How to Clean a Kawasaki 220 Bayou Carburetor

The Bayou 220 was a utility-style all-terrain vehicle produced by Kawasaki between 1988 and 2002, when it was replaced by the Bayou 250. The Bayou's 215 cc single-cylinder engine was fed by a round slide-style carburetor, which relied on the throttle cable to physically lift or lower the throttle slide. During the course of the Bayou's lifetime, its fuel supply can be contaminated by dirt or debris, which will eventually clog the carburetor's fuel jets. To effectively remove clogs, the carburetor must be removed and disassembled before being dipped in a cleaning solution.

Things You'll Need

• 12 mm socket
• 4 mm Allen wrench
• 10 socket
• Pliers
• Gas can
• 10 mm open-end wrench
• Phillips screwdriver
• 10 mm socket
• Punch
• Flat screwdriver
• Container
• Carburetor cleaning solution
• Water
• Compressed air
• Protective gloves
• Safety glasses

Instructions

1. Park your Bayou 220 on a level work area and set the parking brake. Allow the engine to cool for a minimum of 30 minutes.

2. Pull the seat release lever and remove the seat from the Bayou. Unbolt the front brush guard and carrier rack, using a 12 mm socket and a socket wrench. Unscrew the gas cap, then remove the front and rear fuel tank cover, using a Phillips screwdriver or a 4 mm Allen wrench. Remove the screws attaching the front fenders to the foot well panels, using a Phillips screwdriver. Remove the front fender, using a 10 mm socket.

3. Screw the gas cap onto the fuel tank. Unscrew the fuel tank mounting bolts, two at the front of the tank and one at the rear, using a 10 mm socket. Turn the fuel tank petcock lever, located under the left side of the tank, to the Off position. Lift the fuel tank off of the frame and pull the fuel hose off of the petcock outlet, using pliers.

4. Loosen the clamps attaching the carburetor to the air box duct and the engine intake holder, using a Phillips screwdriver. Push the air box duct off of the carburetor, then push the carburetor to the side and out of the intake holder. Lift the carburetor up and out of the ATV's frame.

5. Unscrew the carburetor top cap by hand, then pull the cap, throttle cable and throttle slide out of the carburetor housing. Lay the cable and all attached parts over the side of the ATV's frame for now.

6. Loosen the drain screw at the bottom of the carburetor's float chamber, using a flat screwdriver. Drain any remaining fuel into a gas can, then tighten the drain screw. Pull the fuel hose off of the fuel inlet on the left side of the carburetor. Unscrew the choke plunger from the top of the carburetor, using a 10 mm open-end wrench.

7. Flip the carburetor over and remove the float chamber and gasket, using a Phillips screwdriver. Remove the float from the towers on the bottom of the carburetor, using a punch. Lift the float valve from the brass valve seat between the float towers. Unscrew the valve seat, using a 10 mm socket. Unscrew the main and pilot jets, using a flat screwdriver.

8. Unscrew the pilot air screw, located under the carburetor outlet near the float chamber mating surface, using a flat screwdriver. Count the amount of turns required to unscrew the pilot air screw for later reinstallation.

9. Push the throttle slide up and against the top cap and slip the throttle cable end out of the catch cut into the bottom of the throttle slide. Push the jet needle up and out of the throttle slide.

10. Place the carburetor body, jets, float chamber, jet needle, fuel valve and seat, throttle slide, pilot air screw and float into a container filled with a carburetor cleaning solution. Allow the parts to soak for a minimum of 30 minutes, then rise thoroughly with warm water.

11. Blow dry all of the cleaned parts with compressed air. Blow air directly through the carburetor's air and fuel passages, as well as the pilot and main jet openings. Reinstall the float chamber.

12. Reinstall the valve seat, fuel valve, float, and the pilot and main jets into the carburetor. Screw the pilot air screw and spring into place, setting the screw at the same amount of turns required to remove it. Push the fuel hose onto the carburetor fuel inlet.

13. Push the jet needle into the hole at the bottom of the throttle slide. Slip the throttle cable end into the slide's catch. Push the throttle slide into the carburetor, then screw the top cap into place by hand. Screw the choke plunger into place at the top of the carburetor.

14. Push the carburetor outlet into the engine intake holder, then push the air box duct onto the carburetor inlet. Tighten both clamps to secure the carburetor.

15. Reinstall the fuel tank onto the ATV. Push the fuel hose onto the petcock outlet. Unscrew the gas cap, then reinstall the front fender and both fuel tank covers. Screw the gas cap into place. Reinstall the seat onto the ATV. Reinstall the front brush guard and the carrier rack.

Tips & Warnings

• Avoid smoking while servicing your Bayou 220's carburetor. Flammable fuel vapors will still be released from the carburetor even after it has been drained.

• Most carburetor cleaning solutions are solvent-based and can cause serious skin or eye irritations. Wear protective gloves and eyewear while working with carburetor cleaning solutions.

References

• Kawasaki KLF220A All-terrain Vehicle Serive Manual; Kawasaki Heavy Industries