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Found 68 results

  1. I had a quad fall in my lap a couple weeks ago. The only things I knew about it was it was a Kawasaki Bayou 220, was in pretty rough shape and was free. I couldn't say no to a fun little project. I've been looking a different ATV forums gathering quite a bit of info and decided this was the one I wanted to join. Thanks to this forum, I found the VIN under about an inch of mud and cross referenced it to be a '98. It had been sitting outside for at least 5 years and was told it ran when parked, but had no brakes. Squirrels or mice had been chewing on the handlebar controls and it's generally just kind of beat up. So far, I've gone through the carb (not near as bad as I expected), freed up the brakes (will probably need new cables), replaced the spark plug, air filter, petcock and put a new battery in it. The gas tank had been empty and looked clean so I put some fresh gas in it and tried to crank it today. I got a neutral light, but the starter button did nothing. I tried pull-starting it and it wouldn't fire. I checked the plug and wasn't getting a spark. I started digging and found some potential issues and some definite problems. I have a wiring diagram I found on here but it's just a picture or scan out of a book and hard to read. I don't see a reference to a black/yellow wire, which is my first problem. First, it that a factory crimp? One of those wired looks like it goes to the connector in the 2nd pic. Is that just a spade lug type connector? I pulled on it with some needle nose pliers but it didn't seem to want to come off. In the 3rd pic, should there be a fourth wire? I've read through and bookmarked the threads Andrew Baker and Arizona have going but I figured I needed to start with these obvious issues first. I have lots of pictures, so if there is something else you want to see, just ask. If I don't already have a pic, I'll take one.
  2. last year I bought led lights when I was riding my 4 wheeler the lights started getting dim shut off now my 4 wheeler will not start the battery is hot everything is dead I checked the fuse and its good would there be another fuse I am missing I'm took the led bulbs out and replaced them with the ones that was in there wonder what meh problem is
  3. Hello i was wondering if someone could help me out iv recently got a Kawasaki klf 220 it needed big end bearing changing so i rebuilt the engine and the bike has compression starts first time every time but after i have been riding for about 10 minutes oil starts to leak from the head just below the exhaust so i replaced the gasket still done it so i took it to a shop he done the same and it is still doing it any information would be great thank you
  4. Hey I have a 97 bayou 300 2x4 (klf300b) that i bought for 1000 last June and sunk another 1000 into it already. When i went to look at it, the seller had warmed it up before hand (he was riding it when I got there). it ran good so i bought it and took it home that evening... next morning it wouldn't hardly start. I discovered the carb was clogged, there was chunks of rust in the fuel valve, the choke lever was missing and other things. I have since cleaned the carb and replaced the fuel valve and gas lines and cleaned out the gas tank and cap. Enough background on it, the problem is this: It floods if i push it past half throttle in 4th and 5th gear even going downhill and shifting correctly. It also has to idle and warm up when you first start it which is really annoying now that its cold... It also smokes blue smoke for about 15 seconds when started cold- does not smoke at all once warm but the exhaust still smells like burnt metal. A friend told me that it didn't have enough compression. I also found out that the valves are a common cause for low compression on Kawasakis.. I have never adjusted valves before- the most I've ever got into a engine was a head gasket on a riding mower so I'm new to this. My goal is to get this bike running and starting cold like a top- should i tear down and rebuild the top end? What should i try first? I tore the carb apart and rebuilt it and fiddled with the air screw and nothing changed. I also ordered a compression test kit that should be coming in soon. Ive also considered just selling it for like $500 and taking the hit- Id rather not sink too much more into this machine.. lol
  5. Version 1.0.0

    560 downloads

    1988-2002 Kawasaki Bayou 220 Service Manual The Kawasaki Bayou 220 is one of the most common all-terrain vehicles on off-road trails that is geared toward novice riders and families. It’s also one of the smallest and most inexpensive ATVs on the market, with a retail price under $3,500, as of 2010. The Bayou 220 is Kawasaki’s only ATV of its size. The 220’s sibling is the larger Bayou 250 equipped with a 228cc engine. Engine The Bayou 220’s engine is a 215cc, four-stroke, shaft-driven, air-cooled model. Its bore measures 2.6 inches and the stroke is 2.4 inches. It features a relatively high 9.3:1 compression ratio with fuel delivered through a Mikuni VM24SS carburetor. The electronic ignition is Kawasaki’s DC-CDI. It also features a recoil backup as a starting system. The clutch is an automatic wet multidisc model with power delivered to the wheels via a five-speed transmission, according to ATV Source. Chassis The steel frame supports a front suspension with single A-arms and twin shock absorbers, with the rear suspension a Quad-Link system with two shocks. Front wheel travel is 4.5 inches, while the rear wheel travel measures at 4.9 inches. Front and rear brakes are drums. Size The front tire size is AT21X8-9 with the rear tires measuring AT22X10-10. The ATV’s wheelbase is 43.9 inches, with an overall length of 68.7 inches. Ground clearance is 6.1 inches with the seat height measuring 28.7 inches. It weighs 403 lbs. and can tow up to 450 lbs. Its fuel tank can carry 2.6 gallons. Basics The Kawasaki Bayou 220 is not the fastest ATV on the market, but one reason the Bayou 220 has kept its price low is the lack of amenities. It features a brake light and dual headlamps with high/low beam. There is an auxiliary lighting terminal inside the front cover of the ATV and electrical accessory terminals under the seat. The instrument cluster atop the fuel tank features a fuel gauge, but not much else. There are no speedometer, odometer, hourmeter, tripmeter, high-beam indication or high-temperature light. It does have a reverse/neutral indicator light. The Bayou comes in two colors: hunter green and firecracker red. Features The front A-arm, twin shock and rear Quad-Link twin-shock suspension system is not a true fully independent system, but it allows for a comfortable ride over rough terrain without employing a complex and expensive, fully independent suspension system. The ATV features front and rear steel cargo racks. The ATV is rider-friendly with a limited adjustable throttle to help novices practice their riding skills without twisting the throttle too far and losing control of the vehicle.
  6. just got a 99 Kawasaki bayou replace the coil because the spark was very weak still have the same issue before it would start after a while that it would start everyday as long as you started it every day but if you let it set you play hell starting it looking for information on what could possibly be wrong maybe the CDI box not sure any help would greatly be appreciated thank you
  7. Hi guys new to this forum and thought I’d jump on as I’ve just bought my first quad a Kawasaki bayou klf300c 89 model. It had starting issues when I bought it so I’ve gone thru and replaced the cdi, voltage regulator and starter solenoid aswell as rebuilt the starter motor after all this it was still free spinning on electric start so I pulled the stator cover off to find the fly wheel wasn’t spinning so replaced the one way clutch bearing put it all back together and still not engaging at all. I’m at a loss and looking for some ideas on we’re to look next to solve the problem cheers Ben 👍
  8. I need help with wiring on a 1998 (I think, 10th digit of the VIN was W) Bayou. I'm not getting spark, I'm pretty sure it is due to grounds being off because the harness is pretty hacked as far as the electric start and charging system goes. I'm needing a good wiring schematic. I found one online and there are a few things that don't add up on it so I'm skeptical that it is really for my year and model. Any help would be appreciated. Thanks.
  9. Version 2

    105 downloads

    This service manual is for a 1986-2006 Kawasaki Bayou 300. Adding to downloads library.
  10. Does anyone know what the 3rd item is behind the battery on this ATV ? I know 1 is the, solenoid1 is the CDI box, what is the 3rd.
  11. Help a brother four legger out Bayou300 acts like it's flooding if it's it's in the Alabama sun all day but, I've cleaned the carb. Sometimes it'll backfire even though the timing and valve lash are in spec. Thought it was sticking float but after 2 times cleaning the carb I'm lost. So
  12. 1988 Kawasaki 220 Bayou trying to remove generator/ starter 1way clutch cover to be able to replace 1way clutch. All bolts are removed case cover is dripping what oil that remains...but I can't get the cover to come off..what am I missing? Thx in advance.
  13. 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
  14. I have a 1987-89 (not sure on the year) Kawasaki bayou 300 that has electrical issues, I have replaced the entire harness with a proven good/used one, new CDI box, and two brand new coils, problem is that it tests no charge at the pickup coil, so I replaced and tested again with a so called good one that had been salvaged out of a blown up 220/250 (not sure which, the left side cover is smaller than my 300) in Missouri. It has a proven good OEM stator. I am trying to avoid buying a new start and pickup coil because it is so expensive so if anyone has a suggestion please let me know.
  15. i bought a kwasaki bayou 220 and the person i got it from lost the key so they wired it to bypass the key start to use the pull rope but the wires got unhooked some how now i dont have a clue how to wire it back up to pull rope start. does any1 have a pic of the wires or help me im a newby
  16. Hello all, wanted to sign up for this site as I am sure I will have lots of questions soon. One of my coworkers has given me a free Bayou 220 that does not run, I was told it needs a new wiring harness, however I cannot confirm any of that yet. Next weekend I am going to drive up to the place and pick it up and get some hands on but right now trying to find some service manuals so that I can trace and find out what is going on. My plan is if I can get it to run to do a full restoration and use it to putt around the trails around my house. I have some experience with small engines, currently have six mini bikes and a buggy with a GY6 motor that I brought back to life and I am hoping I can do that same with this. Really hoping the Bayou has good compression and it's only a electrical problem. In the mean time I am going to be reading this forum to learn as much as I can and hopefully find a service manual. I have attached the only pic I have of it so far. Thanks! Daniel
  17. What weight gear oil for this machine? 80w90?
  18. So I bought a Bayou 220 as me 'Black Friday' score, and was informed it has carb issues.. A little history from the previous owner: they suspected the carb was bad as it was 'running like crap' so they did a rebuid kit on it. Didn't fix issue so they took it to a shop where the tech installed an aftermarket(?) carb, but had to modify the throttle cable to get it to work. Quad ran great at 1/4 throttle, but anything above that and the throttle would stick and the machine would run like garbage again. What I know and think: I hear carb issues are common and fairly easy to fix. Also, I think they used the 'universal' rebuild kit that claims '88-'11, but the jets and such were different from '00-'03 (gaskets, etc. appear to be the same) so their original attempt was a good idea, just not good enough. They did give me the original carburetor with the 4-wheeler, but it has the wrong internals. I'm thinking if I can get the right jets, springs, etc for the rebuild, I should be able to get this thing running right. Of course, I still need to charge the battery back up, change all the fluids, replace fuel lines, plug and wire.. ya know, the basics for a machine that's been sitting for roughly 9 months. lol
  19. Recently started shifting hard from neutral to first causing it to stall. I'm able to lift up on the shifter and throttle up and slowly let off the shifter, like driving a standard. That is the only way to get it In gear and stay running. Also if I come to a stop and keep it in gear it wants to continue moving, eventually stalling out. I don't have much experience with the bottom end or clutches. I just now replaced friction and steel plates and that made no difference. Don't know what to do now.
  20. View File 1988-2002 Kawasaki Bayou 220 Service Manual 1988-2002 Kawasaki Bayou 220 Service Manual The Kawasaki Bayou 220 is one of the most common all-terrain vehicles on off-road trails that is geared toward novice riders and families. It’s also one of the smallest and most inexpensive ATVs on the market, with a retail price under $3,500, as of 2010. The Bayou 220 is Kawasaki’s only ATV of its size. The 220’s sibling is the larger Bayou 250 equipped with a 228cc engine. Engine The Bayou 220’s engine is a 215cc, four-stroke, shaft-driven, air-cooled model. Its bore measures 2.6 inches and the stroke is 2.4 inches. It features a relatively high 9.3:1 compression ratio with fuel delivered through a Mikuni VM24SS carburetor. The electronic ignition is Kawasaki’s DC-CDI. It also features a recoil backup as a starting system. The clutch is an automatic wet multidisc model with power delivered to the wheels via a five-speed transmission, according to ATV Source. Chassis The steel frame supports a front suspension with single A-arms and twin shock absorbers, with the rear suspension a Quad-Link system with two shocks. Front wheel travel is 4.5 inches, while the rear wheel travel measures at 4.9 inches. Front and rear brakes are drums. Size The front tire size is AT21X8-9 with the rear tires measuring AT22X10-10. The ATV’s wheelbase is 43.9 inches, with an overall length of 68.7 inches. Ground clearance is 6.1 inches with the seat height measuring 28.7 inches. It weighs 403 lbs. and can tow up to 450 lbs. Its fuel tank can carry 2.6 gallons. Basics The Kawasaki Bayou 220 is not the fastest ATV on the market, but one reason the Bayou 220 has kept its price low is the lack of amenities. It features a brake light and dual headlamps with high/low beam. There is an auxiliary lighting terminal inside the front cover of the ATV and electrical accessory terminals under the seat. The instrument cluster atop the fuel tank features a fuel gauge, but not much else. There are no speedometer, odometer, hourmeter, tripmeter, high-beam indication or high-temperature light. It does have a reverse/neutral indicator light. The Bayou comes in two colors: hunter green and firecracker red. Features The front A-arm, twin shock and rear Quad-Link twin-shock suspension system is not a true fully independent system, but it allows for a comfortable ride over rough terrain without employing a complex and expensive, fully independent suspension system. The ATV features front and rear steel cargo racks. The ATV is rider-friendly with a limited adjustable throttle to help novices practice their riding skills without twisting the throttle too far and losing control of the vehicle. Submitter oxidized_black Submitted 12/14/2016 Category Kawasaki ATV  
  21. I need a service manual for a 1986 185 bayou any help would be appreciated Thanks in advance, Dennis
  22. Hey I just recently bought a 2002 Kawasaki Bayou 220 when you shift it jumps a lot and while it’s riding it it’s jumping as well but won’t stay started when you let off the gas Could somebody tell me what could possibly be the problem? Thank you
  23. View File 1998 Kawasaki Bayou 220 Owners Manual 1998 Kawasaki Bayou 220 owners manual Submitter Joe Brenke Submitted 10/29/2018 Category Kawasaki ATV
  24. So, I've been having issues with my Bayou 220. It's gotten to the point where it was parked for 4 years just because of the issues. Issue 1, Grabby clutch: The clutch is adjusted incorrectly and grabs when shifting from neutral to 1st. It grabs before the engine has a chance to rev, which stalls it. Issue 2, Starter clutch blown out: The starter clutch is busted and spins free both directions. Issue 3, bad shocks: The springs or shocks are bad and the quad leans hard when getting on.
  25. A friend of mine has this Bayou 220 that started running bad and parked it a few years ago. I foolishly volunteered to take a look at it. I noticed right away the choke plunger on the carb was broken and probably the reason it was running bad but now the old gas was evaporated and like turpentine. Before i even tried to start it, i drained/ thoroughly washed the tank out, new fuel filter, new fuel lines. Blew air through the petcock etc. Changed the oil and filter and air filter and new choke plunger and cable. I disassembled the carb and rebuilt it with a kit. I cleaned the main jet with solvent and poked a wire through it to make sure it is clean.. the engine now fires right up with the choke on and dies when i take the choke off. I adjusted the air/fuel screw to about 1.5 turns out and the idle screw about 2.5 turns out. The rubber boot between the carb and head does not have any cracks in it so I don't think it is leaking air. I originally had the clip on the needle on the second from the top ring... when i moved it all the way to the bottom it starts, runs and idles really fast and will idle eeally high with the choke off but if i adjust the throttle cable and/or idle screw to a slower idle it will sometimes stall but the idle will go up and down every few seconds and when you give it gas there is a hesitation... i tried moving the clip down to rhe second from bottom and same problem... i replaced all the parts in the pic to the top right. However, there appears to be a small o ring, washer and spring left over from the kit... i did not see these get removed..... a) any idea if where these extra parts go and if i need them and b) any other ideas on why i cant get it to idle right or carb adjustment ideas? Thanks

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