Softcover - 462 pages - Kawasaki Bayou KLF300 2WD & 4WD ATV 1986 - 2004 Clymer Owners Service & Repair Manual Covers the following Models: * KLF300 2WD Bayou (1986-2004) * KLF300 4WD Bayou (1989-2004) Contents: * QUICK REFERENCE DATA * 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 * 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 * 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 * 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 * 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 * CLUTCH, PRIMARY DRIVE AND EXTERNAL SHIFT MECHANISM Clutch cover / Clutch release mechanism / Clutch / Gear backlash check / One-way clutch check / External shift mechanism / Specifications * TRANSMISSION AND INTERNAL SHIFT MECHANISM Transmission/reverse system identification / Transmission troubleshooting / Transmission/reverse overhaul / Reverse axle / Transmission inspection / Internal shift mechanism / Reverse cable / Specifications * FUEL AND EXHAUST SYSTEMS Carburetor operation / Carburetor / Carburetor adjustments / Throttle cable replacement / Fuel level gauge / Fuel shutoff valve / Air box / Exhaust system / Specifications * 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 * 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 / Tyres and wheels / Specifications * FRONT DRIVE MECHANISM FOUR-WHEEL DRIVE Front propeller shaft / Front axle / Front final gear case / Sub-transmission / Specifications * 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 * 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 * BODY Front carrier / Front guard / Rear carrier / Seat / Fuel tank cover assembly / Front fender / Rear fender / Specifications * WIRING DIAGRAMS Clymer motorcycle & 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. |