rolled it.. parked it.. took it apart.. now no go..

TJ-Bill · 10-08-2009

Hey guys!.. I rolled my bayou a few months ago.. Nothing crazy just got to brave and had the bike come back over me .. landed on the bars/front grill, I bent the front rack and the 1.. 1,, I repeat 1 support I didn't resupport when I put the bumper on.. ANyway I had a few issues after that, so I parked it and took he plastic offvand removed the battery. This was a few month ago, we have a little girl on the way so the wheeler has not been a huge priority.

I've had time over the last few nights to straighten the metal and start bolting things back together.. Tonight I hooked up the switched for the ignition, lights and winch aswell as put in the battery. I flicked the Ign. on and he lights came one, hit the starter button and I heard a few clicks coming from behind the battery then nothing. I checked the battery, it was only reading about 8v so I jumped it with an old car battery I had laying around that was at 11.5v still notta.

Anyway I got my manual here and will start looking through it tonight, We're heading out tomorrow for 3days (long weekend in Canada).. Just wondering if anyone had any similar experinces?.. or comments?.

I haven't checked any voltages besides the battery.. My 1st plan is to charge the battery up fully and put it back in then try again. After that I'll start tracing the starter circuit.. BUT like I said little one on the way so I don't have much time to tinker..

Thanks
Bill

stu#71 · 10-08-2009

Hi Bill,
Yes, charge the battery.
If you are not getting the bike to "turn over" and are just hearing a click noise when you press the starter button then your problem is with the starter motor - most likely the starter solonoid not engaging properly. I would start there.

TJ-Bill · 10-12-2009

Well I had some time today and I tried he bike with another battery.. Nothing.. So I just came in to grab my manual and I'm off back out to the shed.

TJ-Bill · 10-12-2009

OK.. So I checked the starter button, I checked the engine kills switch. Both seem the be working, removed and cleaned the starter circuit realy. I started to remove the starter relay but 2 of the smaller wires and solderd on and don't have a connector. As of right now when I turn the ingintion on and push the button all I get is a click from the starter relay. So obviously the currnet isn't getter past the realay to the starter... I read the manual about how to test the relay but I get confused.. What is R x1 on the multimeter? Mine startes a 20 ohm and goes to 20M.. not R x 1 ? does it mean the lowest setting?

Anyone have any ideas?

stu#71 · 10-12-2009

Yes, the lowest setting. Rx1 just means turn the meter to the setting which expects a reading between 0 and 1 ohm ie booger all resistance is expected.

86klf300guy · 10-12-2009

if the machine rolled over you may have a cylinder full of oil or fuel can cause hydrolock ,pull the plug out and see if the motor will turn over.

just a thought.-corey-

MrGiggles · 10-12-2009

Quote:

Originally Posted by TJ-Bill

OK.. So I checked the starter button, I checked the engine kills switch. Both seem the be working, removed and cleaned the starter circuit realy. I started to remove the starter relay but 2 of the smaller wires and solderd on and don't have a connector. As of right now when I turn the ingintion on and push the button all I get is a click from the starter relay. So obviously the currnet isn't getter past the realay to the starter... I read the manual about how to test the relay but I get confused.. What is R x1 on the multimeter? Mine startes a 20 ohm and goes to 20M.. not R x 1 ? does it mean the lowest setting?

Anyone have any ideas?

There should be 3 wires on the solenoid plug. One black, black with a yellow stripe, and white. The black wire should have battery voltage when the starter button is pushed in.

On the starter relay (rubber boot around it), there are two solid black wires. One is short and goes to the red solenoid plug, the other goes in the harness. The long one should have battery voltage when the starter button is pushed. IIRC there is a brown wire also, it should have juice when the key is on.

TJ-Bill · 10-13-2009

Great thanks I'll check that tonight.

And Corey I drove the bike home after I rolled it and then once more afterwards I think. It's since I took it apart and put it back together that it won't start.. I think it's time to start looking for a parts bike!!

TJ-Bill · 10-13-2009

Well she's alive. Everything seemed fine even though really I wasn't really 100% sure what I was doing.. Anyway I had power to the starter relay and it was clicking so I checked the battery again and it was right around 10.5v so I jumped it with another car battery I had laying around. Bike started to turn over but wouldn't start. Checked for spark. it was good checked compression it was good. Took the carb off and cleaned it, made sure the jets weren't clogged. Put everything back togther and she fired up. Ran abit rough for abit but once it sat for 5-10 min it seemed pretty good.. Hopefully I'll have time to take it for a spin by weekend after I fix the brakes and but the front back together.

86klf300guy · 10-13-2009

opps sorry i must have missed that part.glad to hear you got her fixed,corey-

TJ-Bill · 4 Weeks Ago

Well she's running.. I didn't have to jump it tonight to get it going so that was good.. My chocke is uumm.. "manual" lets say so after I held the choke on for abit it idled pretty good.. I slapped the bare bones back together and went for a 20min drive and all seems good..

2 problems though..

1.. I'm having the hardest time keeping the air tube from the air box to the carb on, it just doesn't seem long enough. I've tried loosening up the air box and securing both ends but it always seems to pop off one end. I can get it on but it's just barely, and after some hard riding it pops off. Any ideas??

2. The diaphram in the break resovior has magically grown in size! it's swelled up and no longer fits in the hole or even near where it's supposed to, leaving me with no breaks.. I found a piece of rubber and rigged something up to seal it but it's not working properly and I don't want to leave it in there because I'm not sure what the brake fluid will do to the rubber. I left the diaphram out for a few days now hopeing it would shrink but it hasn't.. shoudl I try and find anotherone??

I need a parts bike!!

650hardtail · 4 Weeks Ago

as to your break resivoir rubber swelling..have you switched to some 'new 'brake fluid...dot 5 or 6 ??? it may have reacted w the rubber and swelled it ???

TJ-Bill · 4 Weeks Ago

Quote:

Originally Posted by 650hardtail

as to your break resivoir rubber swelling..have you switched to some 'new 'brake fluid...dot 5 or 6 ??? it may have reacted w the rubber and swelled it ???

I Don't think.. I have about 3-4 bottles of brake fluid that I'd been using for a couple years.. Only thing I guess that could have happened is that I used a different type then was in the bike when I got it..

TJ-Bill · 4 Weeks Ago

anyone know if I can't find another diaphram can I use other handle and res. off another bike? as long as the fitting for the line fits right?

99prairie400 · 4 Weeks Ago

I think pretty much all of the bayou and prairie (300 and 400's anyway) are the same. I have a Bayou 400 and a Prairie 400 and they are nearly identical (if not totally identical, I just haven't studied them close enough to confirm)

Do a parts number search on the parts microfiche and then look that part up by application. It'll tell you everything else that exact same part fits.

10-08-2009	#1 (permalink)
TJ-Bill Third Gear And Gaining BTK Intermediate Join Date: Mar 2009 Posts: 125	rolled it.. parked it.. took it apart.. now no go.. Hey guys!.. I rolled my bayou a few months ago.. Nothing crazy just got to brave and had the bike come back over me .. landed on the bars/front grill, I bent the front rack and the 1.. 1,, I repeat 1 support I didn't resupport when I put the bumper on.. ANyway I had a few issues after that, so I parked it and took he plastic offvand removed the battery. This was a few month ago, we have a little girl on the way so the wheeler has not been a huge priority. I've had time over the last few nights to straighten the metal and start bolting things back together.. Tonight I hooked up the switched for the ignition, lights and winch aswell as put in the battery. I flicked the Ign. on and he lights came one, hit the starter button and I heard a few clicks coming from behind the battery then nothing. I checked the battery, it was only reading about 8v so I jumped it with an old car battery I had laying around that was at 11.5v still notta. Anyway I got my manual here and will start looking through it tonight, We're heading out tomorrow for 3days (long weekend in Canada).. Just wondering if anyone had any similar experinces?.. or comments?. I haven't checked any voltages besides the battery.. My 1st plan is to charge the battery up fully and put it back in then try again. After that I'll start tracing the starter circuit.. BUT like I said little one on the way so I don't have much time to tinker.. Thanks Bill

4 Weeks Ago	#15 (permalink)
99prairie400 Top Gear Full Throttle BTK Expert Join Date: Oct 2008 Location: Butner, NC Posts: 303	I think pretty much all of the bayou and prairie (300 and 400's anyway) are the same. I have a Bayou 400 and a Prairie 400 and they are nearly identical (if not totally identical, I just haven't studied them close enough to confirm) Do a parts number search on the parts microfiche and then look that part up by application. It'll tell you everything else that exact same part fits. __________________ 99 Prairie 400 4x4 98 Bayou 400 4x4 http://www.myspace.com/sicivicdude

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10-08-2009	#2 (permalink)
stu#71 Still On The Kickstand Join Date: Sep 2009 Posts: 32	Hi Bill, Yes, charge the battery. If you are not getting the bike to "turn over" and are just hearing a click noise when you press the starter button then your problem is with the starter motor - most likely the starter solonoid not engaging properly. I would start there.

10-12-2009	#3 (permalink)
TJ-Bill Third Gear And Gaining BTK Intermediate Join Date: Mar 2009 Posts: 125	Well I had some time today and I tried he bike with another battery.. Nothing.. So I just came in to grab my manual and I'm off back out to the shed.

10-12-2009	#4 (permalink)
TJ-Bill Third Gear And Gaining BTK Intermediate Join Date: Mar 2009 Posts: 125	OK.. So I checked the starter button, I checked the engine kills switch. Both seem the be working, removed and cleaned the starter circuit realy. I started to remove the starter relay but 2 of the smaller wires and solderd on and don't have a connector. As of right now when I turn the ingintion on and push the button all I get is a click from the starter relay. So obviously the currnet isn't getter past the realay to the starter... I read the manual about how to test the relay but I get confused.. What is R x1 on the multimeter? Mine startes a 20 ohm and goes to 20M.. not R x 1 ? does it mean the lowest setting? Anyone have any ideas?

10-12-2009	#5 (permalink)
stu#71 Still On The Kickstand Join Date: Sep 2009 Posts: 32	Yes, the lowest setting. Rx1 just means turn the meter to the setting which expects a reading between 0 and 1 ohm ie booger all resistance is expected.

10-12-2009	#6 (permalink)
86klf300guy Way Too Much Free Time BTK Expert Join Date: Feb 2008 Location: some where in ohio Posts: 1,203	if the machine rolled over you may have a cylinder full of oil or fuel can cause hydrolock ,pull the plug out and see if the motor will turn over. just a thought.-corey-

10-13-2009	#8 (permalink)
TJ-Bill Third Gear And Gaining BTK Intermediate Join Date: Mar 2009 Posts: 125	Great thanks I'll check that tonight. And Corey I drove the bike home after I rolled it and then once more afterwards I think. It's since I took it apart and put it back together that it won't start.. I think it's time to start looking for a parts bike!!

10-13-2009	#9 (permalink)
TJ-Bill Third Gear And Gaining BTK Intermediate Join Date: Mar 2009 Posts: 125	Well she's alive. Everything seemed fine even though really I wasn't really 100% sure what I was doing.. Anyway I had power to the starter relay and it was clicking so I checked the battery again and it was right around 10.5v so I jumped it with another car battery I had laying around. Bike started to turn over but wouldn't start. Checked for spark. it was good checked compression it was good. Took the carb off and cleaned it, made sure the jets weren't clogged. Put everything back togther and she fired up. Ran abit rough for abit but once it sat for 5-10 min it seemed pretty good.. Hopefully I'll have time to take it for a spin by weekend after I fix the brakes and but the front back together.

10-13-2009	#10 (permalink)
86klf300guy Way Too Much Free Time BTK Expert Join Date: Feb 2008 Location: some where in ohio Posts: 1,203	opps sorry i must have missed that part.glad to hear you got her fixed,corey-

4 Weeks Ago	#11 (permalink)
TJ-Bill Third Gear And Gaining BTK Intermediate Join Date: Mar 2009 Posts: 125	Well she's running.. I didn't have to jump it tonight to get it going so that was good.. My chocke is uumm.. "manual" lets say so after I held the choke on for abit it idled pretty good.. I slapped the bare bones back together and went for a 20min drive and all seems good.. 2 problems though.. 1.. I'm having the hardest time keeping the air tube from the air box to the carb on, it just doesn't seem long enough. I've tried loosening up the air box and securing both ends but it always seems to pop off one end. I can get it on but it's just barely, and after some hard riding it pops off. Any ideas?? 2. The diaphram in the break resovior has magically grown in size! it's swelled up and no longer fits in the hole or even near where it's supposed to, leaving me with no breaks.. I found a piece of rubber and rigged something up to seal it but it's not working properly and I don't want to leave it in there because I'm not sure what the brake fluid will do to the rubber. I left the diaphram out for a few days now hopeing it would shrink but it hasn't.. shoudl I try and find anotherone?? I need a parts bike!!

4 Weeks Ago	#12 (permalink)
650hardtail TRIPLE NUT BTK Beginner Join Date: Aug 2009 Location: BUTLER PA Posts: 76	as to your break resivoir rubber swelling..have you switched to some 'new 'brake fluid...dot 5 or 6 ??? it may have reacted w the rubber and swelled it ???

4 Weeks Ago	#14 (permalink)
TJ-Bill Third Gear And Gaining BTK Intermediate Join Date: Mar 2009 Posts: 125	anyone know if I can't find another diaphram can I use other handle and res. off another bike? as long as the fitting for the line fits right?

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