please confirm my reasons about why my 94 bayou 300 4x4 is smoking. I did a rebuild a year ago, drove it about 5 times doing around 100 miles total. NOW the only thing I didnt replace but I remember now is the valve seals. Like I said I got it bored, got the rings for that bore, CLEANED the valves, and everything else. But the only thing I didnt replace were those valve seals. I do run it with the air filter on. ALSO it does not smoke at idel but when I rev it a little its starts to make a little amount of smoke. I think this is cause by more oil pressure from revving thus letting oil go past the 9 year old seals.

HOW MUCH will it cost? I put a grand of parts in it last fall. I LOVE this atv. Even though I have an 03 grizzly in the shed, the bayou is my pride and joy. My brother bought it off the showroom floor and now I am keeping it in the family.

 

bump

 

KawasakiBayou4x4 wrote: You did put an oversized piston in, didn't you? If the piston is the right one, did you hone the cylinder after it was machined so the new rings could seat themselves?

 

we did everything the manual said. it isnt an overbore or anything like that. It was just to "clean up" the cylender walls. the rings for that clean up were almost identical to the origonal. THey were a little thick. The book said I didnt need a new piston for this, and the dealer said I would need a new piston for this. The old one is literally new. I should be ripping the head out this week.

 

How was your ring gap (top & second)?

Standard gap: 0.20 - 0.35 mm
Service limit : 0.7 mm

Did you stagger your ring gaps?

 

it is either intake valves or exhaust valves[img]i/expressions/face-icon-small-smile.gif[/img][img]i/expressions/face-icon-small-wink.gif[/img][img]i/expressions/face-icon-small-sad.gif[/img][img]i/expressions/face-icon-small-wink.gif[/img][img]i/expressions/face-icon-small-smile.gif[/img]