220 bayou very weak on power

[jddozermike]

I have a early 90s 220 byou. Bought it in ragged but runnning condition, tore it down and had the cylinder bored at a shop and wet to the .050 over, new piston and rings. Got a used head from ebay cuz the original was so wore out that the valve guide was moving in the head.
I never really rode it before the rebuild so i cant really compare it to now.
It seems very guttless when climbing or accelerating especially. We have another 220 bayou so we started swapping parts around, cadburetor, computer, ignition coil and finally the entire wire harnis. disconnected kill switches and key switch. none of this helped. Raised carb needle, lowered needle. cleaned jets. No better. checked timing several times. Took off airfilter, no better.
When riding it sounds and feels like its under major load . Brakes not hanging.
Im thinking maybe need to change jeting.
Any ideas? im at witts end here, Im new to kawasakis but have had LOTS of experience with Yamaha and some Honda.
OH YEAH, also checked valve adjustment.

[John Taylor]

If its just been rebuilt as you said it probably needs to break in. I was told when I bought my Yamaha 4 wheeler years ago to work it hard during break in, opposite then you usually hear. I had brought it in because I felt it was low on power for a new machine. I did what the guy said and rode it hard and now it is 11 years old and has more power then when it was new. This was my experience, not sure it would work for you but I feel everything is still tight in your machine and as you use it, it should start developing more power.

Good luck!!

[dorf]

What's the compression, with throttle held wide open ?

[86klf300guy]

the 3 things that come to mind is.....

1. timing is (how did you time your machine with a book or online help?)
have to make sure the (T) mark is up and lined up on the case.and the piston is at top dead center and on compression stroke.if that is good then the line on the cam should line up with the nub on the head casting.i think its like a 11:00 postion or was it 1:00 (dang crs )ne how the head has a casting nub on it inside the cam gear hole.

2.. a restricted exhaust or muffler.the header pipe is free of dents and no bindes

3... the clutch is jaked, something in the clutch is broken and bindeing up or it may just be sticking.are you useing a wet clutch safe oil?

0.50 you shouldnt have to rejet just play with the needle settings will do good.the only time need to rejet is when you put in bigger intake valves, k/n air filter or exhaust mods or extreme head work with cam mods.

1 question for you .... does the machine idle well ? does it sound loaded up (under a load) while in (N) or does it sound healthy like your other 220 doeswhen you applie the throttle? (or free reving.)-corey-

[jddozermike]

Continued working on this thing. Went up from the stock 30 main jet to a 35 this helped bunches but still had to back the mixture screw 4 turns out to make it way better, so went up to a 45 main jet (all the shop had on hand) and VOLIA!! it runs good now. still not a power plant (like a Yamaha ) But purdy good. At least i wont feel like a loser letting my wife ride it now.

[Fairwind]

Sounds like the carb is as worn out as the head was...Most of the air is leaking AROUND the slide instead of over the needle..That's why the richer jet improved things..

I own 2 bayou's. In top gear, will your machine "top out", go to red line on level ground forcing you to back off?? If so, that's normal power..You swapped the computer?? What computer was THAT??