Complete factory shop manual including electrical wiring diagrams for 1986-2006 Kawasaki KLF 250, BAYOU 250, Workhorse 250, KLF300, Bayou 300 4x4, Bayou 4x2 (KLF250-A1, KLF250-A2, KLF250-A3, KLF300-A1, KLF300-A2, KLF300-B1, KLF300-B2, KLF300-B2A, KLF300-B4, KLF300-B5, KLF300-B6, KLF300-B7, KLF300-B8, KLF300-B8A, KLF300-B9, KLF300-B10, KLF300-B11, KLF300-B12, KLF300-B13, KLF300-B14, KLF300-B15, KLF300-B16, KLF300-B6F, KLF300-C1, KLF300-C2, KLF300-C2A, KLF300-C3, KLF300-C4, KLF300-C5, KLF300-C6, KLF300-C7, KLF300-C7A, KLF300-C8, KLF300-C9, KLF300-C10, KLF300-C11, KLF300-C12, KLF300-C13, KLF300-C14, KLF300-C15, KLF300-C16, KLF300-C6F, KLF300-C17) ATV. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page to save your precious time.

This repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

MAKE: Kawasaki
YEAR: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
MODEL: KLF 250, BAYOU 250, Workhorse 250, KLF300, Bayou 300 4x4, Bayou 300 4x2 (KLF250-A1, KLF250-A2, KLF250-A3, KLF300-A1, KLF300-A2, KLF300-B1, KLF300-B2, KLF300-B2A, KLF300-B4, KLF300-B5, KLF300-B6, KLF300-B7, KLF300-B8, KLF300-B8A, KLF300-B9, KLF300-B10, KLF300-B11, KLF300-B12, KLF300-B13, KLF300-B14, KLF300-B15, KLF300-B16, KLF300-B6F, KLF300-C1, KLF300-C2, KLF300-C2A, KLF300-C3, KLF300-C4, KLF300-C5, KLF300-C6, KLF300-C7, KLF300-C7A, KLF300-C8, KLF300-C9, KLF300-C10, KLF300-C11, KLF300-C12, KLF300-C13, KLF300-C14, KLF300-C15, KLF300-C16, KLF300-C6F, KLF300-C17)

"'86-'06 KLF300.pdf"
680 pages; Kawasaki KLF300 All Terrain Vehicle Service Manual 1986-2006

"'03-'05 KLF250, BAYOU250, Workhorse250.pdf"
322 pages; Kawasaki KLF 250, BAYOU 250, Workhorse 250 All Terrain Vehicle Service Manual 2003-2005

EXCERPT:
Quick Reference Guide
General Information 1
Periodic Maintenance 2
Fuel System 3
Engine Top End 4
Engine Right Side 5
Recoil Starter 6
Engine Lubrication System 7
Engine Removal/Installation 8
Crankshaft/Transmission 9
Wheels/Tires 10
Final Drive 11
Brakes 12
Suspension 13
Steering 14
Frame 15
Electrical System 16
Appendix
...
ENGINE TOP END 4-33
Cylinder and Piston
• Install the second ring [A] so that the “RN” mark [B] faces
up.
• Install the top ring [C] so that the “R” mark [D] faces up.
• Install the piston pin.
○ Oil the piston pin lightly and slide it through the side of the piston without a snap ring.
○ Hold the piston in position over the connecting rod, with the arrow [A] pointing forward, and slide the piston pin the rest of the way through the connecting rod and piston.
• Fit a new piston pin snap ring into the side of the piston so that the ring opening does not coincide with the slit of the piston pin hole.
Cylinder/Piston Wear
• Since there is a difference in cylinder wear in different direction, take a side-to-side and a front-to-back measurement at each of the 3 locations (total of 6 measurements) shown in the figure.
If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder.
20 mm (0.79 in.) [A]
40 mm (1.57 in.) [B]
10 mm (0.39 in.) [C]
Cylinder Inside Diameter
Standard: 68.995 ∼ 69.007 mm (2.7163 ∼ 2.7168 in.), and less than 0.01 mm (0.0004 in.)
difference between any two measurements
Service Limit: 69.10 mm (2.720 in.), or more than 0.05 mm (0.0020 in.) difference between any two measurements
• Measure the piston diameter [A] of each piston 5 mm (0.20 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin.
Piston Diameter
Standard: 68.960 ∼ 68.975 mm
(2.7150 ∼ 2.7155 in.)
Service Limit: 68.81 mm (2.709 in.)
If the piston diameter is less than the service limit, replace it.
...