2003-2005 Kawasaki KLF 250 Bayou Workhorse Service Manual
Technical reference for KLF 250, Bayou 250, and Workhorse 250 models. Documents engine lubrication and final drive systems. PN 92104-002
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Models Covered & Key Technical Specifications
Kawasaki KLF 250 / Bayou 250 / Workhorse 250 (2003-2005) Workshop Service Manual – 322 Pages | Instant PDF Procedure-Database
Functional Archive | Compendium.
- Certified Maximum Resolution: 1300 – 1400 r/min (rpm) establishes the baseline idle speed Standard.
- Designated Assembly Torques: 29 N·m (3.0 kgf·m, 22 ft·lb) signifies the maximum torque for engine drain plugs Procedure.
- Defined Capacity Limits: 2.0 L (2.11 US qt) dictates the engine oil capacity Framework.
- Key Final Drive Backlash: 0.06 – 0.13 mm (0.024 – 0.0051 in.) is the standard specification for the driven gear shaft nut Topology.
- Primary Reduction Gear Backlash: 0.02 – 0.11 mm (0.0008 – 0.0043 in.) defines the standard measurement Margin.
- Baseline Output Drive Gear Nut Torque: 118 N·m (12 kgf·m, 87 ft·lb) is the specified tightening value Protocol.
Professional Workshop Service Manual & Technical Specifications
OEM-Grade Technical Calibration Manual: Kawasaki KLF 250 ATV Workshop Service Manual (2003-2005) – 322 Pages | Instant PDF Procedure-Database
Engineering-Base: KLF250-A1 ~ A3 // Performance-Values: ATV / Engine Lubrication // Validation-Data: 2003-2005
| Performance-Element | Technical-Path | Calibration-Data |
|---|---|---|
| Engine Oil Type | API SF or SG | SAE 10W-40 |
| Front Tire Size | AT21 x 8 - 9 | Dunlop KT856 |
| Rear Tire Size | AT22 x 10 - 10 | Dunlop KT857 |
| Front Brake Play | 1 – 2 mm | 0.04 – 0.08 in. |
| Rear Brake Play | 2 – 3 mm | 0.08 – 0.12 in. |
| Idle Speed | 1300 – 1400 rpm | Standard |
Featuring a modular arrangement of detailed sections covering engine lubrication, final drive systems, wheels, tires, and more. This manual systematically documents procedures for disassembly, assembly, inspection, and adjustment. It details critical specifications for components such as engine oil type, tire sizes, brake lever free play, and idle speed settings, ensuring precise maintenance and optimal performance. The document also includes comprehensive exploded views and torque specifications for various parts.
Procedures
This manual details procedures for engine oil and filter changes, bypass valve removal and installation, oil screen removal and installation, and oil pressure relief valve inspection. It also covers propeller shaft removal, installation, and inspection, as well as rear axle removal, installation, and axle shaft pipe disassembly/assembly.
Specs
The specifications section provides detailed measurements for components such as tires, including standard and service limit tread depths, and wheel alignment parameters like toe-in for front wheels. It also lists engine oil viscosity and capacity requirements.
Systems
Coverage includes the final drive system, outlining bevel gear backlash adjustment and tooth contact patterns, along with output bevel gear case assembly and disassembly. The wheels and tires section details inspection and replacement procedures for rims and tires, including air pressure specifications.
Table
The included table provides detailed torque specifications for various fasteners, such as output bevel gear case bolts, output drive gear nuts, and cam damper mounting nuts, ensuring correct assembly.
Intro
This comprehensive workshop service manual is designed for the Kawasaki KLF 250 ATV, covering models from 2003 to 2005, including Bayou 250 and Workhorse 250 variants.
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