Clymer ATV repair manuals are the best reference book for repair and service information. Written for the do-it-yourselfer as well as the experienced mechanic, Clymer repair manuals are the cheapest way to keep your four wheeler running properly. Every Clymer ATV shop manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the ATV covered. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail, accuracy and clarity to guide the reader through each maintenance, troubleshooting and repair procedure.
Years covered: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
The Clymer Kawasaki Bayou KLF220 & KLF250 manual covers the following models:
1988-2002 KAWASAKI KLF220
2003-2010 KAWASAKI KLF250
Every Clymer Repair Manual contains the following:
Handy thumb-tabs put the chapter you need right at your fingertips.
Detailed substeps expand on repair procedure information.
Notes, cautions and warnings throughout each chapter pinpoint critical information.
Numbered instructions guide you through every repair procedure step by step.
Bold figure numbers help you quickly match illustrations with instructions.
Detailed illustrations, drawings and photos guide you through every procedure.
Exploded views help you identify and examine parts in detail.
Numbered table of contents . . . easy to use so that you can find the information you need fast.
CHAPTER ONE / GENERAL INFORMATION
CHAPTER TWO / TROUBLESHOOTING
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
Models covered: KLF220 KLF250 KLF 220 250