Hello I'm new to the site, we have a Kawasaki bayou 220 not sure on year but I think it's early 90s. So we just got it a few months ago. And just got it running yesterday, it runs good after cleaning the carb. But the fuse that is on the starter solenoid keeps blowing. The lights won't work either. Or the lights on the handle bar don't light up. It does run and start when u pull start it or jump the solenoid with a wire. So the starter does work. So could it be the solenoid? Thanks for the help.

 

Extremely unlikely to be the solenoid, that fuse will be the main one for everything and makers often combine it with the solenoid. Usual suspect for blowing the main fuse is the voltage regulator. Does the fuse blow without ignition being on? If so it is almost certain to be the regulator. Disconnect regulator at its wiring plug and put a new fuse in, if fuse doesn't pop you have found the fault. If fuse only blows with ignition on, it can still be regulator but could be a short anywhere in the system that is "live" with ignition on. There are 220 wiring diagrams in posts on here, if you can find them.

 

I believe It does blow without turning the key. That would make sense. Where would the voltage regulator be ? Thank you so much

 

I'm not sure to be honest. Almost always under the rear plastics on ATVs, it is a heavily finned aluminium casting about the size of a cigarette pack. Usually mat black.

 

Ok thank you.
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