Kawasaki Bayou KLF300 2WD & 4WD ATV 1986 - 2004

Clymer Owners Service & Repair Manual

1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004

by Clymer Staff

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Kawasaki Bayou KLF300 2WD & 4WD ATV 1986 - 2004 - Front Cover

Front Cover

Front Cover

description

Kawasaki Bayou KLF300 2WD & 4WD ATV 1986 - 2004 Clymer Owners Service & Repair Manual Covers the following Models:
● KLF300 2WD Bayou (1986-2004)
● KLF300 4WD Bayou (1989-2004)

Contents:
QUICK REFERENCE DATA

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

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

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

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

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

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

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

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

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

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 / Tyres and wheels / Specifications

FRONT DRIVE MECHANISM FOUR-WHEEL DRIVE
Front propeller shaft / Front axle / Front final gear case / Sub-transmission / Specifications

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

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

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

WIRING DIAGRAMS

Clymer motorcycle & ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

product details

  • Publisher: Clymer Publications
  • ISBN: 0892879254 (0-892-87925-4)
  • ISBN-13: 9780892879250 (978-0-892-87925-0)
  • Format: Softcover, 462 pages
  • Date Published: 10-2004

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