Kawasaki KLF250 Bayou (2003 - 2011)

This Kawasaki Bayou ATV Manual is 424 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Washing the vehicle / Torqu specifications / Fasteners / Lubricants / Threadlocking compound / Expendable supplies / Serial numbers / Warning labels / Basic hand tools / Precision measuring tools / Special tools / Mechanic's tips / Ball bearing replacement / Oil seals / Riding safely / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Starting hte engine / Engine starting difficulties / Engine will not start / Poor idle or off idle performance / Poor medium and high speed performance / Engine starting system / Charging system / Ignition system / Fuel system / Engine overheating / Engine noises / Engine leak down test / Clutch / Transmission / Drive train noise / Handling / Frame noise / Brakes

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist / Service intervals schedule / Periodic lubrication / Engine oil and filter change / Final drive oil change / Control cable lubrication / Non-scheduled lubrication / Periodic maintenance / Non-scheduled maintenance / Reverse cable adjustment / Tune-up / Valve clearance / Compression test check / Spark plug / Air filter / Ignition timing / Pilot screw adjustment / Idle Speed Adjustment / Storage / Specifications

CHAPTER FOUR / ENGINE TOP END
Engine principles / Cylinder head / Compression release lever / Camshaft and rocker arms / Cam chain / Chain guides / Valves and valve components / Cylinder / Piston and piston rings / Specifications

CHAPTER FIVE / ENGINE LOWER END
Servicing engine in frame / Engine removal / Engine installation / Balancer gears and oil pump drive gear / Oil screen / Oil pump / Oil pipes / Left-hand side cover / Stator coil and pickup coil / Flywheel and starter clutch / Crankcase and crankshaft / Recoil starter / Engine break-in / Specifications

CHAPTER SIX / CLUTCH, PRIMARY DRIVE AND EXTERNAL SHIFT MECHANISM
Clutch cover / Clutch release mechanism / Clutch / Gear backlash check / One-way clutch check / External shift mechanism / Specifications

CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission/reverse system identification / Transmission troubleshooting / Transmission/reverse overhaul / Reverse axle / Transmission inspection / Internal shift mechanism / Specifications

CHAPTER EIGHT / FUEL AND EXHAUST SYSTEMS
Carburetor operation / Carburetor / Carburetor float adjustments / Throttle cable / Throttle housing / Choke cable / Fuel tank / Fuel level gauge / Fuel shutoff valve / Air box / Exhaust system / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
Charging system / Stator coil / Voltage regulator/rectifier / Capacitor discharge ignition / CDI unit / Ignition coil / Pickup coil / Exciter coil / Starting system / Starter solenoid / Starter circuit relay / Lighting system / Switches / Auxiliary lighting terminal / Auxiliary electrical terminals / Speedometer housing (late 1999-on Australian and European models) / Fuse / Wiring diagrams / Specifications

CHAPTER TEN / FRONT SUSPENSION AND STEERING
Wheel alignment / Front wheel / Front brake drum/bearing assembly / Handlebar / Steering shaft / Tie rod / Steering knuckle / Control arm / Shock absorber / Tires and wheels / Specifications

CHAPTER ELEVEN / REAR AXLE, SUSPENSION AND FINAL DRIVE
Rear wheel / Rear suspension arms / Rear shock absorbers / Left-hand rear axle hub / Final drive unit / Propeller shaft / Rear axles / Front gear case / Drive gear / Reverse lever and neutral/reverse switch assembly / Specifications

CHAPTER TWELVE / BRAKES
Front drum brake / Front brake shoe replacement / Front brake shoes and brake panel / Rear drum brake / Rear brake drum / Rear brake shoe replacement / Rear brake shoes and brake panel / Brake drum wheel stud replacement / Front brake cables / Rear brake pedal / Rear/parking brake cable assembly / Specifications

CHAPTER THIRTEEN / BODY
Seat / Front carrier / Front cover / Front fender / Rear carrier / Rear fender / Footpegs / Specifications

INDEX

WIRING DIAGRAMS

Models covered: Kawasaki KLF220 KLF250

Years covered: 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011

Clymer Manuals Kawasaki KLF220 Bayou Manual
Clymer Manuals Kawasaki KLF250 Bayou Manual

KLF220 Bayou (1988-2002)
KLF250 Bayou (2003-2011)