1986-2004 Kawasaki KLF300 Bayou ATV Repair Manual by Clymer

Description

This Clymer Kawasaki KLF300 Bayou Repair Manual, 1986-2004 provides detailed service information, step-by-step repair instruction and maintenance specifications for 1986-2004 Kawasaki KLF300 ATVs.

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

Contents include:

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