eManualOnline 1988-2002 Kawasaki Bayou 220 Service Manual PDF The Kawasaki Bayou 220 is one of the most common all-terrain vehicles on off-road trails that is geared toward novice riders and families. It’s also one of the smallest and most inexpensive ATVs on the market, with a retail price under $3,500, as of 2010. The Bayou 220 is Kawasaki’s only ATV of its size. The 220’s sibling is the larger Bayou 250 equipped with a 228cc engine. Engine The Bayou 220’s engine is a 215cc, four-stroke, shaft-driven, air-cooled model. Its bore measures 2.6 inches and the stroke is 2.4 inches. It features a relatively high 9.3:1 compression ratio with fuel delivered through a Mikuni VM24SS carburetor. The electronic ignition is Kawasaki’s DC-CDI. It also features a recoil backup as a starting system. The clutch is an automatic wet multidisc model with power delivered to the wheels via a five-speed transmission, according to ATV Source. Chassis The steel frame supports a front suspension with single A-arms and twin shock absorbers, with the rear suspension a Quad-Link system with two shocks. Front wheel travel is 4.5 inches, while the rear wheel travel measures at 4.9 inches. Front and rear brakes are drums. Size The front tire size is AT21X8-9 with the rear tires measuring AT22X10-10. The ATV’s wheelbase is 43.9 inches, with an overall length of 68.7 inches. Ground clearance is 6.1 inches with the seat height measuring 28.7 inches. It weighs 403 lbs. and can tow up to 450 lbs. Its fuel tank can carry 2.6 gallons. Basics The Kawasaki Bayou 220 is not the fastest ATV on the market, but one reason the Bayou 220 has kept its price low is the lack of amenities. It features a brake light and dual headlamps with high/low beam. There is an auxiliary lighting terminal inside the front cover of the ATV and electrical accessory terminals under the seat. The instrument cluster atop the fuel tank features a fuel gauge, but not much else. There are no speedometer, odometer, hourmeter, tripmeter, high-beam indication or high-temperature light. It does have a reverse/neutral indicator light. The Bayou comes in two colors: hunter green and firecracker red. Features The front A-arm, twin shock and rear Quad-Link twin-shock suspension system is not a true fully independent system, but it allows for a comfortable ride over rough terrain without employing a complex and expensive, fully independent suspension system. The ATV features front and rear steel cargo racks. The ATV is rider-friendly with a limited adjustable throttle to help novices practice their riding skills without twisting the throttle too far and losing control of the vehicle.
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  2. I got it diagnosed and out the door and forgot about this site until now. The manual on this site was probably the wrong one anyway but I'll try to stay semi-active if there are any other manuals I should need. Thanks for your help guys!
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  3. Yup Gw's right there.. The choke plungers are often different, and so are the idle mixture screws different sometimes if it's an aftermarket. The idle screws can't be changed but the choke plunger can mostly.. but it might not always be so.
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  4. I have noticed a difference between the aftermarket choke plunger and the OEM plunger so if an aftermarket carb has been installed the new plunger that comes with the carb needs to be installed along with it.
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  5. Yeah the plunger needs drawing out for choke, and they only work at idle, and it needs to be a slow idle, with the butterfly or slide closed right down. They draw extra air and fuel around past the butterfly or slide and that doesn't work unless the throttle is closed off .
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  6. The plunger should be out to choke, it is more of an enricher more than a true choke.
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  7. TonyWright-did you ever confirm specifically what the issue was? I have a 1 year old Axis 500 that seems like it is having the same issue. Engine makes a rattling noise when coasting downhill (no throttle). 87 hours on the machine-I changed the oil and filter around 50 hours as recommended with oil for wet clutch. This is my third issue with the machine...already replaced driveshaft and fuel injector...really frustrated
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  8. If the clanking's a metallic sound, I'd be checking the axle's universals I think. If it's something like a uj it would sound quite clear, but if it was in the gearbox then it would be a bit muffled and in a different direction. If it was trying to jump gears, having a hand on the gear change might give some indication.. it would jump. You should be able to identify where the sounds coming from a bit better if you lean and/or turn towards all four corners or the drive belt/transmission as it's making the noise. Perhaps get someone else to drive while you clamber around and lean over the sides..haha.. It's what mechanics do.. Given the "clanking" description I'd check out metal to metal contacts before taking the belt covers off. I haven't had much experience with belt drives though and Gw may know they can make quite clanking noises..
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  9. It sounds like a CVT transmission rattle, check pulleys and belt for wear and correct alignment.
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