I have an 88 220 bayou and it was sat down for a few years do to parts. Now i have got it going again and have been riding it for adout 3 week she was dripping oil around the gear shifter, replaced the O-ring did help,So took the right side case off to see what was going on. only to uncover more problem the oil pump gear is made out of PLASTIC and it look ****ed up and was the oil pump was.The gear was just siting there not moveing the pump is it eny easy to take it out r all that cluch stuff have to come to. Can i get i metal one(gear) made and put it in there. Oh eny help with that leak would be good to
It run good dont use oil dont smoke are nothing idle very good start on Frist are 2nd pull even on these cold days

 

I'm preety sure that they make a metal replacement. But, if not go to a place that machines metal they should be able to make you one for cheap.

 

This plastic gear issue was discussed in legnth before in this forum and the the conclusion was that there is no substitute gear made of metal from Kawi or aftermarket companies. If anyone has found one since, please post here. If not, the only option is to install another plastic gear but now on ride with this in mind - HEAT kills the plastic gear, just like your automatic transmission in your car. Don't do anything to overheat the engine oil, such as driving slowly in high gear - when clutch plates slip, it creates lots of heat. To keep the oil cooler, install an auxillary engine oil cooler. Install a engine oil temp gauge to monitor. Change engine oil often and keep it at high side of the level inspection window.

 

You can order a plastic gear, take it to a machine shop and have them copy it in metal, have a bunch made up to get a better unit price, then sell the rest to us on the board and ebay. I'd take one if you do all the legwork and they dont cost too awful much.