Kawasaki Bayou 220 Electric Start Problems

The Kawasaki Bayou 220 ATV may experience electric start failure due to issues like a dead battery, faulty solenoid, bad starter relay or loose electrical connections. Diagnosing the specific cause by checking battery voltage, wiring continuity and voltage drops when engaging the starter can help determine where the problem lies. Potential solutions include recharging or replacing the battery, cleaning connections, replacing damaged wiring, solenoid or relay components to restore electric start operation.

Key Takeaways

• Check battery charge and connections
• Inspect starter solenoid wiring and function
• Test starter relay and associated cabling
• Verify proper engagement of ignition key and switches
• Refuel, replace spark plug and check kill switch
• Inspect overall electrical system condition and connections

Problem	Potential Cause	Solution
No start, no sound	Dead battery	Recharge or replace battery
No start, click sound	Faulty starter solenoid	Replace solenoid

The Kawasaki Bayou 220 is a reliable all-terrain vehicle powered by a four-stroke 223cc engine. However, like any machine, problems can occur - one common issue Bayou 220 owners face is failure of the electric start system. When you turn the ignition key, the engine fails to turn over or only clicks instead of cranking.

Diagnosing the specific cause of Bayou 220 electric start problems takes some investigation, but is usually related to battery, solenoid, relay or general electrical problems. With methodical troubleshooting, you can identify and fix the issue to get back to riding your ATV.

Main Causes of Electric Start Failure

There are four major components that allow the electric starter motor to engage and crank the engine when you turn the ignition switch:

Battery - Provides the initial power to operate the system
Solenoid - Activates to allow high current flow to the starter motor
Relay - Engages to pass battery current to the rest of the system
Electrical connections - Transmits power through the starter circuit

Failure of any component or connection in this starter circuit can lead to issues cranking the motor. The most common root causes include:

• Dead or weak battery
• Faulty starter solenoid
• Damaged relay
• Corroded or loose wiring connections
• Defective ignition switch
• Broken start button contacts
• Tripped overcurrent protection

Thoroughly inspecting and testing each part of the electric starter system is key to diagnosing problems.

Step-by-Step Bayou 220 Starter Troubleshooting

When your Kawasaki Bayou 220 won't start electrically, methodically work through these troubleshooting steps:

1. Check Battery Charge and Voltage

The battery must be fully charged and able to provide high discharge current for the starter motor to operate. Use a digital voltmeter to confirm battery condition:

• With ignition OFF, measure voltage across battery terminals
• Fully charged reading should be 12.6 - 12.8 volts
• Low voltage under 12.4 volts indicates possible dead battery
• Charge battery or replace if badly sulfated

Also inspect battery cables and terminals for corrosion, damage or loose connections that add resistance to the starter circuit.

2. Verify Key Switch and Start Button Operation

Make sure your ignition key switch and start button mechanisms are working properly:

• Insert key and try to start - if no click at all, switch contacts may be bad
• Wiggle key and press button firmly - dirty or worn contacts can cause issues
• Bypass button with spare wire to engage switch directly
• If starter engages now, replace faulty start button

3. Check Solenoid Voltage and Function

The starter solenoid receives a small trigger current from the battery when the start button is pressed. If component fails, the starter won't turn on.

• Verify battery voltage at solenoid small signal terminals when start button is pressed using a multimeter.
• No voltage indicates open circuit - check key switch, button contacts, connectors and wiring
• Attempt to activate starter by directly jumping large terminals with screwdriver - if motor spins now, replace faulty solenoid

4. Test Starter Relay Operation

High discharge current for the starter passes through a large relay. Measure voltage drop across relay terminals while pressing start button:

• Voltage drop over 1 volt - bad connections or undersized relay unable to carry required current
• Zero voltage - relay coil bad, wiring issue or failed ignition switch contacts not triggering relay properly

Replace suspect relay and ensure tight wiring connections if voltage readings are outside specifications.

5. Check Electrical Connections

Starter systems handle very high current. Any corroded, loose or broken wires or connectors can cause power dropouts and starter failure:

• Carefully inspect wiring from battery through switches, relay and solenoid
• Look for frayed/broken leads, burnt insulation, green corrosion indicating moisture
• Clean any corrosion, replace damaged wires and ensure tight connections

Proper electrical contact integrity is essential for reliable starter operation.

6. Other Items to Check

• Refuel tank - electric fuel pump operates when ignition on and pulls high current
• Ensure kill switch set to RUN, not OFF position
• Check emergency cut-off and tether lanyard switches reset and functional
• Replace worn spark plug that makes starting difficult for motor
• Inspect starter motor itself - burnt windings can indicate need for starter overhaul

Following detailed troubleshooting steps can help accurately diagnose electric start problems. In many cases, the root cause is simply low battery charge, a faulty solenoid or corroded electrical connections. Replacing damaged components and ensuring clean, tight contacts in the starter circuit can have your Bayou 220 ATV reliably starting again.

Preventing Future Electric Starter Issues

With electric start failure, the problem is usually isolated to a specific component or connection inside the starter circuit. But steps can be taken to maintain your Kawasaki Bayou 220's battery and electrical system to minimize issues:

• Keep battery fully charged - Use an ATV-specific smart charger that provides proper voltage levels and won't allow overcharging. Check charge status every 4-6 weeks during off-season storage.
• Spray electrical connections yearly - Use an anti-corrosion spray to keep water and contaminants out of plugs and terminals in harsh riding conditions. This prevents buildup leading to resistance and electrical faults over time.
• Check wiring routings - Make sure cables avoid hot components and have protective looming intact. Repair any chafed or frayed wires that can short.
• Keep battery hold-down tight - Loose battery terminals are a major cause of intermittent electrical problems on ATVs. Maintain torque on clamps to ensure reliable contact.

Inspecting these items when doing periodic service, oil changes or routine washing helps maximize long-term reliability of your Bayou 220's starting system. Quickly addressing any small deficiencies before they become larger issues can help prevent being stranded with no electric start on a ride.

Maintaining Your Kawasaki Bayou 220 Battery for Reliable Starts

As highlighted in troubleshooting Bayou 220 electric starter issues, a fully charged battery with tight connections is critical for reliable engine starting. While other electrical faults can cause problems, the battery itself most often plays a central role.

By properly maintaining your ATV battery, you can minimize headaches from a dead machine that won't turn over when you push the starter button. Here are key tips for battery care on your Kawasaki Bayou 220:

Check Water Levels

Unlike sealed batteries, standard wet cell lead-acid batteries like those used on the Bayou 220 have water that must be maintained at the proper level. Battery electrolyte is mostly water that allows internal chemical reactions.

Check the battery water level monthly before riding your ATV. Use distilled water and top up each cell until just covering the internal plates. Never overfill. Low water allows excessive heat buildup during charging and discharging that damages plates.

Inspect Terminals and Cables

Another key task is keeping battery terminals and connecting cables corrosion-free. Monthly, use a wire brush to gently clear any buildup of greenish oxidation on terminals or inside cable clamps. Frayed battery leads should also be replaced.

Re-secure connections tightly so proper contact is made for starter current flow. Spray terminals lightly with an anti-corrosion spray afterward to repel moisture. Tight, clean connections avoid electrical resistance.

Charge Regularly

During winter storage or long sitting periods, use a smart charger to keep your Bayou's battery topped up every 2-3 weeks. Never allow complete discharge - recharge soon after any winching, extended electric accessory use or repetitive restarting drains the battery below 12.4 volts.

Proper levels maximize battery plate life. Deep cycling damage means shorter life before replacement is required. Verify alternator output while riding as well.

Following basic battery maintenance guidelines for water level, corrosion and charging will help ensure your Bayou 220 battery consistently provides abundant starting current when you hit the starter button.

Frequently asked questions

Q1: Why won't my Bayou 220 start with the electric starter?

A1: Common reasons for failure to electrically start include dead battery, faulty starter solenoid, bad ignition switch contacts, and loose or corroded wiring connections.

Q2: What should battery voltage be on a Bayou 220 ATV?

A2: Fully charged, the Bayou 220 battery should measure 12.6 - 12.8 volts across the terminals with the engine off.

Q3: Where is the starter solenoid located on a Bayou 220?

A3: The starter solenoid is attached directly to the starter motor which is located low on the front right side of the engine.

Q4: How do I test a Kawasaki Bayou 220 starter relay?

A4: Use a multimeter connected to battery terminals while pressing the start button - excessive voltage drop over 1 volt indicates potential bad relay or connections.

Q5: Why does my Bayou 220 click but not turn over when I push the start button?

A5: Clicking without the engine cranking is typically caused by a bad starter solenoid that fails to engage and pass current to the starter motor.

Q6: What would cause a Bayou 220 to turn over slowly when hitting the electric start?

A6: Slow cranking from the starter can be caused by a weak battery, dragging starter, bad wiring connections or failing starter motor needing repair.

Q7: Where is the full start cup on a Kawasaki Bayou 220 located?

A7: The full start cup assembly is up under the fuel tank console area, connected to the gear selector lever mechanism.

Q8: How can I tell if my Bayou 220 battery is bad?

A8: Signs of a bad battery include inability to hold a charge, reduced cranking power, low voltage under load, case damage or swelling, and corrosion on terminals.

Q9: Will refueling a Bayou 220 help it start electrically?

A9: Yes, ensuring there is adequate fresh gas is important since the electric fuel pump draws high current when energized during start.

Q10: Why does my Bayou 220 starter stay engaged and not shut off?

A10: Starter staying on after button is released indicates a stuck solenoid or bad ignition switch not breaking the control circuit - replace faulty component.