1986-2006 Kawasaki Bayou 300, KLF300 repair manual

Product Information

Table of Contents

Quick Reference Guide

General Information 1

• Vehicle Identification
• General Specifications
• Location of Labels
• Tools and Techniques

Fuel System 2

• Fuel Tank Removal and Installation
• Fuel Line Inspection
• Fuel Pump Operation Check
• Carburetor Disassembly, Inspection, and Assembly
• Fuel System Cleaning and Inspection

Engine Top End 3

• Cylinder Head Removal and Installation
• Valve and Valve Spring Inspection
• Camshaft Inspection
• Cylinder and Piston Inspection
• Timing Chain and Tensioner Inspection
• Compression Test

Engine Left Side 4

• Stator and Rotor Removal
• Left Crankcase Cover Removal
• Starter Clutch Inspection
• Shift Mechanism Inspection

Engine Right Side 5

• Clutch Cover Removal
• Clutch Inspection and Adjustment
• Oil Pump Inspection
• Water Pump Inspection

Engine Removal/Installation 6

• Engine Removal Procedure
• Engine Installation Procedure
• Engine Mount Inspection and Replacement

Engine Bottom End/Transmission 7

• Crankshaft Removal and Inspection
• Connecting Rod Inspection
• Main Bearing Inspection and Replacement
• Engine Case Disassembly and Assembly
• Transmission Gear Inspection
• Shift Fork and Drum Inspection
• Bearing and Oil Seal Replacement
• Transmission Assembly

Wheels/Tires 8

• Wheel Removal and Installation
• Tire Inspection and Replacement
• Wheel Bearing Inspection and Replacement
• Tire Pressure Adjustment

Final Drive 9

• Differential Inspection and Replacement
• Drive Shaft Inspection
• U-Joint Inspection
• Final Drive Oil Replacement

Brakes 10

• Brake Pad Inspection and Replacement
• Brake Disc Inspection
• Brake Line Inspection
• Master Cylinder Inspection and Repair
• Brake Bleeding Procedure

Suspension 11

• Front Suspension Inspection and Adjustment
• Rear Suspension Inspection and Adjustment
• Shock Absorber Inspection
• Suspension Arm Bushings Replacement

Steering 12

• Steering Shaft Inspection
• Steering Knuckle Inspection and Replacement
• Tie Rod End Inspection
• Steering Alignment Adjustment

Frame 13

• Frame Inspection and Repair
• Subframe Inspection
• Frame Bolt Torque Specifications
• Footpeg and Handlebar Inspection

Electrical System 14

• Battery Inspection and Replacement
• Charging System Check
• Starter Motor Inspection
• Ignition System Inspection
• Lighting System Inspection
• Electrical Component Testing and Replacement
• Wiring Diagram

Appendix 15

• Troubleshooting Guide
  • Engine Troubleshooting
  • Chassis Troubleshooting
  • Electrical Troubleshooting
• Special Tools List
• Torque Specifications
• Wiring Diagrams
• Maintenance Records

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