91 Bayou 220 won't start

[paintslinga2010]

I may get flamed for this but I trust you guys as much as any dudes on a kawasaki forum. But anyway my grandpa gave me his Bayou 220 because it will not start. I have spark and compression. The problem has something to do with it backfiring through the carb. When I pulled it apart I found the carb to be barely in the rubber boot. Of course I think wow found the problem. But I secured it tightly and its blowing gas and air out of the back of the carb. Still no fire. Whats going on here? Timing? Its weird because hes had it for about 5 years and its ran flawlessly aside from some valve tick but i think thats normal on these. He never drove it over 10 mph.

 

[beastlywarrior228]

Check the timing, timing chain, valve lash and see if the valves are even still good. Run a compression test too

 

[paintslinga2010]

I'm definitely going to check the valves tomorrow. I'm hoping that gets it to start. There is enough compression to blow my thumb off the hole. I'm not sure how to check the timing.

 

[paintslinga2010]

The timing marks on the flywheel and the cam sprocket are not lining up. Whats this mean?

 

[beastlywarrior228]

Timings off

 

[paintslinga2010]

This could be caused by? sheared woodruff key? I can turn the flywheel by hand.

 

[beastlywarrior228]

Maybe or the chain skipped

 

[MotoArts]

sheared woodruff key?

Yup.

Bent valves are still a possibility too, even though there's compression.
Need to figure out why it sheared.
Bad cam chain/guide/tensioner...?

 

[paintslinga2010]

There is a compression relief valve on the head for pull starting it. My grandpa never used it and pull started it for a time. That may be why. I'm still not sure if the key is ever sheared. I cant get the flywheel off.

 

[DeadLastRacing]

Need a flywheel puller. Valves could be bent from the non-decomp valve starts?

 

[paintslinga2010]

How generic are these woodruff keys usually? can you get them anywhere?

 

[MotoArts]

Do you mean the flywheel spins like there's no resistance? Does the crank turn with it or does is spin independently from the crank????

Hardware stores have shear keys, but you may have to "modify" one to fit. There are all different shapes, lengths and widths.

 

[paintslinga2010]

I'm confused on whats going on. When I was using the starter there was pretty good compression coming out of the hole. When I pulled the pull starter i could turn the motor with my bare hand which made me think the flywheel was just turning on the crank which could also be why its out of time. Now with the cover off I'm not so sure. I gotta track down a flywheel puller and see more i guess.

Thanks for the help so far guys. I appreciate it.

 

[paintslinga2010]

I took it to get the flywheel popped off today and the key was fine. The guy who popped it off said the timing chain was loose and that is probably the reason it jumped time. So the next step will be to put a new timing chain on and get it in time. He said a valve may be bent. I really hope not. Could bad timing bend a valve? Are these two issues related?

 

[97warrior350]

yes they could be because when it jumped time the valves will be opening at a different time and the piston could have slapped one of the valves.

 

[MotoArts]

Was the chain itself stretched, the automatic adjuster bad, or chain follower(s) worn???
Could be one or all the above. Just don't throw $$ at it, man, ya gotta ask questions.
We're here to help.

 

[paintslinga2010]

When I took the atv to the dealership the mechanic who took the flywheel off said he thinks its the timing chain stretched and it jumped time. The tensioner appears to be working. He said he has seen a lot of engines and he can tell by looking at the chain its stretched because of the angle it goes down into the jug on the right side. I ordered the $50 chain and so far that is all I have into this thing. It may be a shot in the dark but if it doesnt work i will run more thorough tests.

 

['00 WO-YA!]

I'd prolly spend the few extra bucks & be sure the guides are good. They can allow more slack than ya think when they wear. I wouldn't be surprised if it isn't a case of accumulated wear vs. just the chain being worn. Yes, a new chain will be tight enough to give the illusion that things are well but it won't be long til you're back in the same boat if you aren't careful.

 

[MotoArts]

I'd prolly spend the few extra bucks & be sure the guides are good. They can allow more slack than ya think when they wear. I wouldn't be surprised if it isn't a case of accumulated wear vs. just the chain being worn. Yes, a new chain will be tight enough to give the illusion that things are well but it won't be long til you're back in the same boat if you aren't careful.

X2!
Isolate the real problem, and replace what's broken.
Don't half-ass it.

There are waaaay too many "parts changers" masquerading as "mechanics" out there...

 

['00 WO-YA!]

X2!
Isolate the real problem, and replace what's broken.
Don't half-ass it.

There are waaaay too many "parts changers" masquerading as "mechanics" out there...

You know that's right! I fix cars for a living, you wouldn't believe the half-ass **** I see! A guy brought a car in for inspection yesterday that had the gas tank held in place with metal coat hanger twisted up. WHAT!! Who does that? What kind of hillbilly ******** is that?