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Discussion Starter · #1 ·
I just picked it up and it runs and drives. Pull start works but trying to get push start to work. Here's what happens

1) I put new battery in fully charged.
2) I connect the battery, it sparks and the 20a fuse blows instantly.
3) I change the fuse and pops right away.
4) checked starter relay to make sure it's correct. No issue.

Help! Could the relay be bad?
 

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Discussion Starter · #4 ·
Just to clarify a bit more. The are no lights working. Including headlights, taillights and neutral light and push start. So it's all the electrics. The fuse on the starter relay(the round silver cylinder with fuse attached)
blows instantly upon connecting battery.
 

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you're probably just going to have to start checking things with a meter till you find the short.
let me tell you a story though... when I first got my bayou I was cleaning the battery cables and noticed 2 plugs running towards the back of the bike. I thought, huh I must've knocked them apart when I was taking out the battery and hooked them together. when I put the battery in, pop! blew a fuse. turned out they were an auxillary power tap and I was shorting them out.
 

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Discussion Starter · #6 ·
I ordered a new starter solenoid relay. Once I get that then ill go from there. Its either that or a short somewhere.
 

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you're probably just going to have to start checking things with a meter till you find the short.
let me tell you a story though... when I first got my bayou I was cleaning the battery cables and noticed 2 plugs running towards the back of the bike. I thought, huh I must've knocked them apart when I was taking out the battery and hooked them together. when I put the battery in, pop! blew a fuse. turned out they were an auxillary power tap and I was shorting them out.

My bike came with those two wires connected and was blowing fuses. I later also discovered that my taillight power wire was shorted to ground somewhere along the frame, and continued to blow a fuse. I diagnosed this by unplugging the headlight switch and probing the wires and applying 12v to each light. To fix it, I ran a new wire from the front of the bike to the rear for just the rear taillights, and all has been well since.
 

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Discussion Starter · #9 ·
Well I decided to start looking. I took plastics off and checked for issues. Had the wiring diagram in hand and saw nothing. Disconnected the ground and cleaned all the gunk off. Tried it again and soon as negative terminal connects pop went the fuse.
 

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you'll have to isolate each positive wire and see if it connects to ground. easier said than done I know. also check what they're hooked up to to see if they're shorted also. ie, zero resistance. you're about to become super acquainted with its electrical system.
 

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Discussion Starter · #12 ·
I'm going to label the wire harness tonight and disconnect it and inspect it. Then ill begin to reattach it one at a time till the fuse pops.
 

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pop fuse

Your bike has an internal short or a positive wire touching a ground. Get a manual- they are available online for $10. They have procedures to verify whether the starter relay, starter motor relay, or rectifier are functional or not. Still, the pos to ground somewhere still seems like the most likely.

My 92 bayou does not crank with elec starter either. Have not solved it yet though it is not blowing fuses. I have a voltage drop somewhere after the relays as I am only getting .5V to the starter motor. Not fun but I am tired of pulling the rope start.

Good hunting.
 

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Discussion Starter · #15 ·
I have a Hayes manual with the wiring diagrams. Ill start with the wire harness tonight. Ill connect battery and see if I can here cracking if I can't visually find it. If its not that then ill start plugging things back till I pop a fuse. Hopefully it works
 

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Discussion Starter · #16 ·
I took out the harness checked the starter first with a direct hookup and it works. Attached the starter relay solenoid and harness. Fuse popped. Began looking for the break and decided better to order a new one. Hopefully this works
 

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I know this post is old but I was wondering we are trying to figure out how to connect the battery on our 1993 bayou 220 when we bought the bike used from another individual it did not have the solenoid or the starter relay circuit in it also it did not have a battery... Would you happen to know how to hook everything up under the seat? Pictures would be great I'm kind of illiterate when it comes to the wiring diagrams... This is all new to me.
 
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