220 bayou no spark ! - Page 3

sky94 · 09-22-2009

94 model,unfortunately im not at the garage tonite,will get back with those,your correct,the inside of flywheel is all magnetic,exterior strip comes by and lines up with pulser,though is non magnetic...this being said ,not sure how pulser can differentiate anything,since entire exterior of flywheel is earth....Thanx,Stu for your help,Randy

stu#71 · 09-22-2009

The stator should be earthed - that's ok i think.

94 - ok, there's only one wiring diag in my manual here covering a 94 220 Bayou - so that's good! (Do you have the same diag with you?)

This manual says you have an "exciter coil" on your model. Do you have red/blk and a red wire also coming up from the stator (as well as the blue & blk coming up from the pick up coil)?

Check for exciter coil:
Remove the front fuel tank cover
Follow wiring from the crankcase cover on lhs of the vehicle to the electrical connectors inside the the lhs of the rear fuel tank cover. Disconnect the connector
Set meter to rx10 ohms. NOte: during the next step, connect the meter to the side of the connector that leads back to the engine, not to the wiring harness side.
Connect the meter between the red/black and red wire terminals in the connector. These are the exciter coil wires. Compare readings with [those] above. If incorrect the alternator stator must be replaced.

That's worth a check also.

sky94 · 09-22-2009

How many ohms should the red/black.red be?And i do have these wires for sure and i have not checked them,although i have tried two different stators off known running machines....will check these and get back...Thx,Randy

stu#71 · 09-22-2009

100-190 ohms on your '94 220 model (see that already makes the instructions in my manual above crap cos it says set meter to x10 - doh!)
I'm not sure this is the problem but worth checking to rule out.
Those wires should run from the stator, to a connector then up to the CDI

stu#71 · 09-22-2009

Also check your stator coil resistance: 0.2 - 0.8 ohms on your model

stu#71 · 09-22-2009

Quote:

Originally Posted by sky94

i have tried two different stators off known running machines....will check these and get back...Thx,Randy

Also check the wiring from the connector back to the CDI for continuity??

Jinjiro · 09-23-2009

Hi guys, I just joined because I found this thread while searching for a similar problem. I picked up a Bayou 300 yesterday - not sure on year, I think either '86 or '87 since it's the KLF300A. It has no spark, and while I know it needs a new battery, I also think there is a problem with the stator. I am fairly new to ATV/motorcycle engines, but I can turn a wrench on cars.

Here are some pictures of what I found when I removed the stator cover:

It looks to me like I am missing a magnet on the outer piece. Is that the flywheel? Do I need to replace the whole flywheel or just the magnet? There was also no key for the flywheel, just the bolt. Does the stator itself also need to be replaced?

Any help or guidance would be greatly appreciated.

stu#71 · 09-23-2009

Oh dear! That's what is technically known as FUCT (Failed Under Continuous Testing)

You need a new rotor (the bit that dissolved all over your fingers are the magnets I think!), possibly a puller needed for this altho someone may have a trick?
You may save the Stator (last photo)- check the resistances across the stator wires first should be .2-.8 ohms for a 300 86-87 model, .1-.7 for a 300 88-99.
Someone in all that mess there should be a tiny little "key", a piece of metal that slides into the slot in pic2

Jinjiro · 09-23-2009

Thanks, that's what I had guessed but I wasn't 100% sure. Now where is the best place to purchase the replacement parts? I was looking on eBay at the flywheels, but it seems like they do not come with the magnets. Is it technically two separate parts?

I do have a Clymer's repair manual coming, so hopefully that should be a big help in fixing this up.

sky94 · 10-06-2009

Stu,Sky here, had some other things goin on so have been away for awhile....got to the bottom of my ignition problems.....Tested everything you provided me with,everything checked out good....all that was left was the flywheel,found one on Fleabay,off running bike....INSTANT SPARK! Could not really believe it,but bike starts instantly!Thanks for the help! Really appreciate it! Randy

09-22-2009	#44 (permalink)
stu#71 Still On The Kickstand Join Date: Sep 2009 Posts: 32	100-190 ohms on your '94 220 model (see that already makes the instructions in my manual above crap cos it says set meter to x10 - doh!) I'm not sure this is the problem but worth checking to rule out. Those wires should run from the stator, to a connector then up to the CDI Last edited by stu#71 : 09-22-2009 at 10:20 PM.

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09-22-2009	#41 (permalink)
sky94 Newbie Join Date: Apr 2008 Posts: 22	94 model,unfortunately im not at the garage tonite,will get back with those,your correct,the inside of flywheel is all magnetic,exterior strip comes by and lines up with pulser,though is non magnetic...this being said ,not sure how pulser can differentiate anything,since entire exterior of flywheel is earth....Thanx,Stu for your help,Randy

09-22-2009	#42 (permalink)
stu#71 Still On The Kickstand Join Date: Sep 2009 Posts: 32	The stator should be earthed - that's ok i think. 94 - ok, there's only one wiring diag in my manual here covering a 94 220 Bayou - so that's good! (Do you have the same diag with you?) This manual says you have an "exciter coil" on your model. Do you have red/blk and a red wire also coming up from the stator (as well as the blue & blk coming up from the pick up coil)? Check for exciter coil: Remove the front fuel tank cover Follow wiring from the crankcase cover on lhs of the vehicle to the electrical connectors inside the the lhs of the rear fuel tank cover. Disconnect the connector Set meter to rx10 ohms. NOte: during the next step, connect the meter to the side of the connector that leads back to the engine, not to the wiring harness side. Connect the meter between the red/black and red wire terminals in the connector. These are the exciter coil wires. Compare readings with [those] above. If incorrect the alternator stator must be replaced. That's worth a check also.

09-22-2009	#43 (permalink)
sky94 Newbie Join Date: Apr 2008 Posts: 22	How many ohms should the red/black.red be?And i do have these wires for sure and i have not checked them,although i have tried two different stators off known running machines....will check these and get back...Thx,Randy

09-22-2009	#45 (permalink)
stu#71 Still On The Kickstand Join Date: Sep 2009 Posts: 32	Also check your stator coil resistance: 0.2 - 0.8 ohms on your model

09-23-2009	#47 (permalink)
Jinjiro Newbie Join Date: Sep 2009 Posts: 4	Hi guys, I just joined because I found this thread while searching for a similar problem. I picked up a Bayou 300 yesterday - not sure on year, I think either '86 or '87 since it's the KLF300A. It has no spark, and while I know it needs a new battery, I also think there is a problem with the stator. I am fairly new to ATV/motorcycle engines, but I can turn a wrench on cars. Here are some pictures of what I found when I removed the stator cover: It looks to me like I am missing a magnet on the outer piece. Is that the flywheel? Do I need to replace the whole flywheel or just the magnet? There was also no key for the flywheel, just the bolt. Does the stator itself also need to be replaced? Any help or guidance would be greatly appreciated.

09-23-2009	#48 (permalink)
stu#71 Still On The Kickstand Join Date: Sep 2009 Posts: 32	Oh dear! That's what is technically known as FUCT (Failed Under Continuous Testing) You need a new rotor (the bit that dissolved all over your fingers are the magnets I think!), possibly a puller needed for this altho someone may have a trick? You may save the Stator (last photo)- check the resistances across the stator wires first should be .2-.8 ohms for a 300 86-87 model, .1-.7 for a 300 88-99. Someone in all that mess there should be a tiny little "key", a piece of metal that slides into the slot in pic2

09-23-2009	#49 (permalink)
Jinjiro Newbie Join Date: Sep 2009 Posts: 4	Thanks, that's what I had guessed but I wasn't 100% sure. Now where is the best place to purchase the replacement parts? I was looking on eBay at the flywheels, but it seems like they do not come with the magnets. Is it technically two separate parts? I do have a Clymer's repair manual coming, so hopefully that should be a big help in fixing this up.

10-06-2009	#50 (permalink)
sky94 Newbie Join Date: Apr 2008 Posts: 22	Stu,Sky here, had some other things goin on so have been away for awhile....got to the bottom of my ignition problems.....Tested everything you provided me with,everything checked out good....all that was left was the flywheel,found one on Fleabay,off running bike....INSTANT SPARK! Could not really believe it,but bike starts instantly!Thanks for the help! Really appreciate it! Randy

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