1988-2002 Kawasaki KLF220 Bayou ATV Service Manual

Covers KLF220-A1 through A15 Bayou ATVs with procedures for engine, fuel system, electrical system, and drivetrain repairs. PN 98051-1033B

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Document Details

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Document Number / Seller:
31461 / Brian Thompson
File Size:
37.44 MB
File Type:
ZIP
Language:
English
Pages:
400+
Printable:
Yes
Category:
ATV
Last updated / verified
Dec 23, 2025

Models Covered & Key Technical Specifications

Definitive Service Manual: Kawasaki KLF220 Bayou All Terrain Vehicle 1988-2002 Hydraulic-Guide

Kawasaki KLF220 Bayou (98051-1033B) -- 1988-2002 Commercial Registry Handbook | Package.

  • Authorized Volume Data: 1745 mm establishes the overall length of the vehicle chassis.
  • Published Charge Quantity: For engine operation, 215 mL defines the total displacement capacity.
  • Reference End Play: The rear tire measures 10.00-10 for optimal ground contact.
  • Established Cooling Specs: Air-cooled system ensures efficient engine thermal regulation.
  • Measured Mass Specs: 183 kg indicates the dry weight of the base model.
  • Core Twist Specifications: The starter motor produces 14.5 ft-lb of torque for reliable ignition.

Professional Workshop Service Manual & Technical Specifications

Definitive Service Manual: Kawasaki KLF220 Bayou All Terrain Vehicle 1988-2002 Hydraulic-Guide

Operational-Framework: Kawasaki KLF220 Bayou (98051-1033B) / Engine-Type: Air-cooled / Operational-Framework: ATV

Assessment-Parameter Technical-Path Validation-Data
Overall Length 1745 mm 1.745 meters
Dry Weight 183 kg 183000 grams
Engine Displacement 215 mL 0.215 Liters

Cataloging major assemblies into the following sections: General Information, Fuel System, Engine Top End, Engine Left Side, Engine Right Side, Engine Removal/Installation, Engine Bottom End/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, and Electrical System. Each chapter includes exploded views, specifications, and detailed procedures for disassembly, assembly, inspection, and maintenance.

General Information

Adjustment procedures are detailed for throttle controls and brake levers.

Fuel System

Timing procedures are documented for carburetor settings and fuel delivery.

Engine Top End

Technical notes are provided for valve clearance and camshaft timing.

Engine Left Side

Quality checks are addressed for starter motor and ignition system components.

Engine Right Side

The clutch system documents specifications for plate thickness and spring free length.

Documents torque specifications for critical fasteners to ensure proper axial load stability.

FAQ

Determine the **specific** torque specifications for the engine mounting bolts? keyboard_arrow_down

26 N·m (2.7 kg-m, 19.5 ft-lb) is the specified torque for the engine mounting bolts.

What specifications are **designated** for safety precautions regarding battery charging? keyboard_arrow_down

12 V 11 Ah batteries require charging at a rate of 1.2 A for 10 hours, avoiding sparks and open flames.

Check the **critical** lubrication requirements for the starter motor? keyboard_arrow_down

10 mm brush length is the standard, with a 5 mm service limit for starter motor brushes.

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Reviews (4)

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Rated 4 out of 5 stars
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Rated 4 out of 5 stars
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Had a few questions about the manual, but the support team was very responsive and helpful. Highly recommend this for anyone looking to work on their ATV!
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This service manual is incredibly detailed and has everything you need to maintain your Kawasaki Bayou 220. The download process was smooth, and I received the link quickly after my purchase!