I just bought a Bayou 220 "for parts or repair." It's in rough condition but everything seems to be there. The guy said the brakes are frozen, battery dead, tires are bad, and it probably needs a carb. Has been sitting for many years. When pulling the cord, the compression felt strong, and it rolled easily after some air in the tires. For $200, that seemed good enough. I paid him and put it on the trailer.

Back home, I noticed that the key switch was broken, the coil was hanging against the exhaust and melted, and the spark plug wire was all taped up, so I bought a key switch, coil and wire, all for $25. Knockoff parts for this machine are certainly cheap enough.

I have virtually NO experience with ATV engines, but I know the basics.

1. I pulled the cord while holding the spark plug boot away from the plug. ZAP! Got me! She definitely has spark.

2. The headlights came on while I pulled, so the charging system seems to be working.

3. I plugged in a compression gauge, pulled the cord and got her up to 125 PSI. (Is that okay?)

This all seems pretty good to me. I think it's worth replacing the battery, but where should I go from here?

What would you do next?

Thanks.

 

Check it has plenty of oil in sump. Clean the carb out, no altering settings, just remove jets and blow both jets and the holes they came from out with compressed air. Check fuel in tank, if it is stale, drain out and refill with fresh. Check choke works OK, and see if it starts. If it does, ride it along a level private path to check all gears work, remembering you have no brakes. If all that is fine, get the seat re-upholstered, or buy a new one, free off all the brakes, check wheel bearings, steering and ball joints for play at the same time. Check diff oils, and change engine oil and filter. Fit new tyres, you will then have a very good KLF220.

 

Merryman,
Thanks for the nice plan of action. I will follow it. You have given me good advice before. Thank you for your kindness and willingness to help others!

I just looked at the oil window, and it was at the right level and wasn't too dark. I opened up the fuel tank and PHEW! There was orange, stinky old fuel in the bottom. I sure hope the petcock was closed when I was checking compression.

So first order of business, I need to figure out how to suck that nasty fuel out, or how to remove the tank to just dump it.