Kawasaki Bayou KLF220, KLF250 ATV Repair Manual 1988-2011

This Clymer M465-3 DIY repair and service manual covers 1988-2002 Kawasaki KLF220 and 2003-2011 Kawasaki KLF250 ATVs.

The Kawasaki Bayou KLF 220/250 Clymer repair manual includes color wiring diagrams, detailed step-by-step repair procedures, exploded views, diagrams and charts. The repair/service procedures and instructions are based on a complete disassembly and reassembly of the Kawasaki Bayou models mentioned.

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Book Excerpt: 1988-2010 Kawasaki Bayou KLF220, KLF250 ATV Repair and Service Manual GENERAL INFORMATION

This manual contains detailed information about maintaining and repairing the 1988-2002 KLF220 and 2003-on KLF Bayou. Troubleshooting, tune-up, maintenance and repair are not difficult, if you know what tools and equipment to use and what to do. Step-by-step instructions guide you through jobs ranging from simple maintenance to complete engine and suspension overhaul. This manual can be used by anyone from a first time do-it-yourselfer to a professional mechanic. Detailed drawings and clear photographs give you all the information you need to do the work right. Some of the procedures in this manual require the use of special tools. The resourceful mechanic can, in many cases, think of acceptable substitutes for special tools as there is always another way. This can be as simple as using a few pieces of threaded rod, washers and nuts to remove or install a bearing. However, substituting a special tool is not recommended as it can be dangerous and may damage the part. When designing special tools, contact a local community college or high school that has a machine shop curriculum. Some shop teachers accept outside work for advanced student projects.

CLUTCH ADJUSTMENT

The clutch should be adjusted at the intervals specified in Table 1. Refer to Figure 57 when adjusting the clutch. Clutch adjustment adjusts the manual clutch only; the centrifugal clutch is not equipped with an adjuster. Since there is no clutch cable to stretch, clutch adjustment takes up slack due to clutch component wear.

1. Remove the clutch adjust cover (Figure 58).
2. Loosen the clutch adjust screw locknut (Figure 59).
3. Turn the adjust screw (Figure 59) clockwise until resistance is felt, then stop.
4. From this point, turn the adjust screw (Figure 59) counterclockwise until resistance is felt, then stop. Hold onto the adjust screw and tighten the locknut securely.
NOTE: Make sure the adjust screw does not move when tightening the locknut.
5. Install the clutch adjust cover.
6. Test ride the vehicle to make sure the clutch is operating correctly. Readjust if necessary.

Subject: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011 Kawasaki Bayou KLF220, KLF250 service, maintenance, & repair procedures. ISBN-10: 1620922282 ISBN-13: 9781620922286 | Clymer M465-3