Kawasaki Bayou KLF300 2WD & 4WD Repair Manual 1986-2004

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Item # M466-4  ISBN: 9780892879250

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This repair and service manual covers Kawasaki Bayou KLF300 2WD 1986-2004 and Kawasaki Bayou KLF300 4WD 1989-2004.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Notes, cautions and warnings | Safety first | Service hints | Washing the vehicle | Torque specifications | Fasteners | Lubricants | Threadlock | Expendable supplies | Serial numbers | Warning labels | Basic hand tools | Precision measuring tools | Special tools | Mechanic's tips | Ball bearing replacement | Oil seals | Riding safety.

CHAPTER TWO: TROUBLESHOOTING
Operating requirements | Troubleshooting instruments | Starting the engine | Starting difficulties | Engine starting troubles | Engine is difficult to start | Poor idle speed performance | Poor medium to high speed performance | Engine starting system | Charging system | Ignition system | Fuel system | Engine overheating | Engine | 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 | Tires and wheels | Battery | Lubricants | Cleaning solvent | Periodic lubrication | Non-scheduled lubrication | Periodic maintenance | Non-scheduled maintenance | Engine tune-up | Storage.

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.

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 (Canada and Europe) | 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.

CHAPTER SIX: CLUTCH, PRIMARY DRIVE and EXTERNAL SHIFT MECHANISM
Clutch cover | Clutch release mechanism (2-wheel drive) | Clutch release mechanism (4-wheel drive) | Clutch | Gear backlash check | One-way clutch check | External shift mechanism.

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.

CHAPTER EIGHT: FUEL and EXHAUST SYSTEMS
Carburetor operation | Carburetor | Carburetor adjustments | Throttle cable replacement | Fuel level gauge | Fuel shutoff valve | Air box | Exhaust system.

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 (U.K. model) | Fuse | Wiring diagrams.

CHAPTER TEN: FRONT SUSPENSION and STEERING
Wheel alignment | Front wheel | Front hub/brake drum (1986-1987 2-wheel drive) | Front hub (1988-on 2-wheel drive) | Front hub (4-wheel drive) | Handlebar | Steering shaft | Tie rod | Steering knuckle (2-wheel drive) | Steering knuckle (4-wheel drive) | Control arms | Steering stopper adjustment (2-wheel drive) | Steering stopper adjustment (4-wheel drive) | Shock absorber | Tires and wheels.

CHAPTER ELEVEN: FRONT DRIVE MECHANISM FOUR-WHEEL DRIVE
Front propeller shaft | Front axle | Front final gear case | Sub-transmission.

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).

CHAPTER THIRTEEN: BRAKES
Front drum brake (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.

CHAPTER FOURTEEN: BODY
Front carrier | Front guard | Rear carrier | Seat | Fuel tank cover assembly | Front fender | Rear fender.

INDEX | WIRING DIAGRAMS

Clymer 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.

Kawasaki Bayou KLF300 2WD & 4WD Repair Manual 1986-2004