Home > Motorcycles & ATV's > Kawasaki Motorcycle/ATV >   Kawasaki Bayou KLF300 2WD & 4WD Repair Manual 1986-2004
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Details   Details 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. PRODUCT DETAILS: Publisher: Clymer Manuals — 2004 Binding: Paperback — 7 x 10 inches Pages: 462 — Hundreds of b&w photos and illustrations ISBN: 9780892879250

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