2003-2009 Kawasaki Bayou 250, KLF 250 ATV service manual

Product Information

Table of Contents

GENERAL INFORMATION

1. Model Identification
2. Serial Numbers
3. Important Information
4. Specifications
5. Special Tools

PERIODIC MAINTENANCE

1. Maintenance Schedule
2. Pre-Ride Inspection
3. Periodic Maintenance Procedures
4. Air Filter Maintenance
5. Spark Plug Inspection and Replacement
6. Valve Clearance Adjustment
7. Throttle and Cable Adjustment
8. Drive Chain Adjustment
9. Brake System Inspection
10. Tire Inspection and Maintenance
11. Steering System Inspection
12. Suspension System Inspection
13. Electrical System Inspection

FUEL SYSTEM

1. Fuel Tank Removal and Installation
2. Fuel Line Inspection and Replacement
3. Carburetor Removal, Inspection, and Installation
4. Carburetor Adjustment
5. Throttle Cable Adjustment

ENGINE TOP END

1. Cylinder Head Removal and Installation
2. Valve Removal, Inspection, and Installation
3. Piston and Cylinder Maintenance
4. Camshaft Removal, Inspection, and Installation

ENGINE RIGHT SIDE

1. Clutch Removal and Installation
2. Clutch Inspection and Adjustment
3. Oil Pump Removal and Installation
4. Oil Pump Inspection

RECOIL STARTER

1. Recoil Starter Removal and Installation
2. Recoil Starter Inspection and Maintenance

ENGINE LUBRICATION SYSTEM

1. Lubrication Points
2. Recommended Lubricants
3. Oil Change Procedure
4. Oil Filter Maintenance

ENGINE REMOVAL/INSTALLATION

1. Engine Removal Procedures
2. Engine Installation Procedures

CRANKSHAFT/TRANSMISSION

1. Crankshaft Removal and Installation
2. Crankshaft Inspection and Maintenance
3. Transmission Removal and Installation
4. Transmission Inspection and Maintenance

WHEELS/TIRES

1. Front Wheel Removal and Installation
2. Rear Wheel Removal and Installation
3. Tire Inspection and Replacement

FINAL DRIVE

1. Final Drive Removal and Installation
2. Final Drive Inspection and Maintenance

BRAKES

1. Front Brake Removal and Installation
2. Rear Brake Removal and Installation
3. Brake Inspection and Adjustment

SUSPENSION

1. Front Suspension Removal and Installation
2. Rear Suspension Removal and Installation
3. Suspension Inspection and Adjustment

STEERING

1. Steering System Removal and Installation
2. Steering System Inspection and Adjustment

FRAME

1. Frame Inspection and Repair
2. Body Panel Removal and Installation

ELECTRICAL SYSTEM

1. Electrical System Overview
2. Battery Maintenance
3. Charging System Inspection
4. Ignition System Inspection
5. Lighting System Inspection
6. Switches and Relays Inspection
7. Wiring Diagram

APPENDIX

1. Service Data
2. Torque Specifications
3. Troubleshooting Guide
4. Technical Bulletins

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