Kawasaki KVF360, KVF750 2003-2008 Workshop Repair & Service Manual
Catalog:
Model:
Kawasaki KLF 250, BAYOU 250, Workhorse 250, KLF300, Bayou 300 4x4/4x2 1986-2006 Workshop Repair & Service Manual
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.
...
Kawasaki KLF 250, BAYOU 250, Workhorse 250 All Terrain Vehicle Service Manual 2003-2005.....2
tables.....2
LIST OF ABBREVIATIONS.....7
Units of Mass:.....20
Units of Volume:.....20
Units of Force:.....20
Units of Length:.....20
Units of Torque:.....20
Units of Pressure:.....20
Units of Speed:.....20
Units of Power:.....20
Basic Torque for General Fasteners.....24
Throttle Lever Free Play.....28
Valve Clearance (when cold).....31
Engine Oil.....33
Tire Tread Depth.....34
Standard Tire.....34
Final Gear Case Oil.....35
Front Brake Lever Free Play.....36
Cam Lever Angle.....37
Rear (Parking) Brake Lever Free Play .....37
Brake Pedal Free Play .....37
Cam Lever Angle.....38
Spark Plug Gap.....39
Brake Light Switch Timing.....40
Idle Speed.....53
Carburetor Pilot Screw Setting.....53
Fuel Level.....54
Float Height.....54
Rocker Arm Inside Diameter.....81
Rocker Shaft Diameter.....81
Cam Height.....82
Cylinder Compression (Usable Range).....84
Compression Too High.....85
Wet Compression - No Change.....85
Wet Compression - Increase.....85
Cylinder Head Bolt Torque.....86
Cylinder Head Warp.....87
Valve/Valve Guide Clearance (Wobble Method).....90
Valve Seat Surface Width.....91
Valve Seat Surface Outside Diameter.....91
Cylinder Inside Diameter.....98
Piston Diameter.....98
Piston/Cylinder Clearance.....99
Piston Ring/Groove Clearance.....99
Piston Ring Groove Width.....99
Piston Ring Thickness.....100
Piston Ring End Gap.....100
Primary Clutch Housing Inside Diameter.....113
Primary Clutch Shoe Groove Depth.....113
Friction Plate Thickness.....114
Friction Plate Warp.....114
Steel Plate Warp.....114
Clutch Spring Free length.....115
Gear Backlash.....116
Primary Gear Inside Diameter [A].....116
Crankshaft Diameter [A].....116
Secondary Gear Inside Diameter [A].....116
Secondary Gear Collar Diameter [B].....116
Connecting Rod Big End Radial Clearance.....154
Connecting Rod Big End Side Clearance.....154
Crankshaft Runout.....155
Connecting Rod Bend.....156
Connecting Rod Twist.....156
Reverse Knob Free Play.....158
Shift Fork Ear Thickness.....161
Shift Fork Guide Pin Diameter.....161
Shift Drum Groove Width.....161
Gear Shift Fork Groove Width.....161
Toe-in of Front Wheels.....172
Maximum Tire Air Pressure (to seat beads when cold).....177
Tire Air Pressure (when cold).....177
Drive Gear Shims.....192
Driven Bevel Gear Shims.....192
Bevel Gear Backlash (Front).....193
7. Pinion Gear Shims .....205
8. Ring Gear Shims .....205
Bevel Gear Backlash (Rear).....205
Cam Lever Angle (front and rear).....215
Front Brake Drum Inside Diameter.....222
Rear Brake Drum Inside Diameter.....222
Brake Shoe Lining Thickness (Front and Rear).....222
Brake Cam Diameter.....223
Cam Hole Inside Diameter.....223
Tie-rod Length.....241
Battery Troubleshooting Guide.....272
Regulator/Rectifier Output Voltage.....278
Alternator Output Voltage.....279
Stator Coil Resistance.....279
Rectifier Circuit Inspection.....280
Ignition Coil Arcing Distance.....284
Ignition Coil Winding Resistance.....285
Ignition Coil Primary Peak Voltage.....285
Crankshaft Sensor Resistance.....286
Connections:.....287
Crankshaft Sensor Peak Voltage.....287
Ignition Timing.....288
Commutator Diameter.....294
Starter Motor Brush Length.....294
Testing Relay.....295
Testing Relay.....296
toc.....2
Read OWNER'S MANUAL before operating.....7
EMISSION CONTROL INFORMATION.....8
1.....8
2.....8
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only).....9
Foreword.....10
General Information.....12
Before starting to perform an inspection service or carry out a .....13
Especially note the following:.....13
(1).....13
(2).....13
(3).....13
(4).....13
(5).....13
(6).....13
(7).....13
(8).....13
(9).....13
(10).....14
(11).....14
(12).....14
(13).....14
(14).....14
(15).....14
(16).....14
(17).....14
(18).....14
Two-Color Electrical Wire.....15
(19).....15
(20).....15
KLF250-A1 Left Side View.....16
KLF250-A1 Right Side View.....16
Prefixes for Units:.....20
Units of Temperature:.....20
Periodic Maintenance.....22
The scheduled maintenance must be done in accordance with this c.....23
The following tables list the tightening torque for the major fa.....24
Fuel System.....28
Throttle Lever Free Play Inspection.....28
Throttle Lever Free Play Adjustment.....28
Fuel System Cleanliness Inspection.....29
Air Cleaner Element Cleaning and Inspection.....29
Air Cleaner Draining.....30
Fuel Hose and Connection Check.....30
Fuel Hose Replacement.....30
Engine Top End.....31
Valve Clearance Inspection.....31
Spark Arrester Cleaning.....31
Clutches.....32
Clutch Adjustment.....32
Torque -.....32
Engine Lubrication System.....33
Engine Oil Change.....33
Torque -.....33
Oil Filter Change.....33
Torque -.....34
Wheels/Tires.....34
Tire Inspection.....34
Final Drive.....35
Final Gear Case Oil Change.....35
Torque -.....35
Torque -.....35
Propeller Shaft Joint Boot Inspection.....35
Brakes.....36
Front Brake Adjustment.....36
Rear (Parking) Brake Lever Free Play Inspection.....37
Brake Pedal Free Play Inspection.....37
Rear (Parking) Brake Lever and Pedal Free Play Adjustment.....38
Steering.....39
Steering Inspection.....39
Electrical System.....39
Battery Inspection.....39
Spark Plug Cleaning / Inspection.....39
Spark Plug Gap Inspection.....39
Brake Light Switch Adjustment.....40
General Lubrication.....40
Lubrication.....40
Cables: Lubricate with Cable Lubricant.....40
Bolts and Nuts Tightening.....42
Tightness Inspection.....42
Bolts, Nuts, and Fasteners to be checked.....42
Fuel System.....44
Fuel Level Gauge:.....48
Throttle Lever Free Play Inspection.....49
Throttle Lever Free Play Adjustment.....49
Throttle Case Removal/Disassembly.....49
Throttle Case Assembly/Installation.....50
Torque -.....50
Throttle Cable Installation.....50
Throttle Case Inspection and Lubrication.....50
Throttle Cable Lubrication and Inspection.....51
Choke Lever Removal.....52
Choke Lever and Cable Installation.....52
Choke Lever Lubrication.....52
Choke Cable Lubrication and Inspection.....52
Idle Speed Adjustment.....53
Idle Speed Adjustment.....53
Carburetor Pilot Screw Adjustment.....53
Special Tool -.....53
Fuel Level Inspection.....53
Special Tool -.....54
Fuel Level Adjustment.....54
Fuel System Cleanliness Inspection.....55
Carburetor Removal.....55
Carburetor Installation.....56
Carburetor Disassembly.....56
Carburetor Assembly.....57
Carburetor Cleaning.....58
Carburetor Inspection.....58
Air Cleaner Element Removal.....60
Air Cleaner Element Installation.....60
Air Cleaner Element Cleaning and Inspection.....61
Air Cleaner Draining.....61
Air Cleaner Housing Removal.....61
Fuel Tank Removal.....62
Fuel Tank Installation.....62
Fuel Tap Removal.....63
Fuel Tap Installation.....63
Fuel Tank and Fuel Tap Cleaning.....63
Fuel Tap Inspection.....64
Fuel Level Gauge Removal.....64
Fuel Level Gauge Installation.....65
Fuel Level Gauge Check.....65
Engine Top End.....66
Piston Ring Pliers:.....74
Camshaft Chain Tensioner Removal.....76
Camshaft Chain Tensioner Installation.....76
Torque -.....76
Camshaft Chain Tensioner Wear.....76
Camshaft Sprocket Removal.....77
Camshaft Sprocket Installation.....77
Special Tool -.....77
Torque -.....78
Compression Releasing Lever Removal.....79
Compression Releasing Lever Installation.....79
Torque -.....79
Torque -.....79
Rocker Arm and Shaft Removal.....80
Rocker Arm and Shaft Installation.....80
Torque -.....80
Rocker Arm and Shaft Inspection.....81
Camshaft Removal.....82
Camshaft Installation.....82
Cam Wear Inspection.....82
Camshaft Bearing Inspection.....82
Camshaft Chain Removal.....83
Camshaft Chain Installation.....83
Torque -.....83
Camshaft Chain Guide Removal.....83
Camshaft Chain Guide Installation .....83
Torque -.....83
Camshaft Chain Guide Wear.....83
Cylinder Compression Measurement.....84
Special Tools -.....84
Cylinder Head Removal.....85
Cylinder Head Installation.....86
Torque -.....86
Cylinder Head Assembly.....86
Torque -.....86
Cylinder Head Cleaning.....87
Cylinder Head Warp.....87
Valve Clearance Inspection.....88
Valve Clearance Adjustment.....88
Torque -.....88
Torque -.....88
Valve Removal.....88
Special Tools -.....88
Valve Installation.....89
Valve Visual Inspection.....89
Valve Guide Removal.....89
Special Tool -.....89
Valve Guide Installation.....90
Special Tool -.....90
Valve-to-Guide Clearance Measurement.....90
Valve Seat Inspection.....91
Valve Seat Repair (Valve Lapping).....91
Special Tools -.....91
Seat Cutter Operating Care:.....92
Valve Seat Repair.....95
Cylinder Removal.....96
Cylinder Installation.....96
Piston Removal.....97
Special Tool -.....97
Special Tool -.....97
Piston Installation.....97
Cylinder/Piston Wear.....98
Piston/Cylinder Clearance.....99
Piston Ring and Ring Groove Wear.....99
Piston Ring Groove Width.....99
Piston Ring Thickness.....100
Piston Ring End Gap Measurement.....100
This vehicle is equipped with a spark arrester approved for off-.....101
Spark Arrester Cleaning.....101
Muffler Removal.....101
Exhaust Pipe Removal.....101
Exhaust Pipe Installation.....102
Exhaust System Inspection.....102
Engine Right Side.....104
Gear Holder, m1.75:.....108
Engine Right Side Disassembly.....109
Special Tool -.....109
Special Tool -.....109
Special Tool -.....110
Engine Right Side Assembly.....110
Torque -.....111
Special Tool -.....111
Torque -.....111
Torque -.....111
Special Tool -.....112
Torque -.....112
Torque -.....112
Torque -.....112
Clutch Adjustment.....113
Clutch Release Removal.....113
Clutch Release Wear.....113
Primary Clutch Housing Wear.....113
Primary Clutch Shoe Lining Wear.....113
One-way Clutch Inspection.....114
Friction Plate Wear.....114
Friction and Steel Plate Warp.....114
Clutch Spring Free Length Measurement.....115
Gear Backlash.....116
Primary Gear/Crankshaft Wear.....116
Secondary Gear/Collar Wear.....116
Recoil Starter.....118
Recoil Starter Removal.....121
Recoil Starter Installation.....121
Torque -.....121
Recoil Starter Disassembly.....121
Recoil Starter Assembly.....122
Torque -.....123
Recoil Starter Cleaning.....124
Recoil Starter Inspection.....124
Engine Lubrication System.....126
WARNING.....131
Oil Level Inspection.....131
Engine Oil Change.....131
Oil Filter Change.....131
Bypass Valve Removal.....131
Bypass Valve Installation.....132
Bypass Valve Cleaning and Inspection.....132
Oil Screen Removal.....132
Oil Screen Installation.....132
Oil Pressure Relief Valve Removal.....133
Oil Pressure Relief Valve Installation.....133
Torque -.....133
Oil Pressure Relief Valve Inspection.....133
Oil Pump Removal.....134
Oil Pump Installation.....134
Torque -.....134
Oil Pipe Removal.....135
Oil Pipe Installation.....135
Torque -.....135
Engine Removal/Installation.....136
Engine Removal.....139
Engine Installation.....140
Torque -.....140
Crankshaft/Transmission.....142
Outside Circlip Pliers:.....148
Crankcase Disassembly.....149
Special Tool -.....149
Crankcase Assembly.....150
Sealant -.....150
Special Tool -.....151
Torque -.....151
Crankshaft Removal.....152
Crankshaft/Balancer Shaft Installation.....152
Special Tool -.....152
Crankshaft Disassembly.....152
Crankshaft Assembly.....152
Connecting Rod Big End Seizure.....153
Connecting Rod Big End Radial Clearance.....154
Connecting Rod Big End Side Clearance.....154
Crankshaft Alignment.....155
Connecting Rod Bend/Twist.....156
External Shift Mechanism Removal.....157
External Shift Mechanism Installation.....157
Torque -.....157
External Shift Mechanism Inspection.....158
Reverse Knob Free Play Adjustment.....158
Reverse Shift Mechanism Removal.....158
Reverse Shift Mechanism Installation.....159
Sealant -.....159
Transmission Removal.....159
Transmission Installation.....160
Transmission Shaft Disassembly.....160
Special Tool -.....160
Transmission Shaft Assembly.....160
Shift Drum Disassembly.....160
Shift Drum Assembly.....161
Torque -.....161
Shift Fork Bending.....161
Shift Fork Wear.....161
Shift Drum Inspection.....161
Transmission Gear Inspection.....161
Ball and Needle Bearing Replacement.....164
Special Tool -.....164
Ball and Needle Bearing Wear.....164
Oil Seal Inspection.....164
Wheels/Tires.....166
Jack:.....170
Toe-in is the amount that the front wheels are closer together i.....171
Steering Centering Inspection.....171
Steering Centering Adjustment.....171
Toe-in Inspection.....172
Toe-in Adjustment.....173
Torque -.....173
Wheel Removal.....174
Special Tool -.....174
Wheel Installation.....174
Torque -.....174
Wheel (Rim) Inspection.....174
Wheel (Rim) Replacement.....175
Tire Removal.....176
Tire Installation.....176
Tire Inspection.....177
Rear Left Hub Removal.....178
Rear Left Hub Installation.....178
Torque -.....178
Rear Left Hub Disassembly/Assembly.....178
Final Drive.....180
Inside Circlip Pliers:.....186
Output Bevel Gear Case Removal.....187
Output Bevel Gear Case Installation.....187
Torque -.....187
Output Bevel Gear Case Disassembly.....187
Special Tool -.....187
Special Tools -.....188
Special Tool -.....188
Special Tool -.....188
Output Bevel Gear Case Assembly.....188
Special Tool -.....188
Torque -.....188
Torque -.....189
Special Tools -.....189
Torque -.....189
Special Tool -.....189
Output Drive Gear Removal.....190
Special Tool -.....190
Output Drive Gear Installation.....190
Torque -.....190
Special Tool -.....190
Output Bevel Gear Adjustment.....190
Backlash-Related Parts.....191
Torque -.....192
Torque -.....192
Special Tool -.....193
Bevel Gear Inspection.....194
Cam Damper Inspection.....195
Ball Bearing Inspection.....195
Oil Seal Inspection.....195
Propeller Shaft Removal.....196
Special Tool -.....196
Special Tool -.....196
Propeller Shaft Installation.....197
Torque -.....197
Propeller Shaft Inspection.....197
Propeller Shaft Joint and Pinion Gear Joint Inspection.....198
Propeller Shaft Joint Boot Inspection.....198
Rear Axle Removal.....199
Rear Axle Installation.....199
Sealant -.....199
Torque -.....199
Axle Shaft Pipe Disassembly.....200
Special Tool -.....200
Special Tool -.....200
Special Tool -.....200
Axle Shaft Pipe Assembly.....201
Special Tool -.....201
Special Tool -.....201
Special Tool -.....201
Special Tool -.....201
Final Gear Case Oil Level Inspection.....202
Torque -.....202
Final Gear Case Oil Change.....202
Final Gear Case Removal.....202
Final Gear Case Installation.....202
Torque -.....202
Final Gear Case Disassembly.....202
Final Gear Case Assembly.....203
Torque -.....203
Final Bevel Gear Adjustment.....204
Final Gear Case (Backlash-related Parts).....204
Torque -.....205
Torque -.....205
Special Tool -.....205
Torque -.....206
Torque -.....206
Pinion Gear Disassembly.....208
Special Tool -.....208
Special Tool -.....208
Pinion Gear Assembly.....208
Special Tool -.....208
Torque -.....208
Torque -.....209
Bevel Gear Inspection.....209
Ball Bearing Inspection.....209
Oil Seal Inspection.....209
Brakes.....210
Front Brake Adjustment.....214
Brake Pedal Position Inspection.....214
Brake Pedal Position Adjustment.....214
Rear (Parking) Brake Lever Free Play Inspection.....214
Brake Pedal Free Play Inspection.....214
Rear (Parking) Brake Lever and Brake Pedal Free Play Adjustment.....214
Cam Lever Angle Adjustment (Front and Rear).....214
Front Brake Panel Removal/Disassembly.....216
Front Brake Panel Assembly/Installation.....217
Torque -.....218
Torque -.....218
Rear Brake Panel Removal/Disassembly.....219
Rear Brake Panel Assembly/Installation.....220
Torque -.....220
Torque -.....220
Brake Drum Seal Wear.....221
Torque -.....221
Brake Drum Wear.....222
Brake Shoe Lining Wear.....222
Brake Cam and Cam Hole Wear.....223
Brake Shoe Spring Inspection.....223
Brake Lubrication.....224
Brake Cable Removal.....225
Brake Cable Installation.....225
Brake Cable Lubrication.....225
Brake Pedal Installation.....225
Suspension.....226
Shock Absorber Removal.....229
Rear Shock Absorber Installation.....229
Torque -.....229
Rear Shock Absorber Inspection.....229
Front Suspension Arm Removal.....230
Front Suspension Arm Installation.....230
Torque -.....230
Rear Suspension Arm Removal.....230
Rear Suspension Arm Installation.....231
Torque -.....231
Torque -.....231
Torque -.....231
Suspension Arm Assembly.....231
Suspension Arm Inspection.....232
Front Suspension Arm Lubrication.....232
Steering.....234
Steering Stem Removal.....238
Steering Stem Installation.....239
Torque -.....239
Torque -.....239
Steering Knuckle Removal.....239
Steering Knuckle Installation.....240
Torque -.....240
Tie-rod Removal.....240
Tie-rod Installation.....240
Torque -.....240
Tie-rod End Removal.....240
Tie-rod End Installation.....241
Torque -.....241
Steering Inspection.....242
Steering Stem Warp.....242
Steering Lubrication.....242
Steering Stem Clamp Inspection.....242
Steering Stem Bearing Inspection.....242
Tie-rod End Inspection.....243
Steering Knuckle Pivot Lubrication.....243
Handlebar Removal.....244
Handlebar Installation.....244
Torque -.....244
Frame.....246
Seat Removal.....251
Seat Installation.....251
Front Fender Removal.....252
Front Fender Installation.....253
Torque -.....254
Rear Fender Removal.....254
Rear Fender Installation.....255
Torque -.....255
Front Guard Removal.....256
Rear Guard Removal.....256
Electrical System.....258
Spark Plug Wrench, Hex 18:.....264
Light/Dimmer Switch [A].....265
There are a number of important precautions that should be taken.....266
Wiring Inspection.....268
Special Tool -.....268
Battery Removal.....269
Battery Installation.....269
Electrolyte Level Inspection.....269
Electrolyte Specific Gravity Inspection.....269
Initial Charging.....270
Ordinary Charging.....271
Battery Charging Rate/Time Table.....272
Battery Test Charging.....272
Special Tool -.....272
Alternator Cover Removal.....274
Special Tool -.....274
Alternator Cover Installation.....274
Sealant -.....275
Torque -.....275
Torque -.....275
Alternator Rotor Removal .....275
Special Tools -.....275
Alternator Rotor Installation.....276
Alternator Stator Removal.....277
Alternator Stator Installation.....277
Sealant -.....277
Regulator / Rectifier Output Voltage Inspection.....278
Special Tool -.....278
Alternator Inspection.....279
Special Tool -.....279
Regulator/Rectifier Inspection.....280
Charging System Circuit.....282
WARNING.....283
Spark Plug Removal/Installation.....283
Special Tool -.....283
Torque -.....283
Spark Plug Cleaning/Inspection.....283
Spark Plug Gap Inspection.....283
Ignition Coil Removal.....283
Ignition Coil Installation.....284
Ignition Coil Inspection.....284
Special Tool -.....284
Ignition Coil Primary Peak Voltage Inspection.....285
Special Tool -.....285
Special Tool -.....285
Crankshaft Sensor Removal.....286
Crankshaft Sensor Inspection.....286
Special Tool -.....286
Crankshaft Sensor Peak Voltage Inspection.....287
Special Tool -.....287
Recommended Tool -.....287
Alternator Rotor Inspection.....287
Ignition Timing Test.....288
Special Tool -.....288
Ignition System Circuit.....288
Starter Motor Removal.....291
Starter Motor Installation.....291
Torque -.....291
Starter Motor Disassembly.....292
Starter Motor Assembly.....292
Torque -.....292
Torque -.....293
Commutator Cleaning/Inspection.....293
Armature Inspection.....294
Starter Motor Brush Length.....294
Brush Assembly Inspection.....294
Brush Plate and Terminal Bolt Inspection.....295
Starter Relay Inspection.....295
Starter Circuit Relay Inspection.....295
Electric Starter Circuit.....296
Starter Motor Clutch Removal.....298
Special Tool -.....298
Starter Motor Clutch Installation.....298
Torque -.....298
Starter Motor Clutch Inspection.....298
Torque Limiter Inspection.....299
Headlight Beam Vertical Adjustment.....300
Headlight Bulb Replacement.....300
Taillight Bulb Replacement.....301
Neutral and Reverse Indicator Light Bulb Replacement .....301
Lighting System Circuit.....302
Brake Light Switch Adjustment.....303
Switch Inspection.....303
Front Brake Light Switch Connections.....303
Rear Brake Light Switch Connections.....303
20 A Main Fuse Removal.....304
Fuse Inspection.....304
Appendix.....308
NOTE.....319
Engine Doesn't Start, Starting Difficulty:.....319
Starter motor not rotating:.....319
Starter motor rotating but engine doesn't turn over:.....319
Recoil starter not operating.....319
Engine won't turn over:.....319
No fuel flow:.....319
Engine flooded:.....319
Fuel/air mixture incorrect:.....319
No spark; spark weak:.....319
Compression Low:.....319
Poor Running at Low Speed:.....319
Spark weak:.....319
Fuel/air mixture incorrect:.....320
Compression low:.....320
Other:.....320
Poor Running or No Power at High Speed:.....320
Firing incorrect:.....320
Fuel/air mixture incorrect:.....320
Compression low:.....320
Knocking:.....320
Miscellaneous:.....320
Overheating:.....320
Firing incorrect:.....320
Fuel/air mixture incorrect:.....320
Compression high:.....320
Engine load faulty:.....320
Lubrication inadequate:.....320
Rear final gear case overheating:.....321
Clutch Operation Faulty:.....321
Clutch slipping:.....321
Clutch not disengaging properly.....321
Gear Shifting Faulty:.....321
Doesn't go into gear; shift pedal doesn't return:.....321
Jumps out of gear:.....321
Overshifts:.....321
Abnormal Engine Noise:.....321
Knocking:.....321
Piston Slap:.....321
Valve noise:.....321
Other noise:.....321
Abnormal Drive Train Noise:.....321
Clutch noise:.....321
Transmission noise:.....321
Drive train noise:.....322
Abnormal Frame Noise:.....322
Shock absorber noise:.....322
Brake noise:.....322
Other noise:.....322
Exhaust Smokes Excessively:.....322
White smoke:.....322
Black Smoke:.....322
Brown smoke:.....322
Handling and/or Stability Unsatisfactory.....322
Handlebar hard to turn:.....322
Handlebar shakes or excessively vibrates:.....322
Handlebar pulls to one side:.....322
Shock absorption unsatisfactory:.....322
Brake Doesn't Hold.....322
Battery Discharged:.....322
Battery Overcharged:.....322
Kawasaki KLF300 All Terrain Vehicle Service Manual 1986-2006.....324
1986-1987 Bayou 300 Base Service Manual.....0
General INFORMATION.....329
Before Servicing.....330
Untitled.....332
General Specs.....334
Torques.....336
Periodic Maintenance Chart.....338
Fuel System.....339
Exploded View.....340
Specs.....341
Throttle Case & Cable.....342
Choke Lever & Cable.....344
Carburetor.....346
Air Filter.....351
Fuel Tank.....353
Engine Top End.....355
Exploded View.....356
Specs.....358
Special Tools.....360
Cylinder head.....361
Valves.....362
Camshaft Sprocket.....370
Camshaft & Rocker Arms.....371
Cam Chain/Guides/Tensioner.....374
Cylinder/Piston/Rings.....376
Cylinder Compression.....379
Exhaust System.....383
Engine Left Side.....385
Exploded View.....386
Specs & Tools.....387
Engine Cover.....388
Starter Clutch.....388
Starter Chain & Sprockets.....389
Engine Right Side.....391
Exploded View.....392
Specs.....393
Engine Cover.....394
Clutches.....394
Primary Reduction.....399
Lubrication System.....401
Engine Oil & Filter.....401
Oil Pump.....402
Engine Removal/Installation.....405
Engine Bottom End/Transmission.....409
Exploded View.....410
Specs & Tools.....412
Crankcase Splitting.....413
Crankshaft & Connecting Rod.....414
Transmission.....417
Wheels/Tires.....425
Exploded View.....426
Wheel Alignment.....427
Wheels.....429
Tires.....430
Front Hub Bearings.....432
Final Drive.....435
Exploded View.....436
Specs.....438
Special Tools.....439
Final Gear Case Oil.....440
Front Bevel Gears & Cam Damper .....440
Prop Shaft.....448
Rear Axle Shafts.....450
Final Bevel Gears & Differential Gears.....452
Differential Shift Mechanism.....459
Brakes.....463
Exploded View.....464
Specs.....466
Brake Adjustment.....467
Brake Fluid .....469
Brake Bleeding.....470
Master & Wheel Cylinders.....472
Brake Drums.....475
Brake Panels.....476
Brake Pedal & Cables.....479
Suspension.....481
Exploded View.....482
Suspension.....483
Steering.....485
Exploded View.....486
Steering.....487
Frame.....493
Exploded View.....494
Seat.....496
Fenders.....496
Frame Exchange.....498
Electrical System.....499
Precautions.....500
Wiring Diagram.....501
Exploded View.....502
Specs.....504
Special Tools .....504
Battery.....505
Charging System.....509
Ignition System.....512
Electric Start System.....517
Lighting System.....523
Appendix/Troubleshooting.....527
Troubleshooting Guide.....528
General Lubrication.....531
Unit Conversion Table.....532
1988 Bayou 300 2x4 Supplemental Manual .....533
General Information.....538
Model ID.....539
General Specs.....541
Periodic Maintenance Chart.....543
Torque Chart.....544
Wire, Cable & Hose Routing.....547
Fuel System.....552
Exploded View.....553
Specs.....555
Throttle Cable & case.....556
Choke Lever & Cable.....556
Carburetor .....557
Air Cleaner.....558
Fuel Tank.....560
Engine Top End.....564
Exploded View.....565
Specs.....567
Cylinder Head.....567
Valves.....569
Camshaft & Rocker Arms.....571
Cam Chain/Guides/Tensioner.....572
Cylinder/Piston/Rings.....573
Exhaust System.....574
Engine Left Side.....576
Exploded View.....577
Recoil Starter.....578
Engine Cover.....581
Engine Right Side.....584
Exploded View.....585
Clutches/Balancer.....586
Oil Pump.....586
Engine Removal/Installation.....588
Engine Bottom End/Transmission.....590
Exploded View.....591
Crankshaft & Connecting Rod.....593
Transmission.....593
Wheels & Tires.....596
Exploded View.....597
Specs & Tools .....598
Alignment.....599
Rims.....601
Tires.....602
Front Hub.....606
Final Drive.....608
Exploded View.....609
Brakes.....612
Exploded View.....613
Specs.....615
Brake Adjustment.....616
Calipers.....616
Master & Wheel Cylinders.....618
Discs.....619
Drums & Hoses.....620
Suspension.....622
Exploded View.....623
Specs &Tools.....624
Suspension.....625
Steering.....628
Exploded View.....629
Steering.....630
Tie Rods.....630
Steering Knuckles.....631
Frame.....634
Exploded View.....635
Seat & Fenders .....637
Racks.....638
Electrical System.....640
Exploded View.....641
Wiring Diagram.....643
Specs & Tools.....644
Battery & Charging System.....645
Ignition System.....647
Lighting System.....650
Appendix & Troubleshooting.....652
1989-1997 Bayou 300 2x4 Supplimental Manual.....656
Model ID.....657
Specs.....659
1989.....659
1990.....661
1991.....663
1992.....665
1993/1994.....667
1995-1997.....669
Fuel System.....671
Engine Top End.....672
Frame.....673
Electrical System.....673
Ignition System.....675
Icing Circuit.....676
Wiring Diagrams.....677
1998-1999 Bayou 300 2x4 Supplimental Manual.....682
General Information.....684
Specs.....684
Final Drive.....687
Brakes.....688
Electrical System.....689
Exploded View.....689
Charging System.....690
Wiring Diagram.....695
1998.....695
1999.....697
2000-2002 Bayou 300 2x4 Supplimental Manual.....704
Fuel System.....712
Model ID.....706
General Information.....707
Specs.....707
Periodic Maintenance Chart.....710
Wiring, Cable & Hose Routing.....711
Engine Top End.....713
Brakes.....714
Frame.....715
Electrical System.....716
2003-2006 Bayou 300 2x4 Supplimental Manual.....728
General Information.....730
Fuel System.....733
Engine Right Side.....734
Wheels & Tires.....735
Brakes.....736
Frame.....737
Electrical System.....738
1989-2006 Bayou 400 4x4 Service Manual Supplement .....747
1989 Bayou 400 4x4 Supplemental Manual.....749
Index.....748
Foreword.....753
General Information.....755
Model ID.....756
General Specs.....758
Torque Chart.....760
Wiring, Cable & Hose Routing.....764
Periodic Maintenance Chart.....768
Fuel System.....769
Exploded View.....770
Specs.....772
Throttle Case & Cable.....773
Choke Lever & Cable.....773
Carburetor.....774
Air Cleaner.....775
Fuel Tank.....777
Engine Top End.....779
Exploded View.....780
Specs.....782
Cylinder Head.....782
Valves.....784
Cylinder/Piston/Rings.....788
Exhaust System.....789
Engine Left Side.....791
Exploded View.....792
Recoil Starter.....793
Engine Cover.....796
Sub-Transmission Lever.....797
Engine Right Side.....799
Exploded View.....800
Clutches.....801
Balancer.....802
Lubrication System.....802
Engine Removal/Installation.....803
Engine Bottom End/Transmission.....807
Exploded View.....808
Specs & Tools.....811
Transmission.....813
Balancer.....814
Sub-Transmission Case.....815
Oil Pressure Relief Valve.....823
Wheels/Tires.....825
Exploded View.....826
Specs & Tools.....827
Alignment.....828
Rims.....830
Tires.....832
Front Hub.....835
Final Drive.....837
Exploded View.....838
Specs.....841
Front Prop Shaft.....843
Front Axle.....843
Front Final Gear Case.....845
Rear Prop Shaft.....855
Rear Axle.....857
Rear Final Gear Case.....859
Brakes.....867
Exploded View.....868
Specs.....870
Brake Adjustment.....871
Calipers.....872
Brake Pads.....874
Master & Wheel Cylinders.....875
Brake Hoses.....876
Brake Panel Assy.....877
Brake Pedal & Cables.....879
Suspension.....881
Exploded View.....882
Suspension.....884
Steering.....887
Exploded View.....888
Steering.....889
Frame.....893
Exploded View.....894
Seat & Fenders.....896
Electrical System.....899
Exploded View.....900
Wiring Diagram.....902
89-90 USA Model.....902
89-97 Canadian Model.....902
89-93 UK Model.....902
89-90 Australian Model.....902
Specs & Tools.....903
Battery & Charging System.....904
Ignition System.....906
Electric Starting System.....908
Lighting System.....909
Switches.....909
Appendix/Troubleshooting.....911
Riding Conditions.....912
Troubleshooting Guide.....914
General Lubrication .....917
1990-1994 Bayou 400 4x4 Supplemental Manual.....919
Model ID.....920
General Specs.....922
Reverse Knob.....926
Frame.....926
Wiring Diagrams.....927
91-97 USA Model.....927
91-97 Australian Model.....928
1995-1998 Bayou 400 4x4 Supplemental Manual.....929
Model ID.....930
Specs.....932
Wiring, Cable & Hose Routing.....934
Fuel System.....935
Engine Top End.....936
Wheels & Tires.....936
Final Drive.....937
Electrical System.....938
Wiring Diagrams.....940
95 UK Model.....940
95 European Model.....941
98 USA/Canadian Model.....942
98 Australian Model.....943
Switch.....944
1999 Bayou 400 4x4 Supplemental Manual.....945
Foreword.....946
General Specs.....947
Final Drive.....950
Brakes.....951
Electrical System.....952
Charging System.....953
Wiring Diagrams.....958
99 USA/Canadian Model.....958
99 Austrlian Model.....960
99 Europe/UK Model.....962
2000-2002 Bayou 400 4x4 Supplemental Manual.....965
Foreword.....966
model ID.....967
General Specs.....968
Periodic Maintenance Chart.....971
Engine Left Side.....972
Brakes.....973
Steering.....974
Frame.....975
Electrical System.....976
Wiring Diagrams.....978
00-02 USA/Canadian Model.....978
2000 Australian Model.....980
00-02 European Model.....982
2003-2006 Bayou 400 4x4 Supplemental Manual.....985
Foreword.....986
General Specs.....987
Fuel System.....990
Engine Right Side.....992
Hubs.....993
Brakes .....994
Frame.....995
Electrical System.....996
Wiring Diagrams.....998
03-06 USA/Canadian Model.....998
03-06 Europe/UK Model.....1000
4x4 Model ID/VIN Chart .....1003
