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Discussion Starter · #1 ·
95 bayou 300 2wheel. This is my first four wheeler. The guy I bought it from showed me slight drip on his floor from a drain plug he recently retapped. I figured I could handle a small leak from a second hand machine. Well after a few times of riding it the bayou seems to be running low on oil. Now maybe this is normal operations as well so I refilled the oil. But the next day I notice my drip on the floor was slightly larger. I wanted to see this drain plug for myself so I took off the skid plate and found a pretty rough looking installed drain plug. It does have a small drop but also seemed to have an excessive gasket and maybe some grey looking “jb-weld” ish material around it. So that’s scary but I figure surely that’s not the only source since my floor spot Grew a bit. I went on to find recent moist around the head gasket for the top end. I’ve never seen it drip but it drips on the new starter the guy installed so it seems the head gasket leaks too. He did say he replaced that gasket when I inquired about the darken stains around that area of the motor. He said he replaced that gasket during. Ring replacement when the bayou was smoking. It no longer smokes by the way. So I continue on thinking well maybe I can do another top end gasket myself some day but still the oil on the floor suggests a more visible leak. I mean it’s not a lot but it grew as I mentioned. Then I find my what seems to be an awful thing. The pull cord and starter was replaced by the preavious owner and it appears there’s a busted area on the crankcase where the left side cover mounts to the L-case.
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I have not seen oil from there but that looks scary to me. Does this area hold oil? I wondered if it doenst maybe I’ll leave it be but if it does it’s probably the reason I lost some oil. I also found tonight oil on the rubber boot cover I think is for the drive shaft or something. Idk my first ride so I’m unsure of how to proceed. Especially with the case cracked like that. I don’t know how the engine works but if there is indeed oil there in the operation of things it seems like I must do a major engine over haul….. any insight would be so very helpful. I bought this for my daughter but I may have been bitten by going with such an older model.
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scary, but nothing unusual, its too bad the way some people repair and screw over people.

The first picture, thats your engine cover, you would have to split the cases and replace that side cover.

You could at that point perhaps send it to a machine shop or a welder to fix that area.

how low is the oil on the dip stick?
 

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Discussion Starter · #3 ·
scary, but nothing unusual, its too bad the way some people repair and screw over people.

The first picture, thats your engine cover, you would have to split the cases and replace that side cover.

You could at that point perhaps send it to a machine shop or a welder to fix that area.

how low is the oil on the dip stick?
The oil is outside of the two hash marks for safe oil levels by using the sight glass. I hard as hell to use and I wish it had a dipstick.

I’m going to pull the drain pull and see what if anything I can tell that might be wrong here. Maybe even get a diy tap from oreilys and try myself.

regarding the case bolt crack,should oil be coming from there? Idk the functions of this compartment so idk if there is even oil in that area. Any harm in just riding it that your aware of? I really hate to tear this thing down at this point. I’ll have to learn how to do it all which sounds kinda fun but I’d like my daughter to at least ride the summer.
 

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Discussion Starter · #6 ·
new a whole new crankcase cover and who knows what kind of work was done at the top end.
Other than routine maintenance on cars I haven’t done much mechanic work. If I were able to get a new case how much of the engine should I expect to have to change due to the case swap?
 
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