Kawasaki bayou 220 blows relay fuse Everytime I try to start it by hooking it up to battery

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call a dealership and have them cross reference the part numbers to see if they are the same

the solenoid has gone bad most likely. if that checks ok, could be the keyswitch, kill switch or neutral safety switch.

The larger idler gear ring was spinning but not spinning the entire gear. I couldn't figure ... Starter Idle Gear Limiter Kawasaki Bayou 220 250 39076 1060 ' eBay ... kawasaki bayou 300 starter will not engage.

Bayou 220 250 KLF220 KLF250 Kawasaki Service Manual ...

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The Kawasaki KLF220/250 Bayou requires the valve clearance, engine oil and oil filter be inspected every 600 miles. Keep your Bayou free of problems and in ..

well it tells me that the starter is good and you may need a new relay or it may just be the fuse!! Not sure on that model if that is the only fuse or not, on my 300 bayou there is a fuse at the battery and it could be blown as well. The manual will tell you ALL about the machine and give you troubleshooting tips!!

Ok, disconnect your starter and try again. Starter pulls the most Amps, out of your battery during start, and that's why the cables going to it, are practically driven from the battery directly to it with the help of a small relay. You could have a problem with your starter, if the fuse you burn is the big 30A. If smaller Amp fuse is getting "killed", all you got to do is check your fuse box guide and see which sub circuit is the one "in pain".

have the voltage regulator checked for the proper output

On the Bayou 220 you have 2 wires from the Ignition Switch. If I was you I would wire them 2 to a toogle switch or push bottom start.