This repair and service manual covers Kawasaki Bayou KLF300 2WD 1986-2004 and Kawasaki Bayou KLF300 4WD 1989-2004. Table of Contents QUICK REFERENCE DATA CHAPTER ONE: GENERAL INFORMATION Manual organization / Notes, cautions and warnings / Safety first / Service hints / Washing the vehicle / Torque specifications / Fasteners / Lubricants / Threadlock / Expendable supplies / Serial numbers / Warning labels / Basic hand tools / Precision measuring tools / Special tools / Mechanic's tips / Ball bearing replacement / Oil seals / Riding safety. CHAPTER TWO: TROUBLESHOOTING Operating requirements / Troubleshooting instruments / Starting the engine / Starting difficulties / Engine starting troubles / Engine is difficult to start / Poor idle speed performance / Poor medium to high speed performance / Engine starting system / Charging system / Ignition system / Fuel system / Engine overheating / Engine / 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 / Tires and wheels / Battery / Lubricants / Cleaning solvent / Periodic lubrication / Non-scheduled lubrication / Periodic maintenance / Non-scheduled maintenance / Engine tune-up / Storage. CHAPTER FOUR: ENGINE TOP-END Engine principles / Cylinder head / Compression release lever (1988-on) / Camshaft and rocker arms / Cam chain / Chain guides / Valves and valve components / Cylinder / Piston and piston rings. CHAPTER FIVE: ENGINE LOWER-END Servicing engine in frame / Engine removal / Engine installation / Oil screen / Oil pump / Oil pipe (2-wheel drive) / Oil pipes (4-wheel drive) / Oil cooler (Canada and Europe) / Balancer gears and oil pump drive gear / Stator coil and left-hand side cover / Flywheel / Starter clutch, chain and sprockets / Crankcase and crankshaft / Recoil starter / Engine break-in. CHAPTER SIX: CLUTCH, PRIMARY DRIVE and EXTERNAL SHIFT MECHANISM Clutch cover / Clutch release mechanism (2-wheel drive) / Clutch release mechanism (4-wheel drive) / Clutch / Gear backlash check / One-way clutch check / External shift mechanism. CHAPTER SEVEN: TRANSMISSION and INTERNAL SHIFT MECHANISM Transmission/reverse system identification / Transmission troubleshooting / Transmission/reverse overhaul / Reverse axle / Transmission inspection / Internal shift mechanism / Reverse cable. CHAPTER EIGHT: FUEL and EXHAUST SYSTEMS Carburetor operation / Carburetor / Carburetor adjustments / Throttle cable replacement / Fuel level gauge / Fuel shutoff valve / Air box / Exhaust system. CHAPTER NINE: ELECTRICAL SYSTEM Charging system / Stator coil / Regulator/rectifier / Capacitor discharge ignition / IC igniter / Ignition coil / Pickup coil / Starting system / Starter relay / Lighting system / Switches / Cooling fan (U.K. model) / Fuse / Wiring diagrams. CHAPTER TEN: FRONT SUSPENSION and STEERING Wheel alignment / Front wheel / Front hub/brake drum (1986-1987 2-wheel drive) / Front hub (1988-on 2-wheel drive) / Front hub (4-wheel drive) / Handlebar / Steering shaft / Tie rod / Steering knuckle (2-wheel drive) / Steering knuckle (4-wheel drive) / Control arms / Steering stopper adjustment (2-wheel drive) / Steering stopper adjustment (4-wheel drive) / Shock absorber / Tires and wheels. CHAPTER ELEVEN: FRONT DRIVE MECHANISM FOUR-WHEEL DRIVE Front propeller shaft / Front axle / Front final gear case / Sub-transmission. CHAPTER TWELVE: REAR AXLE, SUSPENSION and FINAL DRIVE Rear wheel / Rear suspension arms / Rear shock absorbers / Left-hand rear hub (4-wheel drive) / Final drive unit / Propeller shaft / Rear axle / Differential shift lever and cable (2-wheel drive) / Front gear case and drive gear (2-wheel

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