Kawasaki Bayou KLF220 & KLF250 1988-2003 Service & Repair Manual (Clymer M465-2)

Kawasaki Bayou KLF220 & KLF250 1988-2003 Service & Repair Manual (Clymer M465-2)
Brand:Clymer
Product Code:Clymer M465-2
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Clymer Kawasaki Bayou KLF220 & KLF250 1988-2003

UPC Code:024185788430
ISBN: 9780892878840

Item ID:M465-2

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

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