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If anyone is having issues with the Mikuni VM24SS carb, I thought I would post what issues I had and how I resolved them. Acquired a 93 Bayou 220 that had sat for over 4 years. The carb was extremely corroded and pitted and full of leftover fuel. Cleaned carb and bowl and was able to get the engine to start. Within 30 seconds exhaust would heat up and start to glow red hot. Removed carb and recleaned everything, including a second overnight soak. Needless to say, after removing the carb for the 5th time and my frustration to the limit I realized that my attention had been to the carb body and not to the bowl. There is a small brass rod on the bottom of the carb that goes down into the float bowl but is seperated from the main section. I had cleaned that area very well....I had thought. ***The corrosion had sealed off the channel that runs from the main bowl section to the small tube section on the side of the float bowl. No amount of carb cleaner was going to get it to budge. So i took a small nail and started to scrape away the corrosion and was eventually able to dislodge enought of the corrosion that carb cleaner would flow through that channel. *** I thoroughly cleaned each side of the channel in the float bowl and reinstalled the carb and now the issue of it running lean is gone. On a second note the fuel mixture screw was a nightmare to remove as the threads had been corroded and wouldnt let the screw come out. I used a little cutting oil and worked the mixture screw in and out until I was able to push past the corroded threads and completely remove the needle. After a couple passes with a tap to clean the threads it is like new again. Hope this helps if you are having a lean running machine.

I have a 1992 Kawasaki Bayou, and every time I try to replace the fuse on the starter relay, it blows immediately. I have replaced the battery, and have exhausted all of my ideas. Any help is greatly appreciated!

I just got a 1996 Kawasaki Bayou 220. The wiring is a bit of a mess. My question is I have a white wire and a black/yellow wire that aren’t connected to anything. They’re both located under the seat. The bk/y wire comes from where it splits I think 3 different ways. I’ve checked the diagram and I’m still having no luck. Also are the only wires connected to the ignition switch the brown and the white one? Any help it’s appreciated. Thanks.

hi all first post just found forum and the manuals / wiring diagram BIG THANK YOU im struggling to find the vin number on my frame? I m told left side of frame , lower, nr. in front of the gear pedal ?? haven't found it yet , is it numbers stamped on the frame or a commission plate ?? main prob. no spark no power to coil , off to study the wiring info I've just found thanks again. tom

Hey there all, First off thanks for the board. My Bayou 220 has survived 3 teenagers and is on its 4th now. Up until recently it has been a virtual tank....until I decided to fix it;) Noticed some smoking from the engine block (not exhaust) so figured it was time for a quick top end rebuild. Now that I have it all back together, it fails to start. I've pulled the starter rope until my arm is tired. So I will be as detailed as possible and hopefully get some help. Completed: -New Head gasket -New Valve seals -New piston (standard) -New rings (standard) -All new seals -Cleaned up head and valves (didn't do any resurfacing, as it all cleaned up pretty easy) -All torqued to spec -Piston ring gaps all checked out -Valve clearances (Intake: .18mm, Exhaust .20mm). Not too tight, not too loose. Pros: -Engine IS making decent compression -DO have spark -Will fire for a split second if I drop some gas in the spark plug hole and pull start. Will NOT from carb and or intake valve. Timing: So I followed the guide of: TDC -Flywheel aligns on the “T” mark on the engine site hole -Cam gear mark aligned with the cover mark Seeing as this is my first time doing a top end rebuild on an ATV. Here are my questions and concerns: -I didn't realize (dummy me) that there are 2 TDC's. 1- Compression, 1-Exhaust. How do I know if I'm on the right one? -Does the cam need to be aligned a certain way when put back in? I just aligned the cam gear dimple with the cam and put it in. No alignment. Thanks ahead of time. I feel like I'm 90% there, but I'm missing an important step for completion.

I had a quad fall in my lap a couple weeks ago. The only things I knew about it was it was a Kawasaki Bayou 220, was in pretty rough shape and was free. I couldn't say no to a fun little project. I've been looking a different ATV forums gathering quite a bit of info and decided this was the one I wanted to join. Thanks to this forum, I found the VIN under about an inch of mud and cross referenced it to be a '98. It had been sitting outside for at least 5 years and was told it ran when parked, but had no brakes. Squirrels or mice had been chewing on the handlebar controls and it's generally just kind of beat up. So far, I've gone through the carb (not near as bad as I expected), freed up the brakes (will probably need new cables), replaced the spark plug, air filter, petcock and put a new battery in it. The gas tank had been empty and looked clean so I put some fresh gas in it and tried to crank it today. I got a neutral light, but the starter button did nothing. I tried pull-starting it and it wouldn't fire. I checked the plug and wasn't getting a spark. I started digging and found some potential issues and some definite problems. I have a wiring diagram I found on here but it's just a picture or scan out of a book and hard to read. I don't see a reference to a black/yellow wire, which is my first problem. First, it that a factory crimp? One of those wired looks like it goes to the connector in the 2nd pic. Is that just a spade lug type connector? I pulled on it with some needle nose pliers but it didn't seem to want to come off. In the 3rd pic, should there be a fourth wire? I've read through and bookmarked the threads Andrew Baker and Arizona have going but I figured I needed to start with these obvious issues first. I have lots of pictures, so if there is something else you want to see, just ask. If I don't already have a pic, I'll take one.

Hello. I'm new so I hope I'm posting in the right place. My neighbor gave me a nice looking Bayou 220, but I can't get any fire to the plug. No lights, nothing. So far I've put in a brand new battery and relay. So those are good for sure. No neutral light comes on when the key is turned. Where should I start to try to figure out this electrical problem? I have a new coil to install, but common sense tells me it has to be something before that. I'm cheap so taking it to the dealer is out of the question. Does anyone know the process of elimination in a situation like this? I'd might add it LOOKS like the wires are all where they belong, but I can't say they are for sure. If the machine wasn't in such great shape, I wouldn't bother, but the grandkids should have a lot of fun on this. Thank you in advance for any help someone can offer.

my sons buddy wants to buy a 2001 bayou 220, anything he should look for? I figured this was best place to ask, he is paying 750, is that good

Anyone know where I can get a service manual PDF for a 1994 Kawasaki Bayou 220?