bellarmine

Glad my post was slightly helpful, glad to help, and thanks for the good words Mech. I didn't know you had a belt in there, assumed it was similar to my Bayou 300 shaft drive (yes I assumed, bad idea!...:o) Yes it could very well be your belt, worn out, dirty from your missing hose, slipping, maybe the primary and driven pulley sheaves halves not moving or sticking with engine speed. Because before I knew you had a belt, I was going to suggest checking the clutch adjustment, as on my Bayou 300 if I use the wrong oil, dirty oil, or clutch out of adjustment, the engine will slip in top 5th gear when I'm going full speed, and almost sound like revving in neutral until I back off the throttle a little. Like you no problem in 1st gear, I believe roaring down the road in 5th gear is almost harder on the clutch than pulling 600lbs in 1st. Doesn't sound to me like timing is an issue, if as you say the engine revs up normally and tops out, sounds more like a slipping clutch / belt issue. If you had shaft drive I could give you some tips on the clutches, but I know very little about ATV belts..:o) Finally, about your starter, from what you say I think you have figured out your problem. I also had the same problem with my Bayou, starter would engage then skip and grind and not turn over the engine. Yes, drain the oil (or tilt it up 45 degrees on a block), take off the cover and pull the flywheel. Was not too bad, done lots of outboards before, though I did have to buy a special Kawasaki type flywheel puller bolt on eBay for $30 (not sure if you'd need it). It's called a sprag clutch, spins one way but grips the other. Turns out I didn't even replace the clutch, was still like new, just the tiny circular spring that went around the whole mess had stretched over the years and wasn't making the sprags grip properly. Just changed the spring and been good ever since. Here is a exploded view for your ATV, I just love to pour over these so I can figure out what goes on inside a machine, might as well figure what's in there before you take it apart lol: https://www.partzilla.com/catalog/kawasaki/atv/1997/prairie-400-4x4-kvf400-a1/starter-motor You need the One Way clutch, 13194-1094. This is what you need: https://www.ebay.ca/itm/196386773534 Or this, cheaper from China just use the spring: https://www.ebay.ca/itm/395916084250 Reply to this post and you can get your manual.....:o) Bellarmine

Is there any way to check your max RPM when you're going full speed? Does the engine itself audibly sound like it's going as fast as it used to, or it's not getting up there in hi gear, no power? Shudder the thought, the transfer case is not in Low gear is it (lol!)..........:o) I'm sure they have the service manual here on Quadcrazy, well worth the download. Not sure if it's a similar machine, but regarding your (EXPENSIVE) starter motor quote, check out my starter motor video for my own '86 Bayou 300, family owned since new. Brand new starter on the 'bay is $100, and change it out in 15 minutes, no oil draining or side cover gasket removal required. Finally, yes check your valves, I've left mine go for a few years at times, and sometimes after adjusting them WOW it takes off! Once it went from bogging in the snow in 2nd gear to accelerating in 3rd gear, clearance closed up. Though the shop SHOULD have done that!.....:o) Cut exhaust mount and missing screws for $1000, 'Sloppy' isn't the word I'd use......... Bellarmine

Good news you got it fixed! It is amazing how it tends to be the more obvious stuff that normally you take for granted and don't think to check at first, stuff that normally never goes (until it does..:o) Thanks for the reply Mech. I'm working on a friends 1989 Yamaha Exciter sled and it as a throttle protection system in it, just 2 switches on each end of the cable that tell the CDI if the throttle cable is operating properly and not sticking. I don't know what year Timothy's 250 is (I thought I heard 2000?), but I was feeling pretty sure it has something like that, unless you know better than me then no argument I stand corrected......:o). Feels so good when you actually find something wrong and turns out to the the problem. Cheers!~ Bellarmine

Thought I'd chime in with an idea, what about the sticky throttle cable VARS / VATS safety protection system operating on limiting the engine speed / stalling the engine? Perhaps, when it's on jacks in runs fine because it needs very little throttle, but on the ground under load, it needs more gas and/or you pull the throttle cable more and the sticky throttle protection system then kicks in and stalls the engine? Get the manual and wiring diagram and try temporarily shorting out the throttle safety system system (make sure the throttle actually does move freely first!...:o) Just an idea. Robert

Did you still need help with your hubs? I helped my neighbor with his Sportsman last year, turned out the wire going to one of the hubs was snagged and broken, fixed it, refilled the hubs with oil and all good. I just checked each hub coil with an ohmmeter to make sure they were both good, and then drove it into a snowbank to make sure the front wheels broke traction. Yes, in case you don't know, when the hub coils are energized, the wheels still freewheel until you actually drive the machine under power, then the sprag clutches engage. Also, I think it's stupid the way Polaris makes you hold the "Reverse Override" button to get 4x4 in reverse, I mean if I want 4x4 I want 4x4, period. I get stuck in reverse more often than forward, especially with a plow. Yes, I spent some time looking over the (awful) wiring diagram. I'm sure you have your wiring diagram from the owner's manual (important)? If I recall correctly, you can simply apply 12v directly to the AWD switch, then you have true 4x4 on and off, period. No speedo, no override, just a nice simple ON and OFF switch (isn't that shocking these days? what no computer!!?.......:o) I still have the diagram can double check for you or send it if needed. Let me know if I can further assist. Bellarmine

Hi Bender, I got my friend's KingQuad all dialed in, brakes fixed, now starts and runs great, he's happy. Could you give me some symptoms of your own, and I'll see what I can figure out. I have found in the past that spark problems are very much on or off like a light switch - it either works or not. Much more common is fuel problems. Cheers!~ Bellarmine

Hi, did you still need help with your Bighorn 400? If you're replaced the charging coil / stator. I would say your remaining culprit for sure is your regulator-rectifier, they go rather often, gone through 2 myself. Quick check, put your meter on the battery, note the voltage (12.5V~), then start the machine. If the voltage stays the same or drops slightly, or even rises a little bit but stays below 13v, I'd strongly suspect the regulator is blown - no charging. You can also quickly check your new stator - I think 3 wires. Disconnect the 3 wires, does each one show maybe 20+ volts AC to ground on a meter while idling? Hope this helps, let me know if I can further assist - Cheers!~ Bellarmine

Hi, Did you still need help with your Big Bear? Sorry to hear about your ignition problems. Did you download the service manual for your machine? Not sure of your engine size, this might help: https://www.quadcrazy.com/files/file/313-1997-1999-yamaha-big-bear-350-service-manual/ You'll need 10 posts on here before you can download, I might be able to help with that if needed.....:o) Let me know if I can further assist - Cheers!~ Bellarmine

You're welcome Jake, glad I helped! Hpe I can get my friend's Chinese carb sorted out enough to be usable - is starting and idling nice, and driving full speed pretty good, just an occasional hesitation, and sometimes die on letting off the throttle - getting close. If you want let me know how it goes with your true-blue OEM rebuild, might be interesting to compare........Cheers Jake!~ Bellarmine

Thought Id give you my thoughts for what it's worth, I'd say you probably have an aftermarket upgrade on your LT185 - it's from the mid 80's correct? My '86 Kawasaki Bayou has 4 wheel DRUM brakes, as does my friend's 1993 Suzuki Quadrunner. I'm suprised they'd use a disc brake on the rear end, atv's didn't get around to using disc brakes until the late 90's. What do you have in the front, drum brakes? Can't find anything in parts catalogs either, you're saying the rear is hydraulic as well? All other rear brakes I've seen are cable operated. Sorry I couldn't help more, just an idea....:o) Cheers!~ Bellarmine

Do you still need help with your Beartracker? It sounds to me like your main fuse is blown. Replacing all that stuff is good but if the main feed wire is dead it won't do you any good....:o) Check see if you have power at the ignition switch, if not simply trace back from there. Not sure of the year, you can get your service manual here, should have a wiring diagram. You'll need 10 posts before you can download, I can maybe help....:o) https://www.quadcrazy.com/files/file/447-2001-yamaha-bear-tracker-full-service-manual/ Let me know if I can further assist - Cheers!~ Bellarmine

Congratulations! Nothing gives me a better thrill than getting an engine started that hasn't run in years. Everyone just buys Chinese carbs these days, you actually just cleaned yours and you're good to go, starting to seem like Carb Cleaning is a lost art these days. Have cleaned my '86 Kawasaki Bayou 300 carb a dozen times do it in my sleep, still all 1986 OEM carb parts and seals in there and runs and starts smooth! Hope it's still running good for you and you find a fender, you should be able to find a service manual on here in the Files section for free, you have more than 10 posts so you can get it no problem...:o) Happy Trails~! Bellarmine

Hi Rebel, I took a look, would either of these be of help? https://wholefoodsonabudget.com/wp-content/uploads/2018/08/2012-polaris-rzr-800-wiring-diagram-ranger-900-xp-wiring-diagram-on-polaris-ace-900-wiring-diagram-rh-onzegroup-co-7t.jpg https://faceitsalon.com/polaris-ranger-wiring-diagram/ You have the right idea measuring current at the battery terminal. About your 1amp current draw, I do know that sometimes the electronics stays on for a while. For example, you start with 0amps, turn on the ignition, computer fires up, then you turn off the ignition, computer stays on for 5mins / 30mins / what ever. I read this in my car shop manual, my climate control draws 1/2 amp for 5 mins after turning off the ignition. Maybe you did this, but try checking your current draw after 10mins / 30mins / 1hour, see of the 1amp goes away. Just an idea. Hope this helps, let me know if I can further assist - Cheers Rebel!~ Bellarmine

Hi Matman, How's it going with your Honda Recon, did you still need help with it? At risk of sounding obvious, you can download the service manual right here, that'll tell you if it has an oil filter and anything else you'd need to know: Fortunately you have more than 10 posts so download away...:o) Let me know if I can further assist - Cheers Matman!~ Bellarmine

Hi, did you ever get your fuel gauge sorted? Don't know if it's helpful, but I helped my neighbor with his Hisun EFI ATV last year. Electronic fuel gauge on the LCD cluster was acting up, so I took the sending unit right out of the tank and moved the float bank and forth and watched the gauge with the ignition on. It worked but had a delay, you'd have to wait a few seconds for it to respond, guess like a snubber. Anyway that seemed to fix the problem, bad connection or sticky float, or didn't know about the delay. Hope this helps, cheers!~ Bellarmine

Hi Jakes, Thought I'd comment on my experience with a Shindy kit. I have a 1986 Kawasaki Bayou 300 owned since new. Good machine, weak points in my opinion are the carburetor and starter. Keihin CVK-32 vaccuum slide carb very picky about dirt. Ever so often it won't start, I drain the float bowl helps it fire up (water?), then if it persists it's carb clean time. Probably done it a dozen times now, do it in my sleep. Anyway, I decided at one point about 2014 to put in a new carb kit, since it still had all the original seals and jets from near 30 years before. Like you I bought a Shindy kit, feeling they were good quality and Japanese for a Japanese ATV. Well, from the get go I had a high unstable idle - either racing or died. I'm not sure, the tiny washer on the pilot screw might have been bent. Anyway, I put back in the original pilot screw and problem gone. Further update, for a number of reasons I won't go into here, the machine sat from 2017 until 2020, wasn't started at all. Needless to say I cleaned the carb, upon disassembly I found the Shindy float bowl o-ring had turned to gooey TAR. So, in absence of anything else I put back and am currently using the original OEM float bowl o-ring, jets and parts from 1986, and it is running great. Just needs a bit of ether if it goes much below freezing, getting old. Starts instantly and idles smooth otherwise, see a video on how it starts and my starter motor replace tip below: https://www.youtube.com/watch?v=h1rUehPXoaY So draw your own conclusion. Hope you find that interesting if nothing else. I'm currently helping another fellow with a 1993 Suzuki QuadRunner 300, he bought a Chinese carb for it as the original carb was 'lost' (??), so I have no baseline to compare with. With my experience with my Kawasaki, and like you cleaning all 3 of yours, I'm sure I could have gotten it running perfect by simply cleaning the old carb, but what is to be will be...:o) Am getting close to it running decent. Try putting back in your original OEM parts in one of your OEM carbs and try that - what have you got to lose?....:o) Cheers Jakes!~ Bellarmine

You're welcome Steve. I have the official 1986 Kawasaki manual if that makes any difference, has lots of photographs of checks for the shift mechanism, haven't seen the one on here yet so can't comment on what is in it. I looked in my own manual perhaps you could rotate the shift star gear, so the 1st gear peg is maybe at the 5th gear position? Or the shift drum is worn, which as you say is in the bottom end. I imagine the shift foot lever is not hitting the footpeg lol.......:o) Sorry I couldn't be more help, glad it's working for you after a fashion at least. I've had my 300 Bayou since my Dad bought it new in '86, first machine I learned to drive, fun pretty and easy to work on. Cheers Steve!~ Bellarmine

Hi, do you still need help with your Bayou 300? I have the identical machine, 2x4 tough shaft driven ATV love it. I have the paper service manual, which you can also download here if you have 10 posts. Have you checked the clutch adjustment bolt near the oil sight gauge? Can help with the shifting. Also how about the reverse lockout knob? Might have something to do with the reverse-neutral-1st gear shifting. About your machine, what's the history, was working fine before, is it running currently? At risk of being obvious, it is hard to shift at a stand still, best if it is running and moving. I can check my shop manual for shift adjustment procedures. Just some ideas, let me know if I can further assist. Bellarmine

Hello everyone! Just joined up. I've had a Kawaski Bayou KLF300 2x4 since my Dad bought it new in '86 (nearly as old as I am), done a lot to keep it running through the years, especially with starter motor and carburetor work. I'm a veteran at cleaning the finicky CVK-32 carb, everytime I get idle hard start problems its drain the float bowl, and if no go then clean the carb, done that a dozen times over the years now. Still in pretty good condition, kept out of the rain much its life, still runs like a Swiss watch starts right up, though now needs a bit of ether to get going if it's much below freezing. I have a video I made on how to replace the starter motor quickly without removing the engine side cover or even draining the oil, so for my first post thought I'd post it here to help everyone else. If someone needs a hand with this machine drop me a line! I'm also working on a 1993 Suzuki QuadRunner 300 for a friend, could use a bit of help with that so I've made a separate topic here: Thanks everyone, cheers!~ Bellarmine

Hello everyone! Just joined up. As an introduction, I've had a Kawaski Bayou KLF300 2x4 since my Dad bought it new in '86 (nearly as old as I am), done a lot to keep it running through the years, especially with starter motor and carburetor work. I'm also working on a 1993 Suzuki QuadRunner 300 for a friend. Seems original carb was MIA so he bought one online, put a 120 main jet in and then asked if I could help - still running bad. So I'm here asking if anyone has the specs for idle screw turns, float height and valve adjustment specs. Looking to download the service manual soon from here when I'm able to. I've cleaned out the carb and reassembled it, it had some assembly errors, and so far got it to start and idle fairly well, bit unstable, and it drives good but tends to stumble when starting out with light throttle, and then when releasing the throttle sometimes it dies. Think I'm getting close to having it dialed in. Also have to look at the rear brakes, pedal goes through the floor and no braking at all. Everything else appears pretty good, even the speedometer works. Thanks in advance to everyone, cheers!~ Bellarmine