Frank Angerano

Drill and bolt up ? Stainless hardware? I’m constantly snapping bolts exactky like this. I wind up using stainless nuts bolts and lock washers with thread lock but wondering if you went a diffent route.

Welcome to QC. I posted about this a little while back asking the same question @Ajmboy added a few links in in the post take a look. It seems that there are not a lot of places to ride these days. Hopefully this was helpful.

Here is a little bit of input on a few ways to bring up the codes. It seems that some models are diffent and turning the ignition on and off does not work on some models. I called my friend who has a 05 said you have to turn the key off wait a few seconds and hold the yellow override button down and turn ignition on and then press the yellow button to scroll through the options and if there is a code it will come up. The bike can be running or not and has to be in neutral and 2wd. I’m attaching a few links that he pointed to watch. Good luck.

Quick question is there a yellow mode button on your left hand grip control ?

I would look into all the fluids, oils etc see if any water got into the crankcase or through the air filter and any other oil filled parts of the bike, maybe change the fluids anyway just to be safe. Only other thing ithats left is electronics check all the plugs maybe open them up and use a leaf blower to clear any residual water from the fuse block and all electronic parts.

The wiring is going to be a big factor here. Only thing on your side is the color coordinated wiring. This should be somewhat easy once you’ve studied and went through the harness. If you can find the manual for this bike just take your time and follow the yellow brick road with the wiring. I’ve went as far as taking the entire harness off of my bike and hung it on the rafters of my garage and went through it and all made repairs, taped off and respliced as needed. It’s not as bad as it sounds and takes a lot of the guess work out of the wiring and puts the harness/wiring to rest. As far as carb and compression I am not so sure going with the 400 carb was a good idea but once you get the other issues put to rest you can see how it runs under the 400 carb. Maybe with that aftermarket exhaust you might get lucky. Compression issue sounds normal for a bike that year based on wear and tear it may be ok. I would double check and make sure that the number you seen was accurate.

If you have trouble I can snap a pic of the actual bike location for you.

Yes there is. It’s located on the right rear side of the engine. It’s a black cover with three bolts. I attached a pic of the cover. I have the same bike and had to replace the cover after cracking it.

Does that bike have a rev limiter? Just a shot in the dark once I heard back firing. May be an issue.

Throw back Thursday lol October 2012. That’s prob a huge help. Great job digging that up!

I agree with that but it may be your only option at this point to diagnose.

Sounds like the starter is fine. I had a similar problem on my Yamaha and I was actually able to put the starter back in and take the side cover off to see what’s going on as you engage the starter and see whats taking place during rotation, but spray the gears down with lube prior to testing to avoid lubrication problems.

Are you bench testing the starter ? If so when you put power to the starter does the starter gear engage in and out when power is applied ?

Kolpin Matrix Seat Bag - Mossy Oak Breakup - 91150 https://www.amazon.com/dp/B001AZEMI0/ref=cm_sw_r_cp_api_G9DzAb0KPVJ40 Take a look at this bad boy. Love it ! May have to pull the trigger on it.

Great thread/topic. I picked up the bag that @Ajmboy has on his Suzuki in the photo a while back. It’s good but everything I kept in there got thrown around. I bought a piece of foam and cut it to size and installed it. It was about 6 inches deep and I cut out the middle to keep things in order. Works ok. I like that Coleman one and that kwik tek that @quadmaniac has shown also. May have to give that a try. I also just bought this side bag from Kwik Tek ATVFB-MO, ATV Fender Pack (Mossy Oak) https://www.amazon.com/dp/B000OF92I2/ref=cm_sw_r_cp_api_krDzAb2DRBF2Y I’m still waiting on it. Keep you posted!

So I picked up a new project. Going to need a littl engine work on the top end to fix a slight knock but it’s a great bike! Kawasaki 400 bayou 4x4! Needs a rear carrier rack but other then that it’s a completely orignal never taken apart or damaged bike. The rear rack was taken by somebody. Not sure yet what color or if I’m going to keep it stock but either way it’s getting torn down, cleaned and fresh painted frame etc. Pictures to follow soon of how it turns out !

Thanks @Ajmboy for getting back to me. So the oil was good. The problem I think was I found a leak on the halve adjustment cap there is an o ring or gasket if you will, that was missing and silicone put in there as a fix. Previous owner said he ran it low when he found the leak on the top end but thought there was no damage. So anyway the journal is scored, not terribly but it’s noticeable. So I’m assuming that was causing the knock up top. Oil pressure is good and the new o ring/gasket is in place. And the bike is running great. But when you rev it up i can hear it. So having said all that I reached out to that eBay link that you sent and asked for some pics of that head assembly esp the journals. Thanks a million. This bike has never been touched by anyone. It’s orignal and completely in tact. So that’s why I like it. The gears shift like its right from the dealer. The problem with this bike is the first gear is a SL super low gear. Makes for a very high rpm I’m thinking that’s where a lot of the damage comes from. So to sum it up I think I’m going to change the top end If the one that’s on line it’s in good condition and go from there. I have reached out to a few machine shops that do this kind of work and looking into both options. Only because I got the bike for $300 bucks and it’s in amazing condition. Keep you posted. Thanks

After hearing this bike run for a while I def hear something in the head. It’s not a tick but a slight knock. So I tore into it and found that the journals that support the cam on the opposite side of the timing chain are worn leaving a little wiggle room for the cam to kinda flop around. Im looking into a semi new valve body and see a lot of used ones in good condition for about 200 bucks. My question is am I wasting my time ? Is this normal ? Is there another fix ? Should I ride it out ? Is it going to tear the top end apart ? @Ajmboy @davefrombc any ideas ?

Thanks @quadmaniac I ripped into the carb it was packed with solidified gas and the float and bowl needle were jammed in place. After a good soaking and rebuild kit I reinstalled it and fired up the bike. I noticed a little oil coming from the top of the head but no ticking, I did not have much time to look into it. I think I’m going to rip the plastics off and tear the top end down for an inspection and fresh gaskets and seals. I seen a lot of posts about this engine on you tube with upper end problems with cam issues where the cam is seated. Hopefully this is a simple gasket problem and nothing more. Thanks for the input.

Hey QC people, hope everyone’s doing well. I just picked up a 1998 bayou 400 4x4 in great condition for a song and a dance! Good deal. It has been sitting since 2014. Original owner!!! Anyway he put the bike away in 2014 and has not touched it. He said the head has a little tick that’s about it. I love the way the bike looks and it seems like a well built bike. Im posting because I’m curious if anyone has any input on this bike? Good bad ? It’s in amazing condition but the fuel was left in it and gas peacock turned on of course so a carb rebuild is in order and some really stanky gas In the tank. But any input on this bike would be appreciated! Thanks.

I agree with @Ajmboy at the very least i would ask for another bike. This sounds like one of those bikes that’s going to have problem after problem. A new bike should not have to be taken apart and or have a new carb put on. And why up the jet? Makes no sense.

Start at the battery and check the solinoid as well to make sure no wires are shorted out. Work your way back on the harness all the way up to the controls and check the push start button to make sure it’s not stuck. The key ignition switch as well. Look for any old work that may have been done on the wiring like additional electrical tape and things that were added on. Go through it all. You can also unplug one plug at a time and see if it continues. As far as the carb goes was it an original or aftermarket carb ?

Wow! Sounds like you have a project bike on your hands. Honestly you have to see if this bike is worth the effort. Parts for this bike I found have been expensive. Was the carborator new or used? it’s possible and sounds like the float or needle has an issue. Maybe stuck or the float has a hole in it. Or the needle is stuck or has fallen out into the bowl if not put together correctly. I would start with taking the carborater apart and going through it to see what’s going on. If it was a new carb I would send it back before you think about taking it apart. Was the start button you installed an original part or from another bike, hole made ? You can find used controls on eBay as I did. Start button controllers, brake handles and so forth. I would try to find the correct controls instead of adding aftermarket or “custom” start buttons/controls. The wiring with this bike is over designed and a pain in the as* when it comes to trouble shooting but the proper controls have wire color markings that all match up making it somewhat easy to connect in the proper place. It sounds like your push button is stuck or not a spring type maybe when pressed? Disconnect it and see if you can connect the battery and go from there. I would tackle one problem at a time and move forward, crboraters are manageable and can be somewhat inexpensive when it comes to rebuilding them. Replacing with an OEM carb can me expensive.

Hello big country and welcome to QC. I have the same bike. No manual but I have broken the bike down and rebuilt it as well as fixed various problems that have occurred. So any questions you may have I might be able to help You with should you have a problem.