Kawasaki KLF 250 BAYOU 250 WORKHORSE 250 Service Manual ATV


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Pages: 318
Format: PDF (High-Quality PDF Manual)
Language: English
Instant Download (Life Time Downloads)
Searchable Text
Wiring Schematics

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Factory Service Repair Manual For Kawasaki KLF 250 BAYOU 250 WORKHORSE 250 ATV. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.

Format: PDF
Language: English
Pages: 318
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: No


Kawasaki ATV KLF250, BAYOU 250, Workhorse 250


Years: 2003, 2004, 2005, 2006, 2007, 2008, 2009


– General Information
Before Servicing
Model Identification
General Specifications
Unit Conversion Table
– Periodic Maintenance
Periodic Maintenance Chart
Torque And Locking Agent
Periodic Maintenance Procedures
Fuel System
Throttle Lever Free Play Inspection
Throttle Lever Free Play Adjustment
Fuel System Cleanliness Inspection
Air Cleaner Element Cleaning And Inspection
Air Cleaner Draining
Fuel Hose And Connection Check
Fuel Hose Replacement
Engine Top End
Valve Clearance Inspection
Spark Arrester Cleaning
Clutch Adjustment
Engine Lubrication System
Engine Oil Change
Oil Filter Change
Tire Inspection
Final Drive
Final Gear Case Oil Change
Propeller Shaft Joint Boot Inspection
Front Brake Adjustment
Rear (Parking) Brake Lever Free Play Inspection
Brake Pedal Free Play Inspection
Rear (Parking) Brake Lever And Pedal Free Play Adjustment
Steering Inspection
Electrical System
Battery Inspection
Spark Plug Cleaning / Inspection
Spark Plug Gap Inspection
Brake Light Switch Adjustment
General Lubrication
Bolts And Nuts Tightening
Tightness Inspection
– Fuel System
Exploded View
Special Tools And Sealant
Throttle Lever And Cable
Throttle Lever Free Play
Throttle Lever Free Play
Throttle Case Removal/Disassembly
Throttle Case Assembly/Installation
Throttle Cable Installation
Throttle Case Inspection And
Throttle Cable Lubrication And Inspection
Choke Lever And Cable
Choke Lever Removal
Choke Lever And Cable Installation
Choke Lever Lubrication
Choke Cable Lubrication And Inspection
Idle Speed Adjustment
Carburetor Pilot Screw Adjustment
Fuel Level Inspection
Fuel Level Adjustment
Fuel System Cleanliness Inspection
Carburetor Removal
Carburetor Installation
Carburetor Disassembly
Carburetor Assembly
Carburetor Cleaning
Carburetor Inspection
Air Cleaner
Air Cleaner Element Removal
Air Cleaner Element Installation
Air Cleaner Element Cleaning And Inspection
Air Cleaner Draining
Air Cleaner Housing Removal
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tap Removal
Fuel Tap Installation
Fuel Tank And Fuel Tap Cleaning
Fuel Tap Inspection
Fuel Level Gauge Removal
Fuel Level Gauge Installation
Fuel Level Gauge Check
– Engine Top End
Exploded View
Special Tools And Sealant
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Camshaft Chain Tensioner Wear
Camshaft Sprocket
Camshaft Sprocket Removal
Camshaft Sprocket Installation
Rocker Arms And Shafts
Compression Releasing Lever Removal
Compression Releasing Lever Installation
Rocker Arm And Shaft Removal
Rocker Arm And Shaft Installation
Rocker Arm And Shaft Inspection
Camshaft Removal
Camshaft Installation
Cam Wear Inspection
Camshaft Bearing Inspection
Camshaft Chain And Guides
Camshaft Chain Removal
Camshaft Chain Installation
Camshaft Chain Guide Removal
Camshaft Chain Guide Installation
Camshaft Chain Guide Wear
Cylinder Head
Cylinder Compression Measurement
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Assembly
Cylinder Head Cleaning
Cylinder Head Warp
Valves, Guides, Seats, Springs, Oil Seals
Valve Clearance Inspection
Valve Clearance Adjustment
Valve Removal
Valve Installation
Valve Visual Inspection
Valve Guide Removal
Valve Guide Installation
ValveToGuide Clearance Measurement
Valve Seat Inspection
Valve Seat Repair (Valve Lapping)
Cylinder And Piston
Cylinder Removal
Cylinder Installation
Piston Removal
Piston Installation
Cylinder/Piston Wear
Piston/Cylinder Clearance
Piston Ring And Ring Groove
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap Measurement
Exhaust System
Spark Arrester Cleaning
Muffler Removal
Exhaust Pipe Removal
Exhaust Pipe Installation
Exhaust System Inspection
– Engine Right Side
Special Tools And Sealant
Engine Right Side
Engine Right Side Disassembly
Engine Right Side Assembly
Clutch Adjustment
Clutch Release Removal
Clutch Release Wear
Primary Clutch Housing Wear
Primary Clutch Shoe Lining Wear
One Way Clutch Inspection
Friction Plate Wear
Friction And Steel Plate Warp
Clutch Spring Free Length Measurement
Primary Reduction
Gear Backlash
Primary Gear/Crankshaft Wear
Secondary Gear/Collar Wear
– Recoil Starter
Recoil Starter
Recoil Starter Removal
Recoil Starter Installation
Recoil Starter Disassembly
Recoil Starter Assembly
Recoil Starter Cleaning
Recoil Starter Inspection
– Engine Lubrication System
Engine Oil Flow Chart
Engine Oil And Oil Filter
Oil Level Inspection
Engine Oil Change
Oil Filter Change
Bypass Valve Removal
Bypass Valve Installation
Bypass Valve Cleaning And Inspection
Oil Screen Removal
Oil Screen Installation
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal
Oil Pressure Relief Valve Installation
Oil Pressure Relief Valve Inspection
Oil Pump
Oil Pump Removal
Oil Pump Installation
Oil Pipe
Oil Pipe Removal
Oil Pipe Installation
– Engine Removal/Installation
Exploded View
Engine Removal/Installation
Engine Removal
Engine Installation
– Crankshaft/Transmission
Special Tools And Sealant
Crankcase Disassembly
Crankcase Assembly
Crankshaft/Balancer Shaft And Connection Rod
Crankshaft Removal
Crankshaft/Balancer Shaft Installation
Crankshaft Disassembly
Crankshaft Assembly
Connecting Rod Big End Seizure
Connecting Rod Big End Radial Clearance
Connecting Rod Big End Side Clearance
Crankshaft Alignment
Connecting Rod Bend/Twist
External Shift Mechanism Removal
External Shift Mechanism Installation
External Shift Mechanism Inspection
Reverse Knob Free Play Adjustment
Reverse Shift Mechanism Removal
Reverse Shift Mechanism Installation
Transmission Removal
Transmission Installation
Transmission Shaft Disassembly
Transmission Shaft Assembly
Shift Drum Disassembly
Shift Drum Assembly
Shift Fork Bending
Shift Fork Wear
Shift Drum Inspection
Transmission Gear Inspection
Ball Bearing, Needle Bearing, And Oil Seal
Ball And Needle Bearing Replacement
Ball And Needle Bearing Wear
Oil Seal Inspection
– Wheels/Tires
Wheel Alignment
Steering Centering Inspection
Steering Centering Adjustment
ToeIn Inspection
ToeIn Adjustment
Wheels (Rims)
Wheel Removal
Wheel Installation
Wheel (Rim) Inspection
Wheel (Rim) Replacement
Tire Removal
Tire Installation
Tire Inspection
Rear Hub
Rear Left Hub Removal
Rear Left Hub Installation
Rear Left Hub Disassembly/Assembly
– Final Drive
Special Tools And Sealant
Output Bevel Gear Case
Output Bevel Gear Case Removal
Output Bevel Gear Case Installation
Output Bevel Gear Case Disassembly
Output Bevel Gear Case Assembly
Output Drive Gear Removal
Output Drive Gear Installation
Output Bevel Gear Adjustment
Bevel Gear Inspection
Cam Damper Inspection
Ball Bearing Inspection
Oil Seal Inspection
Propeller Shaft
Propeller Shaft Removal
Propeller Shaft Installation
Propeller Shaft Inspection
Propeller Shaft Joint And Pinion
Gear Joint Inspection
Propeller Shaft Joint Boot Inspection
Rear Axle
Rear Axle Removal
Rear Axle Installation
Axle Shaft Pipe Disassembly
Axle Shaft Pipe Assembly
Final Gear Case
Final Gear Case Oil Level Inspection
Final Gear Case Oil Change
Final Gear Case Removal
Final Gear Case Installation
Final Gear Case Disassembly
Final Gear Case Assembly
Final Bevel Gear Adjustment
Pinion Gear Disassembly
Pinion Gear Assembly
Bevel Gear Inspection
Ball Bearing Inspection
Oil Seal Inspection
– Brakes
Brake Adjustment
Front Brake Adjustment
Brake Pedal Position Inspection
Brake Pedal Position Adjustment
Rear (Parking) Brake Lever Free Play Inspection
Brake Pedal Free Play Inspection
Rear (Parking) Brake Lever And Brake Pedal Free Play Adjustment
Cam Lever Angle Adjustment (Front And Rear)
Brake Drum And Panel
Front Brake Panel Removal/Disassembly
Front Brake Panel Assembly/Installation
Rear Brake Panel Removal/Disassembly
Rear Brake Panel Assembly/Installation
Brake Drum Seal Wear
Brake Maintenance
Brake Drum Wear
Brake Shoe Lining Wear
Brake Cam And Cam Hole Wear
Brake Shoe Spring Inspection
Brake Lubrication
Brake Pedal And Cables
Brake Cable Removal
Brake Cable Installation
Brake Cable Lubrication
Brake Pedal Installation
– Suspension
Shock Absorbers
Shock Absorber Removal
Rear Shock Absorber Installation
Rear Shock Absorber Inspection
Suspension Arms
Front Suspension Arm Removal
Front Suspension Arm Installation
Rear Suspension Arm Removal
Rear Suspension Arm Installation
Suspension Arm Assembly
Suspension Arm Inspection
Front Suspension Arm Lubrication
– Steering
Steering Stem Removal
Steering Stem Installation
Steering Knuckle Removal
Steering Knuckle Installation
Tie Rod Removal
Tie Rod Installation
Tie Rod End Removal
Tie Rod End Installation
Steering Maintenance
Steering Inspection
Steering Stem Warp
Steering Lubrication
Steering Stem Clamp Inspection
Steering Stem Bearing Inspection
TieRod End Inspection
Steering Knuckle Pivot Lubrication
Handlebar Removal
Handlebar Installation
– Frame
Seat Removal
Seat Installation
Front And Rear Fenders
Front Fender Removal
Front Fender Installation
Rear Fender Removal
Rear Fender Installation
Front Guard Removal
Rear Guard Removal
– Electrical System
Special Tools And Sealant
Parts Location
Electrical Wiring
Wiring Inspection
Battery Removal
Battery Installation
Electrolyte Level Inspection
Electrolyte Specific Gravity
Initial Charging
Ordinary Charging
Battery Test Charging
Charging System
Alternator Cover Removal
Alternator Cover Installation
Alternator Rotor Removal
Alternator Rotor Installation
Alternator Stator Removal
Alternator Stator Installation
Regulator / Rectifier Output
Voltage Inspection
Alternator Inspection
Regulator/Rectifier Inspection
Ignition System
Spark Plug Removal/Installation
Spark Plug Cleaning/Inspection
Spark Plug Gap Inspection
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Inspection
Ignition Coil Primary Peak Voltage
Crankshaft Sensor Removal
Crankshaft Sensor Inspection
Crankshaft Sensor Peak Voltage
Alternator Rotor Inspection
Ignition Timing Test
Electric Starter System
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Commutator Cleaning/Inspection
Armature Inspection
Starter Motor Brush Length
Brush Assembly Inspection
Brush Plate And Terminal Bolt Inspection
Starter Relay Inspection
Starter Circuit Relay Inspection
Starter Motor Clutch
Starter Motor Clutch Removal
Starter Motor Clutch Installation
Starter Motor Clutch Inspection
Starter Chain And Sprockets
Torque Limiter Inspection
Lighting System
Headlight Beam Vertical Adjustment
Headlight Bulb Replacement
Taillight Bulb Replacement
Neutral And Reverse Indicator
Light Bulb Replacement
Brake Light Switch Adjustment
Switch Inspection
Main Fuse Removal
Fuse Inspection
Wiring Diagram (USA And Canada Models)
Wiring Diagram (Europe Model)
Wiring Diagram (Australia Model)
– Appendix
Cable, Wire, And Hose Routing
Troubleshooting Guide

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Kawasaki KLF 250 BAYOU 250 WORKHORSE 250 Service Manual ATV