I'm trying to adjust the timing on a 1999 Bayou 220. Any help will be appreciated. Thanks.

 

Take cover off camshaft cover on top left side of motor. Next remove the Flywheel inspection plug on near recoil starter. Use a nickel and a pair of pliers as this can be hard and most slotted screw drivers are not that wide. Remove the timing chain tensioner and reassemble as per instructions. Tie the chain up with a wire so it will not fall down in head and remove the sprocket with impact wrench. Remove the recoil starter cover (no gaskets required for reassembly.). Using a tool rotate the crankshaft till you see the "T" in the Flywheel inspection plug hole. Next replace the sprocket for the cam shaft with correctly (it is notched on the back). The camshaft sprocket has a mark on it near the teeth that should line up with a projection on the top middle portion of the Camshaft Cover. This will take a degree of manipulation.. MAKE SURE that the sprocket is full on the cam shaft. Using an impact wrench and red thread locker (permatex) or similar reinstall the bolt for the sprocket. Next replace the timing chain tensioner. This HAS to be done correctly. I did it wrong first and nearly ruined my engine when the chain almost broke.

 

What I did wrong was INCORRECT reassembly of the timing chain tensioner after it was removed. ANY time it is removed it needs to be properly reassembled. To do this remove it from the motor completely. Loosen the lock bolt on top of the tensioner. The shaft, spring, and bearing will fall free.

Reassembly instructions:
1) Replace the spring on the shaft and compress till you can use a piece or wire or a thin nail to hold it compressed while doing the other steps.
2) Place the bearing back in the tensioner unit.
3) Insert the shaft into the tensioner unit completely. (make sure the slots are UP for the lock bolt to catch on..
4) Tighten the lock bolt on the shaft.
5) Remove wire/nail and the spring will expand.
6) Install on the motor.
7) Loosen the lock nut and the tensioner will release. Tighten locknut.
Complete.

 

This worked for my 2001 Bayou. Info straight from a Kawasaki Bayou shop manual. Worked for me.