Kawasaki KLF300 2WD Bayou (1986 – 2004) Manual

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Description

Written from hands-on experience gained from the complete strip-down and rebuild of a Kawasaki KLF300 2WD Bayou, this can help you understand, care for and repair your Kawasaki KLF300 2WD Bayou. We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over 900 photos, will help you get the job done right. Regular servicing and maintenance of your Kawasaki KLF300 2WD Bayou can help maintain its resale value, save you money, and make it safer to drive.

What’s covered

Kawasaki KLF300 2WD Bayou, 1986-2004
Kawasaki KLF300 4WD Bayou, 1989-2004

Table of contents

This Kawasaki Bayou ATV manual is 480 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Washing the vehicle / Fasteners / Lubricants / Threadlocking compound / Expendable shop supplies / Serial numbers / Warning labels / Basic hand tools / Special tools / Precision measuring tools / Mechanics tips / Ball bearing replacement / Oil seals / Riding safely / Specifications

CHAPTER TWO / TROUBLESHOOTING

Operating requirements / Troubleshooting instruments / Starting the engine / Starting difficulties / Engine hard to start / Poor idle speed performance / Poor medium and high speed performance / Engine starting system / Charging system / Ignition system / Fuel system / Engine overheating / Engine / Engine noises / Cylinder 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 (1988-on) / 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 / Oil screen / Oil pump / Oil pipe (2-wheel drive) / Oil pipes (4-wheel drive) / Oil cooler / Balancer gears and oil pump drive gear / Stator coil and left-hand side cover / Flywheel / Starter clutch, chain and sprockets / 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 / Reverse cable / Specifications

CHAPTER EIGHT / FUEL AND EXHAUST SYSTEMS

Carburetor operation / Carburetor / Carburetor adjustments / Throttle cable replacement / Fuel level gauge / Fuel shutoff valve / Air box / Exhaust system / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM

Charging system / Stator coil / Regulator/rectifier / Capacitor discharge ignition / IC igniter / Ignition coil / Pickup coil / Starting system / Starter relay / Lighting system / Switches / Cooling fan / Fuse /
WIRING DIAGRAMS / Specifications

CHAPTER TEN / FRONT SUSPENSION AND STEERING

Wheel alignment / Front wheel / Front hub/brake drum (1986-1987 2-wheel drive) / Front hub (4-wheel drive) / Handlebar / Steering shaft / Tie rod / Steering knuckle / Control arms / Steering stopper adjustment / Shock absorber / Tires and wheels / Specifications

CHAPTER ELEVEN / FRONT DRIVE MECHANISM FOUR-WHEEL DRIVE

Front propeller shaft / Front axle / Front final gear case / Sub-transmission / Specifications

CHAPTER TWELVE / REAR AXLE, SUSPENSION AND FINAL DRIVE

Rear wheel / Rear suspension arms / Rear shock absorbers / Left-hand rear hub (4-wheel drive) / Final drive unit / Propeller shaft / Rear axle / Differential shift lever and cable (2-wheel drive) / Front gear case and drive gear (2-wheel drive) / Specifications

CHAPTER THIRTEEN / BRAKES

Front brake drum (1986-1987) / Disc brake / Front caliper (1988-on 2-wheel drive) / Front caliper (4-wheel drive) / Front master cylinder / Brake disc / Rear drum brake / Brake hose replacement / Rear brake pedal/cables / Brake bleeding / Specifications

CHAPTER FOURTEEN / BODY

Front carrier / Front guard / Rear carrier / Seat / Fuel tank cover assembly / Front fender / Rear fender / Specifications

INDEX


WIRING DIAGRAMS

Models covered:
1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 Kawasaki KLF300 2WD
1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 Kawasaki KLF300 4WD
KLF 300
Clymer Kawasaki Bayou KLF300 2WD Manual
Clymer Kawasaki Bayou KLF300 4WD Manual

KLF300 2WD Bayou (1986-2004)
KLF300 4WD Bayou (1986-2004)

Print manual

Part number: CM4664
ISBN-13: 9780892879250
Language: English
Publication date: