1991 bayou 220 electric start problem - ATVConnection.com ATV Enthusiast Community



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Old 06-12-2018, 12:32 PM
Weekend Warrior
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Default 1991 bayou 220 electric start problem

Just purchased a 1991 bayou, in great condition. The previous owner told me that the only issue was the electric start.After researching on the internet I have found several possible fixes but I would like pinpoint the problem.I have removed the recoil starter which worked with no problem. After removing the generator cover I noticed that the gear behind the generator is loose, is this where my problem lies? The gear will only spin in one direction but the looseness sort of scares me. Please help any replies will be greatly appreciated.Thanks
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Old 06-13-2018, 01:57 AM
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First off, what is the problem with the electric start, won't work at all, spins but doesn't spin the engine over, what?
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Old 06-13-2018, 04:35 AM
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The starter will just spin , does not engage the flywheel. Battery is new and fully charged, solenoid is good, all cables and connects are clean and tight. Could the one way starter clutch be bad?
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Old 06-14-2018, 02:43 AM
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Yes, to be certain, now you have the cover off, press the start button. If the big gear behind the flywheel spins round, but the flywheel doesn't, the one way clutch isn't working.
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Old 06-14-2018, 08:06 AM
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Gear definitely not turning, will order parts today, should take 4-5 days to receive, will keep you posted on my results. Thank you for the quick response and help.
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Old 06-15-2018, 01:30 AM
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If the gear isn't spinning when the starter motor is running, it isn't the one way clutch, but the starter drive itself that is faulty. Not sure on the 220, but the 300 has a gearbox inside the starter, and a chain drive to the flywheel gear.
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Old 06-15-2018, 05:04 AM
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Large gear does not spin, it appears to be driven by the idler gear.When the starter button is pushed the starter and the idler gear spin but nothing happens to the large gear behind the flywheel.
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Old 06-16-2018, 01:58 AM
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Right so it is the gear teeth on either the big gear behind the flywheel, which you can see, or the idler gear teeth, or something is missing/broken, which keeps them lined up.
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