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  1. Hi all, I have a 1994 Bayou 220 with low compression, how do I decide if I need a new top end or just rings?
  2. I bought a 220 for my daughter and after riding for while it cut off and wouldn't start back up. Found the cam and rockers completely destroyed. When I replaced the head and got it running I checked and had no oil pressure. Pulled the side cover and the oil pump was missing the plastic gear. There were no pieces in the anywhere to be found. The side cover didn't look like it had been off in a long time. I wonder how long this thing was run without an oil pump. Put a new pump on it and its been running great.
  3. Need to know where lines on bottom of breather box goes and any on carburetor
  4. 2001 bayou 220 KLF220A Need some help putting a new ignition switch on this thing. I'm not finding homes for all the wires. I can hook up the white wire and brown wire, But the switch has a B/W and Solid Yellow wire i can't find a home for, and there aren't any more wires in the vicinity from the harness that match this, except one red wire with a double female end crimped on, and a few B/Y grounds. None of the wiring diagrams i've founder or have been given match. I'm also wondering if i have the wrong switch? some switches appear to have 4 wires and other just 2, the Brown wire and a White wire. I'm at a loss here. Thanks.
  5. Looking for a service/owners manual PDF
  6. Hello all! New to the site, I came here seeking answers as I've decided to help my cousin get his once good running buyou 220 going again. I've owned an 82 kawasaki kz1100 and have done lots of work to it over 20 years of ownership. Looks like the wire diagram colors are same or similar to my bikes wiring, a definite plus Cousin was riding through fairly high weeds and brush after it's rained, when it just died. It would turn over but no fire. This to me sounds like perhaps a CDI issue or a fried coil, idk that why I'm asking you gurus LOL
  7. Hello all!! I'm new to the forum here and hope to be a regular. I am fairly mechanically inclined and a ticketed small engine mechanic... Yet the infamous meddling gods that rule over our chaotic existence decided I must do this the hard way .. Got a used machine last summer, bought it KNOWING the machine didn't run but figured it would be an easy fix. The guy said he tried replacing the cdi box with one he bought online and sure as **** it doesn't work. It's garbage and rotted from sitting outside anyway now. Bought a whole wiring harness on Amazon and they sent a stupid mess of components meant to fit on some sort of crappy Chinese 110cc quad despite the product page stating for Bayou 300. Fast foward, parts returned, bought this Aftermarket CDI bundled with a new regulator for $40 and these also claim to be for my machine, with multiple people leaving reviews that it fit their machine perfectly implying like they just plugged in an were done. This is clearly not the case as this new one has pigtail wires. The old one had a rectangular 6 pin connector socket which I have long ago cut off. Although it was a 6 pin plug originally, only 5 wires were populated in the harness.. New CDI has 5 wires also and I'm REALLY hoping they didn't send me another AC box instead of DC like I presume I need and they screwed me on the last order. The two wires black and blue on their own are obviously to the pulse coil and I have spliced and taped them accordingly. The other three wires are where I am dumb stumped and I am unable to express the amount of happiness it would bring me if someone can point me in the right direction!!! So the last 3 wires are as follows, we have a black wire, a green/white stripe, and a yellow wire. The image I uploaded shows a red wire from what I can tell but mine are Blk/Grn/Yellow. I tried supplying 12v constantly to the yellow, pulse coil to the seperate black and blue wires, and green touching the red/yellow to ignition coil and black to a blk/yellow ground wire to see what would happen. Nothing while cranking. I was quite sure it definitely isn't hooked up but was trying something before I sat down and gave up.. On a side note, when attaching constant 12v from battery via alligator wire to yellow CDI wire it arcs ever so gently. Was mindful of this and checked box/wiring to make sure it wasn't heating up and damaging something. Also checked multiple times and it always sparks just as hard upon connecting it which tells me I havent cooked anything in my new CDI yet hopefully as it appears to be energizing. SORRY a many time for the rediculous long post I just wanted to offer as much information about my situation upfront so someone can more likely help. Thanks again guys hope someone can help me wire this unit up!
  8. Hey freinds, I picked up a beautimus 02 kaw 220 bayou. What I know about this machine .. Not ran in 4 to 5 yrs after providing seller with yrs of trouble free service . It was left under a tree after the seller bought a larger atv. After sitting for 5 yrs My 1st gift was 1)fresh oil and filter 2)new gas and "filters" 2 inline I'll explain in a sec. 3) new amazon carb airfilter and boot to carb 4) Start and ran for 30mins 5) add a little atf fluid rans 3 mins 6) another new oil filter and more new oil I FORGOT NEW BATTERY also.... I pulled it twice ..not doing that agian The bike ran like a top no worries besides thee reverse cable will not function as its ment to. After 3 to 4 weeks it started to die. I found white crude in the carb from water In the fuel somehow.. not sure how.. So new amazon carb as I boughtv2 the 1st time in case one was crap. I've bought alot of these cheap carbs only 4 or 5 percent has been problematic .. So back to a clean tank and added 2 inline filters just incase and it starts runs idles like a new bike . But thus time I have a small stumble in the 1st 10 to 15 percent of throttle travel. We are in Texas about 130 ft Elevation. Reckon the jets need adjustment or replaced or is there other adjustments I can make. Cheers joe
  9. I just got a 1996 Kawasaki Bayou 220. The wiring is a bit of a mess. My question is I have a white wire and a black/yellow wire that aren’t connected to anything. They’re both located under the seat. The bk/y wire comes from where it splits I think 3 different ways. I’ve checked the diagram and I’m still having no luck. Also are the only wires connected to the ignition switch the brown and the white one? Any help it’s appreciated. Thanks.
  10. The Kawasaki is a 1989 Bayou 220. Neutral has been found, by pulling the recoil starter, engine turned over the wheels did not turn, so my next step is to put a battery in and see what happens. Oil is half way up the sight glass. The concern I have is the throttle lever is not moving. Suggestions please?????
  11. I am new to this site. Now down to business, I have been given a Kawasaki 220, tires are trashed and it has been setting for a long time. Do I need a battery in it to find neutral? I know there is a neutral switch and if I shift down(7 times????) then up one using the neutral switch I should be in Neutral. As you see I am in a learning curve here ......coments welcome.
  12. I am trying to run down a problem with my Bayou 220. I think it's a 96. The battery has been dead for years. Years and years. It pull starts right away and I don't use it a ton so I hadn't bothered to put a new battery in until now. I've got a new battery in it and now nothing works that should (and used to). The starter, headlights, and dash lights are all inop. I've looked at the wiring diagram and done a little messing around and haven't had any luck. Fwiw the starter works when jumping the relay. The 4 wheelers pull starts and runs fine. Any ideas where to start?
  13. I have oil leaking from the bevel gear housing and found what I believe to be the oil seal damaged and ordered new seal. When looking at the diagram it show the oil seal on the outside of the housing between the housing and drrive shaft. My question is shouldn't is be in the housing?
  14. Was given a 1997 Bayou 220 for free that had sat in the back of a barn for almost 9 years. Owner had parked it because his kids got too big for it, and they have other bigger bikes, said when it was parked it ran fine. He gave it to me as a trade from some networking I did in his home. First steps: *Marvels Mystery Oil bath down the cylinder to free up the piston rings (I let sit for 24hrs) *New battery as old one was shot from not having a charge for 8 years. I took my multimeter to the entire wiring harness and cleaned EVERY contact possible, as not even the headlights were working. After a few hours, everything electrical is now working. Headlights, green dash light, red reverse light (goes on and off with changing from reverse to neutral), and starter spinning strong (after a conversation with my mallet). *Drained old oil (no glitter!) 2qts fresh oil with new filter. *CDI was shot-- had zero spark and using a multimeter up the wiring harness everything was good up to the CDI—replaced with new one along with new plug wire and new plug now have excellent spark The original carb was a total loss. I'm assuming it was parked full of fuel with the fuel switch on. It looked like they found it buried in the sand and put it on, it was so eaten and corroded my thumb went through it trying to get it apart—so new carb. I did also inspect the intake and none of what was in the carb made it into the engine, thankfully. After oil bath, compression was still low—threw some brake cleaner down the intake and noticed smoke escaping from the head gasket—took the head off and saw the original head gasket was completely shot. Replaced that, and now compression is up to 90 from 50. I'm assuming, it'll need to go through a few heat cycles for the compression to really build back up (had the same issue with my 2000 Kodiak 400 from siting for 5yrs after a few heat cycles went to 180) While the head was off, I did a leak test on the valves and liquid stayed, so no signs of gaps in the valves sealing. Also took a look at the piston and wall and both are in excellent shape, very clean conditions. At this point, the bike should fire off or at least pop… but now that compression is back it's sucking air in though both the carb AND the exhaust pipe. Putting my hand on the pipe (no muffler) I can feel it sucking air in, doing the same with the back of the carb, I can feel it sucking air there as well. It isn't pushing air out anywhere. I've checked timing and it's correct. The TDC mark on the flywheel is lined up with the spot on inspection hole. The mark on the timing gear in the head is lined up with the mark on the casting there as well, so timing is spot on. I don't believe it has a leak from the exhaust valve due to the leak test I did. I also don't believe a valve is sticking, I can see them both moving just fine when looking through the inspection holes. In the past, I've had a bike have intake from exhaust and exhaust going out carb, but that was the timing being off, which doesn't seem to be the issue here. Any advice on this would a big help as I'm stumped on what could be causing double air intake. Chances are it might be something simple that I'm not even thinking of. At this point, I'm about to order a box of hair from Amazon Prime from all the head scratching going on.
  15. I just picked up a Bayou 220 and I get no spark. Tested the coil and it was bad, replaced with a new one. Tried to start, and still no spark, but now the new coil is bad as well. Any thoughts?
  16. Hi, I am working on a 2000 Bayou 220. It seems to have very weak spark, and I suspect this is giving me a no start/hard start issue. I can sometimes get the ATV to start, but when it wont start it wont even run on carb spray. Is a weak spark common for this ATV? Should it have a strong vibrant spark like any other small engine? I have tested the stator and have .8 ohms between all 3 yellow wires, and it is open to ground on each of the yellow wires. Carb has been cleaned, and with the airbox off I can see it wicking fuel up through the main jet when I crank it. 125PSI compression
  17. I am proceeding with the restoration of my bayou 220, the recoil starter came only with the external part, the internal part has nothing of it, I saw that some repairs are sold but the model does not exist, in a video I saw that there is one of the honda very similar ... Is it possible for me to adapt only the internal part? I would like to know if someone has already done it. I saw some polaris kits on Aliexpress too, but I don't know if it would be possible to adapt
  18. 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?
  19. Hi all, new here and trying to figure out an issue with a Bayou 220 I just got. It sounds (to my novice ears) like it ticks more than other engines I’ve heard. I also hear it occasionally backfire (briefly) and the engine gets very hot (I’ve never run it enough to shut down). I’m thinking it needs a valve clearance adjustment but I’m wondering if any other experienced Bayou owners or anyone else has any ideas before I start tearing into something I don’t need to? Thanks everyone!
  20. Hello, I am reviewing the differential of my bayou 220 and I came across two situations: 1 - How can the final drive roll be changed? in the manual it shows that the part can be disassembled, but not to the point of being able to change the bearing; 2 - the differential pinion has a gap, so I would like to know if it would need adjustment or if it is so. I put a photo and a video to show WhatsApp Video 2021-03-07 at 18.29.09.mp4
  21. Hey so i have a 1990 bayou 220, and its missing the wiring harness so i went online and bought a bayou 300 wiring harness by mistake. Will it work if i use the 220’s cdi box and ignition coil?
  22. Hi all, I was gifted this Bayou but she's been sitting quite some time. It won't crank using the factory start button but when I jumper the starter solenoid it cranks but there is no spark. The key has power coming in on the white wire and when turned on supplies power to the brown wire coming out. I guess I should start with testing the pickup? I heard I may be able to jumper the wires coming from the pickup with an LED bulb and it will flash? I noticed in the manual that it should have around 110 ohms resistance so I'll check that as well. One thing I noticed was that the starter circuit relay has power on one of the black wires with the key on- this doesn't seem normal as I'm assuming the black wires are grounds? I think one of them comes from the start switch, travels through the starter circuit relay and then grounds the starter relay? Mine is a 1991 so it has the 7 wire CDI (ignitor) and a 2 yellow wire alternator ( as opposed to the later 3 wire type ) with another 2 wires for the source coils (black & red wires ). The pickup wires are blue and black I do believe. Any help appreciated and yes I will test the pickup ASAP. I'm trying to understand how the system works and I don't understand what the yellow / red wire from the kill switch does- I assume it gets grounded when the kill switch is "on" and therefore grounds the CDI so it can't activate the ignition coil? I noticed in the diagram that that yellow / red wire looks like it may be grounded by the ignition key switch when in the "off" position? I also don't have 12v power at any of the wires going into the CDI- doesn't the CDI need to be powered? I also read on this forum that someone used a GM HEI module in place of the factory CDI just to test it for spark- does anyone have any info on that? I hope I'm not missing something simple! Here is a link to the diagram for my bike (which was posted by another user): https://www.quadcrazy.com/atvforum/topic/13742-1988-bayou-220-lost-spark/?tab=comments#comment-101193 Any help appreciated!
  23. I recently acquired 1994 Bayou 220 (leaks oil, leaks gas). Beginning by cleaning carb. When I took the float bowl off, the brass overflow tube is not straight (see image). I am not sure if this is "right" or was damaged/modified at some point (although I can't image why). I have looked for an image or drawing that would show this clearly with no luck. Should this tube be straight vertical; and if so, should I attempt to straighten it, replace it, or leave it be (not sure if this would effect the required float level setting as the end of the tube sits just a little lower at the angle). Prob putting too much thought into this, but any info would help! Thanks!!
  24. Hi all new to the sight haven a problem with my 1988 kawasaki bayou 220 it ran then just died when out one day get gas but no spark any info will help I'm new to the ATV got it used and ran like a champ but don't know where to start when it comes to this
  25. Just was given a 220 bayou, turns over and was wired by a crazy mouse on drugs helped by a committee of politicians taking advice from lil green folk from Mars! This is going to be fun. Claimed the stator was bad. My other project is an old lakota, died driving with no spark and has sat for a bit due to building a house n life! In other words,I may need lots of advice!
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