texaskaw

will replacing the main 30 amp fuse with a 30 amp 12 volt circuit breaker cause charging problems

1994 bayou 400

sounds better. The hot melted plug still worries me though that it may have a short to ground somewhere??

Does the new multimeter read higher voltage at the battery now??

ill check battery tomorrow. I am going to check all wiring again this weekend.

bought a new multimeter...stator not grounded,alternator putting out 9 - 10 volts at idle,39-42 at higher rpm...

Unplug wires from alternator and start engine. test voltage out of each yellow wire-to ground- 60 volts minimum. yes.

turn engine off and check each yellow wire to ground with ohm meter. Should be no continuity to ground. no reading in ohms??

not grounded..but only 1-2 volts coming from alternator.I have been asking about the wires and regulaor getting real hot on 3 or 4 forums ,all said normal.the regulator plug was melted when I replaced it.pulled plug today from alternator its melted too.

I guess the stator I bought is bad.man I cant get a break on this money pit bike.

OUCH! Can U unplug yellow wires to stator and check with ohmeter? Is there power to earth down through stator??

how do I check voltage out of alternator/3 yellow wires from alternator.should be around 60 volts?multimeter from yellow wires to ground? all 3 wires?

well put on a new battery Saturday.been starting fine until today ..battery down enough it wont crank .there is no spark at all when you put cables on like there may be a short or something......

now everthing on this piece of !@#$ has been replaced except cdi unit......I have checked all wiring many times...cant find short................................

is that when engine is running?

yep,engine running

They do run pretty hot. Make sure your battery is OK? Put a test meter across the battery terminals and check the charge rate is not over 14.5volts. Cheers

multimeter shows 12.7 - 12.9 volts. it will drop to 6-8 volts for a second sometimes.

1994 bayou 400. regulator/rectifier got real hot to the touch melted one wire connection in plug.replaced stator and reg/rectifier runs fine but reg/rect is still hot and yellow wires from alternator are hot.any ideas what might be.

well I was wrong.its dead again,

Its fixed and running.......bad ground connection

checked valve clearance they are right. A blue spark jumps all over electrode but it is real small.I cant figure out how it was running fine cut it off now it wont start. Bout ready to throw a match on it..

fighting this thing for a month now.No spark at plug.

New ignition coil,pick up coil,stator,reg/rectifier,all new wiring.Started it up today rode for an hour shut it off.Tried to start later wont start.pulled plug wire it firing a blue spark while starter button is pressed.Tried new plug no change. It stared a couple times an ran for few seconds then died.Will CDI act this way? The reg/rectifier get pretty hot is this normal?

I purchased the seals for water pump.finally got old one out and noticed shaft bearing are pretty loose.i see the clip on outer side of case against outer bearing.shaft will move towards inside a little ways then stops.how does shaft and bearings an oil seal come out. I cant find much help in manual

1994 bayou 400 4x4

KLF 400B

there was just a small amount,guess waterpump seals leaking.

changing stator in a 94 bayou 400.the oil is milky ,mixed with water.I am replacing water pump seals.how much oil ( if any) should be in this side of engine. there has been ( to me ) a lot of condination from vent tube lately. don't think head gasket is bad it was running ok when it was running. what do you think..

Two more places you should look. First check the trigger coil resistance and if its up to snuff. Try checking the key ignition. There is a continuity check you can do for that also. Otherwise, you can run a jump wire on the wiring harness side to elimininate the key. once it is jumped out and you get a constant spark then you have your problem. Use a small wire to jump with until the neutral light comes on then the bike should fire up. If this is too complicated then dont take any chances on it unless you know what your doing.

you talking about pickup coil? regular ohm meter ok? key ignition replaced with toggle switch and green neutral lite has always come on when switch is closed.will a regular ohm meter work to check cdi if needed/ I have older needle type and digital type. think stator would act up like this or cdi? thanks for any help.

new coil no difference.bike has been setting 2 weeks now no spark at plug. today I checked plug ,its firing now....any ideas what going on?

I checked coil with ohm meter shows to be bad.I will try this first .where is the cheapest place to buy cdi unit if this one is bad..

yes it has,will cdi go bad or break down slowly or all at once.

thanks for reply.

i just did a full rebuild on a bayou 300, i had the same trouble with mine. i got it from a guy that had it sitting behind his house for a few years, i had to replace the CDI box and the voltage reg, they went bad over time i guess, if you need any help let me know.

I just read this post,I have a 94 klf 400.no spark at all.was running great then it died. waited a few minutes it would start. sometime it would run then stop reving to higher rpm.what do you think?

been acting up for a couple weeks.running fine then dies,no spark at plug.wait few minutes start up again runs for maybe hours.also sometimes it will run great then it starts losing rpm.will not wind up to higher rpms then it will pickup and go for awhile.well now there is no spark any time ,nothing....