Arizona

is the hose fitting at bottom of carb just a vent/overflow? Do I just run it down off the frame towards the ground

Great, ordered it. Looking at the new part it should be pressed in from the outside. Thanks Az

Here are the pics, if the seal in installed from the outside just a matter of removing the reverse lever and popping it out and installing a new one. If from the inside (hope not) it will be an ordeal. Any ideas where to buy the seal? Were the ones on e/bay correct?

Fires right up now. Idles great, got it put back together and fixed all the lights. Everything seems to work. Cant ride it, missing rear tires. Showing up tomorrow the old ones must have been the original, no tread and full of holes and side walls cracked bad and leaking. One thing. I installed a new carb, was cheaper than a rebuild kit. There are literally no vacuum lines to It except the fuel line. Can you tell me where they connect to off the carb?

I did that yes, but I think maybe a bad ign switch and other things added to the problem. The thing is since I jumped the relay and put it back to normal, it starts up fine. Ill just leave it if it stays working, if not will try to replace the relay.

I have a couple other topics on this Bayou but this one is the reverse lever seal is leaking. Talked to the dealer and have no listing on the seal. Looks fairly simple but is the seal installed from the outside of crankcase or from the inside before I remove it. Next question where can I get the new part? I found these on ebay but not sure if they fit. any ideas where to buy it? https://www.ebay.com/itm/Kawasaki-KLF220-88-02-Bayou-KLF250-03-10-Winderosa-822138-Engine-Oil-Seal-Kit/352356942519?fits=Year%3A1995|Model%3ABayou+220|Make%3AKawasaki&epid=209928936&hash=item520a1c42b7:g:ZKUAAOSwx6pYooaN:sc:USPSFirstClass!78006!US!-1

Ok some updates, I replaced ign switch even though seemed to work properly. I started with pull starter, still wont crank. But ran and when shut key off the engine shuts off now! Today decided to recheck relay, 12v on Brown key on Green - 1.2 Ohms key off Green - 101.7 Ohms Key On! I jumped the 2 Blqck wires and it cranks and starts with the starter button now. I reconnect everything relay included and now it starts no matter what? I am assuming problem with the n/safety switch? Don't think it should change just with key on and off or am I thinking wrong.

Waiting for day off to continue. Yea is a pain to fix others rig. Looking at the harness and other wiring I really don't see any other areas where they messed with it. Looks pretty stock and no burns or messed up wiring. Ill check the regulator on Friday and also see which one had power at ign. I did check starter switch and is open so figure its bad. Now I tried to jump wires on opposite end of connector and still no crank with key on and off. LOL at least im not posting trash just to get a download

LOL, Now I know what he meant when I asked for the keys and he said they don't use the keys. I will check those on next day off. Thanks Az

No haven't. What am I looking for? How to test

Yes, checked ign switch. Has 12v. and neutral light lights up and reverse light comes on when in reverse. I did check for continuity on the starter switch. With it unplugged while pressing the start button its open. Guessing the switch is bad? Can I jump the 2 wires and see if it cranks? Hoping replacing the switch will fix it. I do have the 12v at the relay with key on. Last, is it normal for the engine to continue running and start with the key off and kill switch open? Running of magneto? Kinda weird but it works. The only thing that keeps it from starting with the pull starter is the kill switch, Key on or off.

Which clip are you referring to ? Do I unplug the main connector? Not sure what you mean Also update. I started it up today, Just pull started it as it still no crank. Drove it around, I cleaned the kill switch and it now works. Couple of problems, 1st while running if I turn off the key it stays running, will only stop if I use kill switch. With ign. off I can start it if kill switch is off. Seems ign. only runs accessories with elect. Is this correct?

started new thread topic

I took apart the kill switch/starter/light off handlebars. See pic Black wire on starter switch has continuity with black wire on kill switch so left kill switch disconnected but jumped using fused jumper from starter switch to black wire on bottom side of kill switch. Still no crank. How to check this starter switch? black wire goes to kill switch below and black w/stripe wired in to kill switch at top. see pic. Kill switch cannot find new one for sale how to bypass and still allow crank signal?

This thread is continued from old one at Ok No crank on 1995 Bayou 220 Starter relay have ground at green (n/safety switch 12v at Brown (signal wire from key) Have also Jumped the black wires still no crank. relay does click when key turned on and off. I know the kill switch is bad and all testing was done with it disconnected. I did connect it for a moment just to see if it cranked and it did not.

No cigarette lighter just a hole with a cover on it. Under it has 2 wires. 1 is fused and both are cut and disconnected. What about the white wire and black wire with yellow stripe by the starter relay in pic 3. are they supposed to be connected anywhere or are they test leads? After checking what you said I will start a new topic on it. I found out yesterday it is a 1995 model Bayou 220 Thanks

Ign switch is ok, just removed it out of the cowling to access wiring better. Jumped the 2 blacks like you said still no crank. Thanks for the info on starter circuit I am kinda handy with meters was in auto repair for 23 yrs but 1st atv and kinda rusty at it. Have to wait till next day off to mess with it. Any info on the wires that are disconnected? Thanks. Az

Ok Update. I was taking the starter relay off and found the 30 amp fuse under the cover when you unplug it. It was blown. I replaced it and no crank. Grounded the green wire on the other relay which you said to try still no crank. I unplugged the kill switch and jumped the starter relay and it started for a second. I was only using starting fluid. Now I know it will run. Why wont it crank at the switch? Starter relay bad? its in neutral. Also any ideas on the other wires not plugged in I showed in pic 3 white wire and black/yellow and the 2 unconnected wires under the steering wheel? Thanks in advance Az

Ok, No fuse found anywhere. Power to starter relay, nothing coming out of any of the wires except the 2 you can jump. Is this also a fuse combo relay? Next I ran a fused jumper wire from Pos/Batt. to Single white wire not connected to anything by battery and get power back to combo starter/relay. Got power at key switch still no power at Pos. Ign. coil or Neg coil Does the relay/fuse have to be good to get power at coil? Next Still jumpered I disconnected kill switch still no power at coil. Last question The white wire on pic 3 is what I jumpered 12v to. that one and the one next to it are not plugged to anything. Are they supposed to be plugged in or are they both test connectors? This is under the steering wheel. both wires cut. What are they supposed to go to? Cig. lighter?

Subscribed, Same problems on mine, Any updates on this?

I recently bought a used 220 They said needs carb work, ran fine when parked (4 years ago) After looking at it. I have no power at ign. switch or coil, lights etc. Have power at starter relay which I can jump and it cranks but of course no spark. Is there a fuse I am missing? Found one under steering wheel, 2 wires connected to it which aren't there anymore. Battery fully charged just no power anywhere that I can see. Need ideas where to start.

Thanks for the add