Kawasaki Bayou KLF300 2WD (1986-2004) & 4WD (1989-2004) Service Repair Manual

The online edition of this manual will be available immediately without download. The physical manual will be dispatched directly by Haynes and will arrive separately from any other parts ordered.

Clymer ATV repair manuals are written specifically for the do-it-yourself enthusiast. From basic maintenance to troubleshooting to complete overhaul, Clymer manuals provide the information you need. The most important tool in your tool box may be your Clymer manual, get one today. Every Clymer manual contains hundreds of original photographs and illustrations developed from a complete disassembly and assembly of a motorcycle. This, in addition to extensive research, allows Clymer to achieve an unmatched level of detail, accuracy and clarity. The step-by-step instructions and two-column text with large print are user-friendly. Bold figure numbers make it easy to quickly match instructions with illustrations and photos. Thumb-tabbed chapters, numbered table of contents and an extensive index make it possible to locate the desired section quickly.

The Haynes Online Manual gives you the trusted content of the famous printed Workshop Manual with extra features to get the job done. Online Manuals provide the following benefits: Troubleshooting tool for fast diagnosis of common problems. Colour-coded wiring diagrams for key systems. Videos tutorials for common DIY tasks. Colour photographs with approximately 750 in each manual. Photos can be zoomed in to observe key details. Fully searchable Dictionary of automotive terms. Hyperlinks to additional relevant information in other manual chapters. Print any page at home.

Kawasaki KLF300 2WD and KLF300 4WD manual.

What's Covered

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)