Make sure any wiring is well of of the way of the lugs of the tire!..
Or you may find yourself rewiring the lights.

 

Replaced the tail light and went down to the mud hole at the gate going the the field.
...No Problems...
At low speed there is a small bounce but once you speed up is not bad at all.

 

Quick update. 1 the gas valve is still NOT leaking. 2 i tilled the garden to 8"+- had tree days of rain and the bayou went through it with no problems. i did notice the plastic baler twine holding the Redneck Retreads on are stretching a bit so ill keep an eye on that till i fix it good.

 

its official!!! The judge has decided!!!
The 91 Bayou 220 has been resurrected!
i have a 25 year old city slicker niece that made a smart *** remark about all the "trash" on the farm back in september. Well long story short. She made a bet that i would not be able to get the thing running and driving.
Now she and hear two daughters(7 and 9) must spend the summer living and working on my farm with no cell phones! Fyi she hates being out in the country. LOL
if i would have lost the bet?
i would have to trash all my stuff in the old barn (minus the tools) and along the fence rows!

ill post the final cost tomorrow.

 

$$..Kawasaki BAYOU 220 KLF220..$$

Kawasaki oil filter bypass valve $19.56
Front wheel rim $21.96
Petcock valve $6.95
Fuel filter $1.76
Bolts $1.99
LED light $1.38
Brake shoes full set $3.98
Oil filter X2 $4.99
CDI Module $20.95
FUBAR tire and rim all total $25.00
Air Filter Box $11.00
Tires $104.28
Oil $18.00
Redneck Retreads $5.00

Total $246.53

 

Good Job fixing that old bayou. I am currently in the middle of a similar project restoring a polaris 350L 4x4. It looks very similar to your bayou. I liked all the "fixes" that you did. You're a very resourceful dude. My restoration is much more expensive as a result of me not being as resourceful, but it should also return a very nice product in the end. I'm hoping to get it looking like

this one. This isn't mine though, I just got the pic off the internet to show you what it's supposed to look like.
I live in Las Vegas, so there's no snow here. Anyways, I enjoyed reading your build, and I hope mine turns out the same.

 

Thank you very much... Would love to see any progress on your polaris.

My grand dad would say if you have money save it. if you can fix it do it. Dont buy what you can make and give God thanks for things you do and dont have.

 

Update. The plastic baler twine holding the Redneck Retreads on are stretched to the point where the tires are slipping inside them at times. im going to try 2mm stainless steel cable and springs weve got lying around farm.
P.S. Cant believe it the gas valve is still NOT leaking.

 

Update.
All is good and Redneck Retreads still working!..