Kawasaki KLF 250 ATV Workshop Service Manual (2003-2005) – 322 Pages | Instant PDF

Kawasaki KLF 250 BAYOU / Workhorse Service Manual - 2003-2005

This official service publication provides specialized engineering data and procedural workflows necessary for the maintenance and repair of the Kawasaki 228cc utility vehicle series. It features high-precision technical benchmarks, including the critical 11 N-m specification for the clutch adjustment locknut, which ensures consistent engagement and prevents premature friction plate wear during heavy-load operations. Engineers and technicians can utilize this documentation to maintain factory-grade reliability and operational uptime across all listed chassis configurations.

Technical Applicability & Serial Ranges

Series KLF250-A (Single-Cylinder SOHC 4-Stroke)

• 2003 KLF250-A1: Beginning Frame No. JKALFMA1_3B500001 or JKALF250AAB600001
• 2004 KLF250-A2: Beginning Frame No. JKALFMA1_4B523201 or JKALF250AAB601301
• 2005 KLF250-A3: Beginning Frame No. JKALFMA1_5B534201 or JKALF250AAB602001

Asset Protection & Operational Efficiency

• Detailed exploded views and fastener torque specifications ensure components are secured to factory standards, preventing mechanical failure.
• Periodic maintenance schedules established by the manufacturer facilitate preventative care, significantly reducing the risk of catastrophic engine or drivetrain damage.
• Step-by-step diagnostic protocols for fuel, electrical, and cooling systems minimize diagnostic time and maximize vehicle availability for agricultural or industrial use.

Documentation Metadata

• Print Number: 99924-1284-03
• Total Page Count: 322
• Edition: Third Edition (April 27, 2004)

Calibration Data & Factory Benchmarks

This manual details precise tolerances for engine and chassis systems, including valve clearances (Exhaust: 0.18–0.23 mm; Inlet: 0.15–0.20 mm) and cylinder compression targets (930–1435 kPa with electric starter). Technicians must adhere to these benchmarks to maintain the 12.5 kW power output and 17.9 N-m torque rating specified for this 228 cc air-cooled powerplant.

System Architecture & Visualization

Technical diagrams and exploded views illustrate the 5-speed plus reverse constant-mesh transmission and the shaft-driven final drive system. These visual aids serve as primary navigation tools for complex assemblies, such as the torque tube-link rear suspension and the independent swing axle front configuration.

Table of Contents

• Chapter 1: General Information (Model Identification, Specifications)
• Chapter 2: Periodic Maintenance (Chart, Torque, Procedures)
• Chapter 3: Fuel System (Carburetor, Air Cleaner, Fuel Tank)
• Chapter 4: Engine Top End (Cylinder Head, Valves, Camshaft)
• Chapter 5: Engine Right Side (Clutches, Balancer Gear)
• Chapter 6: Recoil Starter (Removal and Disassembly)
• Chapter 7: Engine Lubrication System (Oil Pump, Relief Valve)
• Chapter 8: Engine Removal/Installation
• Chapter 9: Crankshaft/Transmission (Crankcase, Shift Mechanism)
• Chapter 10: Wheels/Tires (Tires, Hubs, Axles)
• Chapter 11: Final Drive (Bevel Gears, Propeller Shaft)
• Chapter 12: Brakes (Front/Rear Drums, Adjustment)
• Chapter 13: Suspension (Shock Absorbers, Arms)
• Chapter 14: Steering (Handlebar, Tie-Rods, Knuckles)
• Chapter 15: Frame (Fenders, Carriers, Footrests)
• Chapter 16: Electrical System (Ignition, Alternator, Battery)
• Chapter 17: Appendix (Wiring, Troubleshooting)

Operational Limits & Fluid Specifications

• Engine Oil: SAE 10W-40 (API SF/SG or SH/SJ with JASO MA); Capacity: 2.0 L (2.11 US qt).
• Final Gear Oil: API GL-5 Hypoid (SAE 90 above 5°C); Capacity: 0.2 L (0.21 US qt).
• Standard Spark Plug: NGK DR8ES with a gap of 0.6–0.7 mm (0.024–0.028 in).
• Tire Pressure: Front and Rear 21 kPa (3.0 psi) cold; max seating pressure 250 kPa (36 psi).

FAQ

Which specific serial number ranges are covered for the Kawasaki KLF 250 series? This manual provides technical coverage for the KLF250-A series from 2003 through 2005. This includes the A1 model starting with frame number JKALFMA1_3B500001, the A2 model starting with JKALFMA1_4B523201, and the A3 model starting with JKALFMA1_5B534201.

What is the correct engine oil specification and capacity for a standard oil change? For optimal engine performance, use a high-quality 4-stroke engine oil such as SAE 10W-40 with an API classification of SF, SG, SH, or SJ. When the oil filter is not being replaced, the engine requires a refill capacity of exactly 1.5 liters (1.58 US quarts).

Does this documentation include detailed guidance on the fuel and carburetion system? Yes, the manual contains a dedicated Fuel System chapter that provides comprehensive teardown and adjustment procedures for the Mikuni VM24SS carburetor. This includes specific factory settings such as the pilot screw position and the float level height of 17.0 mm plus or minus 2.0 mm.

What specific diagnostic procedures are provided for the vehicle's electrical charging system? The manual outlines a structured troubleshooting workflow for the electrical system, including a stator coil resistance test. Technicians can verify the health of the charging system by measuring the resistance across the yellow leads, which should ideally fall between 0.4 and 0.6 ohms.

How does the digital layout of this manual assist with urgent field repairs or specific component overhauls? The digital manual is structured with a Quick Reference Guide and linked chapter tabs, allowing for immediate navigation to critical schematics like the wiring diagram in the Appendix. Users can print high-resolution exploded views of assemblies, such as the 5-speed semi-automatic transmission or the shaft drive system, to ensure every washer and gear is correctly oriented during reassembly.