1988-2011 Kawasaki Bayou KLF220, KLF250 Service, Repair & Maintenance Manual by CLYMER
The Models Include:- KLF220 Bayou (1988-2002)
-
KLF250 Bayou (2003-2011)
Every Clymer contains hundreds of original photographs and illustrations
developed from a complete disassembly and assembly of the Motorcycle. This, in
addition to extensive research, allows Clymer to achieve an un-matched level of
detail, accuracy & clarity.
The step-by-step
instructions and two column text with large print are user friendly, bold figure
numbers make it easy to quickly match instructions with illustrations and
photos. Thumb tabbed chapters, numbered table of contents and extensive index
make it possible to locate the desired section quickly. This manual includes a
Quick Reference Data section with frequently used specifications and the
following chapters:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first /
Service hints / Washing the vehicle / Torqu specifications / Fasteners /
Lubricants / Threadlocking compound / Expendable supplies / Serial
numbers / Warning labels / Basic hand tools / Precision measuring tools
/ Special tools / Mechanic's tips / Ball bearing replacement / Oil seals
/ Riding safely / Specifications
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Starting hte
engine / Engine starting difficulties / Engine will not start / Poor
idle or off idle performance / Poor medium and high speed performance /
Engine starting system / Charging system / Ignition system / Fuel system
/ Engine overheating / Engine noises / Engine leak down test / Clutch /
Transmission / Drive train noise / Handling / Frame noise / Brakes
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist / Service intervals schedule / Periodic lubrication /
Engine oil and filter change / Final drive oil change / Control cable
lubrication / Non-scheduled lubrication / Periodic maintenance /
Non-scheduled maintenance / Reverse cable adjustment / Tune-up / Valve
clearance / Compression test check / Spark plug / Air filter / Ignition
timing / Pilot screw adjustment / Idle Speed Adjustment / Storage /
Specifications
CHAPTER FOUR / ENGINE TOP END
Engine principles / Cylinder head / Compression release lever / Camshaft
and rocker arms / Cam chain / Chain guides / Valves and valve components
/ Cylinder / Piston and piston rings / Specifications
CHAPTER FIVE / ENGINE LOWER END
Servicing engine in frame / Engine removal / Engine installation /
Balancer gears and oil pump drive gear / Oil screen / Oil pump / Oil
pipes / Left-hand side cover / Stator coil and pickup coil / Flywheel
and starter clutch / Crankcase and crankshaft / Recoil starter / Engine
break-in / Specifications
CHAPTER SIX / CLUTCH, PRIMARY DRIVE AND EXTERNAL SHIFT MECHANISM
Clutch cover / Clutch release mechanism / Clutch / Gear backlash check /
One-way clutch check / External shift mechanism / Specifications
CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission/reverse system identification / Transmission
troubleshooting / Transmission/reverse overhaul / Reverse axle /
Transmission inspection / Internal shift mechanism / Specifications
CHAPTER EIGHT / FUEL AND EXHAUST SYSTEMS
Carburetor operation / Carburetor / Carburetor float adjustments /
Throttle cable / Throttle housing / Choke cable / Fuel tank / Fuel level
gauge / Fuel shutoff valve / Air box / Exhaust system / Specifications
CHAPTER NINE / ELECTRICAL SYSTEM
Charging system / Stator coil / Voltage regulator/rectifier / Capacitor
discharge ignition / CDI unit / Ignition coil / Pickup coil / Exciter
coil / Starting system / Starter solenoid / Starter circuit relay /
Lighting system / Switches / Auxiliary lighting terminal / Auxiliary
electrical terminals / Speedometer housing (late 1999-on Australian and
European models) / Fuse / Wiring diagrams / Specifications
CHAPTER TEN / FRONT SUSPENSION AND STEERING
Wheel alignment / Front wheel / Front brake drum/bearing assembly /
Handlebar / Steering shaft / Tie rod / Steering knuckle / Control arm /
Shock absorber / Tires and wheels / Specifications
CHAPTER ELEVEN / REAR AXLE, SUSPENSION AND FINAL DRIVE
Rear wheel / Rear suspension arms / Rear shock absorbers / Left-hand
rear axle hub / Final drive unit / Propeller shaft / Rear axles / Front
gear case / Drive gear / Reverse lever and neutral/reverse switch
assembly / Specifications
CHAPTER TWELVE / BRAKES
Front drum brake / Front brake shoe replacement / Front brake shoes and
brake panel / Rear drum brake / Rear brake drum / Rear brake shoe
replacement / Rear brake shoes and brake panel / Brake drum wheel stud
replacement / Front brake cables / Rear brake pedal / Rear/parking brake
cable assembly / Specifications
CHAPTER THIRTEEN / BODY
Seat / Front carrier / Front cover / Front fender / Rear carrier / Rear
fender / Footpegs / Specifications
INDEX
WIRING DIAGRAMS
Publisher: Clymer Publications
Softcover: 424 pages
Dimensions: 10.0 x 7.0 x 0.9 inches