Bayou 220 owners out there

[zeek123]

yeah i looked at the wiring and its not hacked up at the cdi and i did notice the marks but looked for the t so i will make sure that i get that timed first before doing anything else

[zeek123]

Someone HELP!!!!!!!! I need to know if the T on the flywheel so line up with its mark as soon as the piston hits top dtc please please someone help me

[1252smoke]

yes the t should be top dead center the piston should be at the very top of its stroke good way to tell for sure take a plastic straw in the spark plug hole turn the engine over slowly

[zeek123]

ok i did that and it is at the very top and none of the marks line up and somone just told me that its the little key in the flywheel that is gone so i am guessing i am going to have to pull off that side of the motor . Do i need a puller to get the flywheel off and does this mean that the valves are bent too????

[1252smoke]

yes I think you will need a puller and a healthy impact gun to remove the starter cup (this is located under the recoil starter) they use non aerobic lock tite far as the valves with the cam chain off and the cam set on 12:00 position turn the engine over make sure your timing chain doesn't fall in to the case if you have good compression you golden Never seen a key way fail?? on these engines

[zeek123]

they said that is why i cant get the t mark and the pistion to line up together at tdc so i am going to pull the side off to seeif the woodruff key is sheared

[1252smoke]

they are correct that could be the only reason for it
only thing you can do is remove the side cover and take a look

[zeek123]

well i will let you know how it goes and wish me luck i am going to take it apart tomrrow night

[1252smoke]

looked at a one of the engines out of bayou in my garage just now the tdc mark on it comes up on every other time the piston comes to the top of its stroke but it my be off it does not run catastrophic failure

[zeek123]

lol well i well see what happenes

[1252smoke]

zeek ill call a friend of mine that works at a Kawasaki dealer tomorrow to make shore that I'm not telling you wrong

[1252smoke]

called and talk to my dealer friend confirmed that I’m wrong the t mark should come every time the piston is at the top of its stroke it requires a fly wheel puller to get the key way out but being that its off means the fly wheel has spun on the crank shaft so you my get lucky the fly wheel may come off without puller after the nut is removed just don’t apply to much pressure to any one spot of the fly wheel

sorry bout that don’t know what I was thinking

good luck hope you get it running !!

[zeek123]

well guess what it was the key i pulled the fly wheel and it was sheared off so now i have to get a new one ............ happy that is was something small for a bike that i only paied 150. for lol

[1252smoke]

ya hop that's all it needs the 1 of the guys I ride with spent $800.00 on a 94 ran for 3 days I ended up replacing valves along with springs, timing chain, chain sliders, $400.00 just to get it running again it was slap wore out needed more parts to make it 100% ended up trading him out of it making it my project bike started posting on atvtalk of the build on sunday

[sky94]

Newto the site,first post,you guys sound pretty knowledgable,heres my problem...lost spark on my 220,if you turn it over,it will spark once,just as you let off the starter button.Things ive tried so far.....2 different coils{off running bikes],2 different pulse coils,2differerent stators,completely changed out the wiring harness,2 different cdi boxes,all from a running bike.Always have had the same result...getting frustrated,the bike used to run great,one day was idling in my drive,quit,never fired again...If anyone has any ideas,id really appreciate it,Thanks in advance,Randy

[zeek123]

have you looked at your timing that is what was worng with my bike and found out that the key for the flywheel was sheared off

[zeek123]

cool well smoke i hope i dont have to do any of that i checked pretty much everthing that i could and hoping this is all that is wrong with it

[1252smoke]

Best of luck keep me posted

[1252smoke]

sky94 sounds like possibly a kill switch on the left handle bar or the ignition switch its self Id take a look at a wiring diagram and track the ignition system wires other than that you done well by eliminating problems

[zeek123]

hey smoke i changed the key and got it back together but now i need to get a battery to turn the motor over because the pull start is broke