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  1. 1990 kawasaki bayou 300c idles fine but pops out exhaust and intake when trying to excel, will not take throttle past 1/4 , any one had this problem? have replaced carb twice, same thing, fresh built engine cylinder head, same as before, new spark plug, flywheel key is good, pulser test good, good spark
  2. Hi everyone Merry Christmas! Am a newbie here so I can’t access the service manual till I have 10 posts, how much torque when bolting down the top end on a Bayou 300 4x4? On the 4 long bolts
  3. Hi all, Just looking for a second opinion before I start ordering parts. It looks like from the below tests it must be a failing stator. Background - quad runs fine but when I use winch it will drain battery, I can then pull start but even after running for 20 mins if I turn it off, battery still dead and does not seem to get charged at all. Voltage at battery after charging using trickle charger is 12.5. Start up and voltage shows 13.1 at idle, if I rev it up voltage drops to 12.5. LED lights also flicker at night even with fully charged battery. Really more annoying than anything and if it is stator I prob will not change until it becomes more of an issue or maybe during next oil change. Thanks for looking, appreciate any replies! Stator plug and letters show how I tested. [ ] A [ ] B C [ ] Checked resistance on stator (manual says .1 to .7) A = .7 B = OL C= OL Voltage idle and 3/4 throttle A = 31/55 B = 15/33 C = 15/32
  4. 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!
  5. I have a 99 kawasaki bayou 300 4x4 I just bought. It ran when I test drove it. I tried shifting from high range to low range and think it may not have been completely in neutral. I drove it onto trailer and put into neutral. Upon getting it home neutral light didn't come on, wouldn't start and wheels locked. I opened up and verified it is in neutral by looking at star thingy in case. Everything on that side looked good but it wouldn't change gears because it was in between high and low range. Got that adjusted and now it shifts but still no neutral light and rear tires are still locked. Was going to check neutral safety switch but can only find videos and pics of the 2 wheel version so I'm trying to figure out how to get to it I know it's under gear shifter and case on left side but don't know what to take off and would that make the tires lock. Front wheels move but rear are locked. Thanks for any help and advice. God bless America
  6. Just picked up a 1998 bayou 300 4x4, runs but spits and sputters. runs worse when i put on the air filter. guy said it has a brand new carb. Does adjusting the valves help with the cold start and not run right until it warms up?
  7. Hi, I have an EU '94 KLF300 Bayou with ignition issues. I got it last summer and used it for about 20 hours, then one sunny day we used it for about an hour, parked it, and then it didn't want to start again. It has a *really* weak spark, I've only been able to see it once while testing. I'm just getting started on this, I'm going to go through all the weak/no spark trouble shootings from the manual. Since I've already invested like 10 hours digesting the manual and forum threads that I possibly can, I thought that it would be nice to create a thread like this in case I come up with a solution that can help someone else. So far I've replaced the spark plug, I will replace the spark plug cap with a NGK VD05F (5kOhm resistance). I'm going to check the resistance in the pickup coil, stator coil and ignition coil next. I have tried two CDIs, right now I mounted the original CDI which actually gave the most output to the spark plug out of the two A question for you, is it possible to make any assumptions about the CDI by measuring the resistance like in the manual? There's a "resistance table" that you can refer to when measuring between the different connections. I'm asking because I haven't yet seen anyone in the forums that has mentioned that they've measured the CDI resistances and made any conclusions from that. I'll attach a photo of my Bayou Pär, Sweden
  8. View File 1986-2006 Kawasaki Bayou 300 Service Manual This service manual is for a 1986-2006 Kawasaki Bayou 300. Adding to downloads library. Submitter Ajmboy Submitted 05/11/2018 Category Kawasaki ATV  
  9. I have a 1989 Bayou 300 and i have to keep replacing the ignition coil on it. Does anyone know what might cause this ? It runs great for a few weeks and then it just stops firing and won't start back until the coil is replaced. I have put 3 new coils on it already.
  10. Hi there! We just bought 4 acres and needed a work rig for moving stuff around and blazing trails. Been looking at buying a quad for a long time and finally got the opportunity. Found a very good condition 1994 Kawi Bayou 300 4x4. Runs great and seems to be in great operating condition with one little thing. The unit seems to have an issue with reverse. Previous owner did tell me about it and its totally usable but the issue is annoying enough that I want to try and fix it. Im pretty mechanical oriented so don’t think this will (hopefully) be too much of an issue. I bought the kawasaki shop manual on ebay and should be here next Friday but wanted to get a head start on it. The issue seems to be similar to this post but I think may be more mechanical than just the switch. https://www.quadcrazy.com/atvforum/topic/14281-1994-bayou-220-neutral-safety-switch/ Here goes! Neutral light is always on when key in on position I found that the green wire coming out of the block from neutral switch is grounded to chassis. When plugged in to switch light never turns on no matter what gear its in (and wont start). Machine can go from 1st directly into Reverse if you don’t feather it. This is the part that that makes me want to fix it. I feel like its dangerous and could possibly do some damage. It usually takes 3-4 tries to 'find' neutral. The reverse turn knob seems to be operable and cable is connected and operates the reverse 'selector' when turned. Springs back when released both at the switch and at the 'selector' inboard of the shifter. When in reverse the red reverse light does not illuminate Based on above and looking at the post above it seems that this would indicate that the reverse stopper is 'broken' and rotated in an 'in gear' position. I see a few posts on here where people have said it can crack. If I plug the green wire back in and turn machine to 'on' I can move the shifter through all gears and the neutral light and reverse light stay off. Again, to me it seems that the 'reverse stopper' is probably broken, stuck where the switch thinks its in a forward gear and the shaft is probably just spinning inside it. Am I on the right track here? I wanted to get a head start on this and looking at parts diagrams it looks like the part number for the 'reverse stopper' is 13091-1443, found one on ebay for $30 shipped. I hate buying parts before tearing it down but if this is the likely culprit I would take a $30 gamble to buy it so I can have it on hand when the manual arrives. The other question I have which I hope is an easy answer is none of the parts diagrams I have found show the bevel gear gasket part number. Can anyone tell me what the part number is for this? Many, many thanks for the info and I promise to post pics once I have it apart.
  11. Here's today's weird question--has anyone have any thoughts about putting a snow blade on a 87 Kawasaki bayou 300? My kid is thinking about using my bayou and I'm thinking it's too much money and time to do that. It ha to have a mount, winch, and all that goes with it.
  12. I'm having an issue shifting into 1st gear from neutral. No problem shifting into any other gear including reverse. When I depress the foot pedal it doesn't go into 1st gear. After repeatedly pressing it sometimes it will go into 1st gear, other times I have to rock the machine slightly and then it will go into 1st gear. I took the right side cover off and removed the clutches to get a better look. I've taken all the parts of the shifting mechanism off thinking I would find a worn part but everything looks fine. When I watch the shifting action from neutral to 1st gear, the part that engages the shift star (drum) is pushing on the peg that is connected to the shift star but it can't push it far enough down to get it out of neutral before it bottoms out. What am I missing? Is the issue actually inside the transmission? Thanks for any and all help.
  13. Version 2

    209 downloads

    This service manual is for a 1986-2006 Kawasaki Bayou 300. Adding to downloads library.
  14. Hello everyone! Just joined up. I've had a Kawaski Bayou KLF300 2x4 since my Dad bought it new in '86 (nearly as old as I am), done a lot to keep it running through the years, especially with starter motor and carburetor work. I'm a veteran at cleaning the finicky CVK-32 carb, everytime I get idle hard start problems its drain the float bowl, and if no go then clean the carb, done that a dozen times over the years now. Still in pretty good condition, kept out of the rain much its life, still runs like a Swiss watch starts right up, though now needs a bit of ether to get going if it's much below freezing. I have a video I made on how to replace the starter motor quickly without removing the engine side cover or even draining the oil, so for my first post thought I'd post it here to help everyone else. If someone needs a hand with this machine drop me a line! I'm also working on a 1993 Suzuki QuadRunner 300 for a friend, could use a bit of help with that so I've made a separate topic here: Thanks everyone, cheers!~ Bellarmine
  15. Motor starts right up, but when I open it up past quarter throttle it bogs way down while ridding, the longer it runs the worse it gets. If I just leave it in neutral and give it full throttle it revs up and down. Back history: Bike sat for 3 years, Installed new plug, cleaned the fuel tank, took it to a shop and had the carburetor gone though. Picked up from shop, motor bogged down first day and barely got me back to the truck an 1 mph. Took back to shop after a month I was told it had a bad plug, I told him I just replaced it. Got quad home and it is doing the same thing!!!!!!!!! Thanks in advance for your support! The carburetor has recently been gone through by a shop
  16. Hello, I have read many forum topics on this matter but have never found a similar problem. So i bought a cheap as* quad thats got all sorts of parts on it. It's a 1997(if you look the date on frame) Kawasaki KLF(Bayou) 300 EUROPEAN Model (atleast I think, since I'm from Europe), the engine is 1988 if I'm not mistaken and the CDI is 1995.-2006. ( 21119-1447, 6pin ). My problem is that I don't have spark. I would diagnose the issue but connectors from CDI to wiring harness have almost all different colors and I'm not sure if they are connected correctly (pictures below). Pickup coil is putting out around 400 ohms and is pulsing. CDI is being fed 12v by one y/r wire that is coming to connector and with 12v to one gray wire which is coming from ignition switch ( quad actually doesn't have ignition switch so I'm not sure if gray should be supplying power or not). Stator looks good cause when crancking all three yellow wires put out around 5v AC. Neutral light is also on which means the switch should be ok, if it even matters. I know it's not the ignition coil since I get no power nor any kind of pulsing to G/W wire that is coming to it ( and I even put another one on there just to check an it ended with the same result). I'm nowhere near proffesional around this type of stuff so any help would be amazing.
  17. Hello- Not certain of model year here-was plowing snow and when I went to reverse, nothing...no bang, no grind no whine, motor just kept running smoothly but no gears either direction. Took it to recommended local mechanic and his diagnosis [after ~ 2 hr of shop time] is bent or broken shift fork. Estimate of 33 hrs of shop time to replace [@ $95/hr] + parts [~ $500?]. Says he won't install used parts and couldn't find any OEM. I THINK I located some OEM for ~ $75 apiece-without the machine handy I can't check ser # to be certain they are the correct ones. I realize I'm still living in the last millenium in many ways, but this just seems waaay out of line to me. I was prepared for maybe $1200 quote but $3500-4000 seems nuts. Anyone who has done [or paid to have it done] this particular job want to chime in? I'm not real anxious to tear into to it myself but I do have tools and have done rebuilds on ancient Datsun trucks. No way I'm shelling out that much $$$ on a machine this old even if it has been babied for much of it's life.
  18. Hello, Could anybody help me... I need instructions or videos how to adjust clutch of my atv Kawasaki KLF 300 4x4 year2000
  19. Need help have no power to anything i can jump starter solenoid but no spark at plug no neutral lights or anything no power to anything passed the starter solenoid neutral switch is good
  20. Hi there I am in need of a manual for my KLF 300 Bayou 4x2 . I've found others on here for the 4x4 model, but was wondering if I need a separate 4x2 manual. Does anyone know?
  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. I have a 2004 Kawasaki KLF300. I’m not sure What is the black/yellow, brown, and red wire wrapped together in the wire hornets of a klf300. I got it used and notice some wires not connected. They are located in the front area The reason why I am asking because I’m having issues with it firing up. I cleaned the carb put new spark plugs and gas.
  23. Hey I have a Kawasaki 300 boyu and it die in 5 gear and can’t get in Neutral try rocking it and moved it back and forth but nothing can same one here help me pls
  24. The clutch cover goes on and fits, but the little L chapped arm that has gear slots is concerning me. It appears it goes to wear the clutch adjust bolts are on the cover. Is there a specific way to tell how it mounts on the gears in relationship with the basket? I don't want to deal it up unless it's right
  25. Hi guys New to the forum. i ended up here google searching for info on a bayou 300 i have here which has a nice squeek to it. looks very much like its not getting oil fed to the head. it was one of 2 bayous i got hold of to add to a third one i already had here. it looks like the previous owner had diesel in the sump instead of oil. its had fresh oil /filter in it but develops a squeek once it warms up. ive managed to work out the oil feed to the head is not getting anything so if anyone has a circuit diagram not just the parts manifest that would help out as im still looking for a service manual to download. Cheers
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