This service manual covers the 1986-2006 Bayou 300 2x4
Contents
1. _ 1 8 Periodic Maintenance Chart 1 10 www midwestmanuals com 1 2 GENERAL INFORMATION Before Servicing Before starting to service a vehicle careful reading of the applicable section is recommended to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed des criptions have been included wherever necessary Nevertheless even a detailed account has limi tations a certain amount of basic knowledge is also required for successful work Especially note the following 1 Dirt Before removal and disassembly clean the vehicle Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the vehicle For the same reason before installing a new part clean off any dust or metal filings 2 Battery Ground Remove the ground lead from the battery before performing any disassembly operations on the vehicle This prevents a the possibility of accidentally turning the engine over while partially disassembled b sparks at electrical connections which will occur when they are disconnected c damage to electrical parts 3 Tighten ing Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them evenly in a cross pattern This is to avoid distortion of the part and o2. 2 15 Fuel Tank Removal _ 2 15 Fuel Tank Installation 2 15 Fuel Tap Removal _ _ _ 2 16 Fuel Tank Inspection _ _ 2 16 Fuel Tank and Tap Cleaning _ _ 2 16 Fuel Tap Inspection _ _ 2 16 www midwestmanuals com 2 2 FUEL SYSTEM Exploded View J A Apply adhesive www midwestmanuals com Specifications Item Throttle Lever Free Play Carburetor Make Type Main Jet Option Main Air Jet Jet Needle Needle Jet Pilot Jet Option Pilot Air Jet Pilot Screw Starter Jet Option Service Fuel Level from the bottom edge of carburetor body Float Height Air Cleaner Element Oil Grade Viscosity Special Tool Along with common hand tools the following more specialized tool is required for complete fuel system servicing Fuel Level Gauge 57001 1017 FUEL SYSTEM 2 3 Standard 2 3mm Keihin CVK32 130 125 128 132 135 100 N27Q 6 38 35 40 140 2 turns out 55 58 60 0_5 mm below 1 5 mm above 17 0 2 mm SE class SAE30 www midwestmanuals com 2 4 FUEL SYSTEM Throttle Case and Cable Throttle Lever Free Play Inspection Check throttle lever free play If free play is not within specifications adjust the throttle cable see Th
3. Throttle Cable Removal __ ______ 2 5 Throttle Cable Installation _ _ _ 2 5 Throttle Case and Cable Lubrication 2 5 Throttle Case Inspection Throttle Cable Inspection Choke Lever and Cable Choke Lever and Cable Removal Choke Lever and Cable Installation Choke Lever and Cable Lurbication 2 6 2 6 2 6 2 6 2 7 2 7 Choke Cable Inspection 2 8 Carburetor 2 8 Carburetor Pilot Screw Adjustment 2 8 Idle Speed Adjustment _ _ 2 9 Fuel Level Inspection 2 9 Fuel Level Adjustment 2 9 Fuel System Cleanliness Inspection 2 10 Carburetor Removal 2 10 Carburetor Installation 2 10 Carburetor Disassembly 2 10 Carburetor Assembly 2 11 Carburetor Cleaning 2 12 Carburetor Inspection 2 12 Air Cleaner _ __ _ _ _ 2 13 Air Cleaner Element Removal 2 13 Air Cleaner Element Installation 2 14 Air Cleaner Removal 2 14 Air Cleaner Installation 2 14 Air Cleaner Element Cleaning 2 14 Air Cleaner Element Inspection and Replacement 2 15 Fuel Tank _ __ __
4. and may not apply to every country www midwestmanuals com 1 8 GENERAL INFORMATION Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or liquid gasket Letter used in the Remarks column means L Apply a non permanent lockingagentto the threads o Apply an oil to the threads and seated surface S Tighten the fasteners following the specified se quence St Stake the fasteners to prevent loosening Fastener Engine Top End Cylinder Head Bolts Cylinder Bolt 6mm 8mm Valve Clearance Adjusting Screw Locknuts Camshaft Sprocket Bolt Camshaft Chain Guide Pivot Bolt Engine Left Side Starter Clutch Allen Bolts Engine Right Side Oil Drain Plug Primary Clutch Hub Nut Secondary Clutch Hub Nut Secondary Clutch Spring Bolts Engine Removal Installation Engine Mounting Bolts 8 mm 10mm Engine Mounting Bracket Bolts Engine Bottom End Transmission Oil Pipe Banjo Bolts Shift Drum Stopper Bolt Shift Drum Pin Plate Bolt Shift Shaft Return Spring Pin Clutch Release Cam Pin Balancer Gear Nut Balancer Drive Gear and Oil Pump Drive Gear Nut Wheels Tires Wheel Nuts Front Hub Nuts Use the basic torque table below for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned
5. threads Basic Torque for General Fasteners Thread dia mm N m 12 29 12 12 41 9 8 49 29 125 78 12 25 34 25 20 12 12 17 17 83 78 34 34 5 6 8 10 12 14 16 18 20 N m 3 4 4 9 5_9 7_8 14 19 25 34 44 61 73 98 115 155 165 225 225 325 Torque kg m 1 2 3 0 1_2 1 2 4 2 1 0 5 0 3 0 13 0 8 0 1 2 2 5 3 5 2 5 2 0 1 2 1 2 1 7 1 7 8 5 8 0 3 5 3 5 Torque kg m 0 35 050 0_60 0_80 1 4 1 9 2 6 35 4 5 6_2 7 4 10_0 11 5 16_0 17 0 23 23 33 ft Ib 104 in Ib 22 104 in Ib 104 in Ib 30 87 in Ib 36 22 94 58 104 in Ib 18 0 25 18 0 14 5 104 in Ib 104 in Ib 12 0 12 0 61 58 25 25 ft Ib 30 43 in Ib 52 69 in Ib 10_0 135 19_0 25 33 45 54 72 83 115 125 165 165 240 Remarks S S L o o L L o o www midwestmanuals com GENERAL INFORMATION 1 9 Fastener Torque Remarks N m kg m ft Ib Final Drive Front Gear Case Bolts 8 mm 25 2 5 18 0 Output Shaft LH Bearing Housing Bolts 12 1 2 104 in Ib LH Bearing Holder 98 10 0 72 St Drive Gear Nut 14 mm when 16 mm 88 93 9 0 9 5 65 69 0 Driven Gear Nut 78 8 0 58 0 Driven Gear Shaft Oil Seal Housing Nuts 25 2 5 18 0 Front Gear Case Plug Odometer Gear 20 2 0 14 5 Holder Option Propeller Shaft Housing Nuts 25 2 5 18 0 Axle Shaft Pipe Bolts 20 2 0 14 5 Pinion Gear Nut 7
6. Shoes or Pads Clutch Friction Material Gaskets Insulators SAFETY INSTRUCTIONS Operate if possible out of doors or in a well ventilated place Preferably use hand tools or low speed tools equipped if necessary with an appropriate dust extraction facility If high speed tools are used they should always be so equipped If possible dampen before cutting or drilling Dampen dust and place it in properly closed receptacle and dispose of it safely LIST OF ABBREVIATIONS ampere s Ib pound s after bottom dead center m meter s alternating current min minute s after top dead center N newton s before bottom dead center Pa pascal s bottom dead center PS horsepower before top dead center psi pound s per square inch degree s Celsius r revolution direct current rpm revolution s per minute farad s TDC top dead center degree s Fahrenheit TIR total indicator reading foot feet V volt s gram s W watt s hour s S1 ohm s liter s Read OWNER S MANUAL before operating www midwestmanuals com Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work A basic knowledge of mechan ics the proper use of tools and workshop procedures must be understood in order to car
7. appliance with a pilot light eSlip the throttle cable lower end out of the carburetor pulley see Throttle Cable Removal eLoosen the clamps on the carburetor holder and the air cleaner duct ePul1 the air cleaner duct off the mouth of the carbu retor ePull the carburetor out the carburetor holder eUnscrew the starter plunger cap and free the lower end of the carburetor choke cable from the carburetor see Choke Cable Removal Carburetor Installation Carburetor Installation is the reverse of removal Note the following eRoute the carburetor vent hose as shown A Carburetor Vent Hose Check fuel leakage from the carburetor I WARNING oFuel spilled from the carburetor is hazardous eAdjust the pilot screw see Carburetor Pilot Screw Adjustment elf the carburetor has been disassembled or if there is some other reason that the fuel level may be incorrect inspect the fuel level see Carburetor Fuel Level In spection eAdjust the idle speed see Idle Speed Adjustment eAdjust the throttle cable see Throttle Cable Adjust ment Carburetor Disassembly eRemove the carburetor see Carburetor Removal eRemove the carburetor top end as follows eRemove the upper chamber cover screws and take off the cover and spring ePul1 out the vacuum piston with the diaphragm ODuring carburetor disassembly be careful not to damage the diaphragm Never use a sharp edge to remove diaphragm eSlide the jet needle
8. for certain oil or grease seals during installation to avoid damage to the seal lips Before a shaft passes through a seal apply a little high temperature grease on the lips to reduce rubber to metal friction 14 Circlip Retaining Ring Replace any circlips and retaining rings that were removed with new ones as removal weakens and deforms them When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more 15 Lubrication Engine wear is generally at its maximum wh ile the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles Don t use just any oil or grease Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease MoS in the assembly of certain engine and chassis parts Always check manufacturer recommendations before using such special lubricants 16 Electrical Wires All the electrical wires are either single color or two color and with on ly a few exceptions must be connected to wires of the sa
9. of equipment This manual contains five more symbols in addition to WARNING and CAUTION which will help you distinguish different types of information NOTE o This note symbol indicates points of particular interest for more efficient and convenient operation www midwestmanuals com Indicates a procedural step or work to be done o lndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a WARNING CAUTION or NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it follows lt r Indicates a conditional sub step or what action to take based upon the results of the condi tional step it follows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require specified tightening torque oil grease or a locking agent during assembly www midwestmanuals com GENERAL INFORMATION 1 1 D General Information Table of Contents Before Servicing 1 2 Model Identification 1 4 General Specifications 1 6 Torque and Locking Agent
10. with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition eAdjust the throttle cable see Throttle Cable Adjust ment Throttle Case and Cable Lubrication Whenever the throttle case is disassembled or in accordance with the Periodic Maintenance Chart per form the following eApply a thin coating of multi purpose grease to the throttle control lever pivot area and the throttle cable ends www midwestmanuals com 2 FUEL SYSTEM A Apply grease A Apply grease _Lubricate the throttle cable by seeping the oil between the cable and cable housing Cable Lubrication Throttle Case Inspection With the throttle cable disconnected from the throttle lever the lever should move freely and return smoothly by spring If the lever bends disassemble the throttle case and clean and iubricate the throttle case see Throttle Case and Cable Lubrication Examine the lever and case for cracks Replace the case assembly if it is cracked Throttle Cable Inspection With the throttle cable disconnected at the both ends the cable should move freely within the cable housing If cable movement is not free after lubrication see Throttle Case and Cable Lubrication if the cable is frayed or if the cable housing is kinked replace the cable Choke Lever and Cable Choke Lever and Cable Removal Remove the carburetor see Carburetor Removal Unscrew the star
11. 0 1 7 L Continued on next page Canadian Models U S Models www midwestmanuals com GENERAL INFORMATION 1 7 Items KLF300 A 1 A2 Drive Train Primary reduction system Type Gear Reduction ratio 2_888 78127 Clutch type Transmission Type Primary Secondary Gear ratios 1st Final drive system Overall drive ratio Final gear case oil Frame Type Caster rake angle Camber Trail Tread Front tire Type Size Rear tire Type Size Suspension Front Rear Brake type Front Rear Electrical Equipment Battery Headlight Taillight Alternator Type Bulb Type 2nd 3rd 4th 5th Reverse Type Reduction ratio Type Capacity Type Wheel travel Type Wheel travel Rated output Voltage regulator Type Auto centrifugal wet Auto multi disc wet 5 speed plus reverse constant mesh return shift 3_090 34 11 1_928 27 14 1_368 29 19 1_000 23123 0_769 20 26 3_072 26 11 x 26 20 Shaft 4_886 20 16 x 43 11 10_858 Top gear API GL 5 Hypoid gear oil SAE 90 above 5 C 41 F or SAE 80 below 5 C 41 F 0_3 L Double tubular 4 0 8 lG 17 mm 830mm Tubeless 22 x 9_00 10 Tubeless 24 x 11 00 10 Double wishbone link 115 mm Torque tube link 120 mm Drum Hydraulic Drum Mechanical 12 V 19 Ah Semi sealed beam 12 V 60W 12V8Wx2 Three phase AC 23 5 A 9 000 r min rpm 14 V Short circuit Specifications are subject to change without notice
12. 8 8 0 58 0 St Ring Gear and Differential 29 3 0 22 L Gear Housing Bolts Final Gear Case Cover Bolts 25 2 5 18 0 Final Gear Case Filler Cap 29 3 0 22 Final Gear Case Drain Plug 20 2 0 14 5 Differential Shift Fork Holder Screws 6 9 0 70 61 in Ib Brakes Master Cylinder Clamp Bolts 11 1 1 95 in Ib S Brake Lever Pivot Nut 5 9 0 60 52 in Ib Wheel Cylinder Bolts 7 8 0 80 69 in Ib Shoe Adjuster Bolts 7 8 0 80 69 in Ib Brake Panel Mounting Bolts Front 20 2 0 14 5 Rear 29 3 0 22 Rear Axle Nuts 145 15 0 110 B rake Hose Banjo Bolts 25 2 5 18 0 Brake Pipe Nipple 20 2 0 14 5 Brake Pedal Nut 29 3 0 22 Suspension Shock Absorber Mounting Bolts 34 3 5 25 Suspension Arm Pivot Bolts 10mm 34 3 5 25 12 mm 88 9 0 65 Steering Handlebar Holder Bolts 20 2 0 14 5 S Stem Clamp Allen Bolts 20 2 0 14 5 Stem Bottom End Nut 29 3 0 22 Stem Bearing Housing Bolts 20 2 0 14 5 Tie rod End Nuts 41 4 2 30 Tie rod Adjusting Sleeve Locknuts 29 3 0 22 Knuckle Arm Pivot Nuts 41 4 2 30 Electrical System Alternator Rotor Bolt 59 6 0 43 Spark Plug 27 2 8 20 Neutral and Reverse Indicator Switch L Mounting Screws www midwestmanuals com 1 10 GENERAL INFORMATION Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition The first service is vitally important and must not be n
13. al Installation Engine Bottom End Transmission Wheels Tires Final Drive Brakes Suspension Steering Frame Electrical System Appendix www midwestmanuals com KaVlasaki KLF300 All Terrain Vehicle Service Manual www midwestmanuals com l w V gt amp gt l C v fJ t gt V n 1ti d l i ui r l tJa c d PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM US Model onlyl To minimize the noise emissions from this product Kawasaki has equipped it with effective intake and exhaust silencing systems They are designed to give optimum per A S formance while maintaining a low noise level Please do not remove these systems or alter them in any which results in an increase in noise level II qSl w m 61 1 tr li d JI xt t it l lt er r tI t It t o lt nA ii II tf lt i R if A ABDC AC ATDC BBDC BDC BTDC C DC F OF ft g h L WARNING CONTAINS ASBESTOS Breathing asbestos dust is dangerous to health Follow safety instructions This w arning may apply to any of the following components or any assembly containing one or more of these components Brake
14. e of the car buretor body so that the zero line is several milli meters higher than the bottom edge of the carburetor body Turn the fuel tap to the ON position to feed fuel to the carburetor and gauge then turn out the carburetor drain plug a few turns Wait until the fuel level in the gauge settle eKeeping the gauge vertical slowly lower the gauge until the zero line is even with the bottom edge of the car buretor body NOTE ODo not lower the nzerou line below the bottom edge of the carburetor body If the gauge is lowered and then raise it again the fuel level measured shows somewhat higher than the actual fuel level If the gauge is lowered too far dump the fuel out of it into a suitable container and start the procedure over again Read the fuel level in the gauge and compare it to the specification Tighten the drain plug and remove the fuel level gauge If the fuel level is incorrect adjust it see Fuel Level Adjustment Fuel Level 0 5 1 mm above the bottom edge of the carburetor body FUEL SYSTEM 2 9 Fuel Level Adjustment Remove the carburetor see Carburetor Removal Drain the carburetor into a suitable container Remove the float bowl by taking out the screws with lockwashers Slide out the pivot pin and remove the float Bend the tang on the float arm very slighty to change the float height I ncreasing the float height lowers the fuel level and decreasing the float height raise
15. e the throttle case and cable before assembly installation see Throttle Case and Cable Lubrication eBe certain that the return spring is correctly installed on the throttle lever www midwestmanuals com A Return Spring Hook eTighten the throttle lever bolt to 6 9 N m 0 7 kg m 61 in lb of torque eSwing the throttle control lever so that the carburetor throttle valve is fully open Turn the throttle limiter screw until it is spaced about 1 mm away from the throttle lever stop I WARNING COperation with an improperly assembled throttle case could result in an unsafe riding condition eAdjust the throttle cable see Throttle Cable Adjust ment Throttle Cable Removal eRemove the front fender see Front Fender Removal in the Frame chapter eRemove and disassemble the throttle case to free the upper end of the cable from the case see Throttle Case Removal Disassembly eSlip the cable lower end out of the pUlley A Cable End FUEL SYSTEM 2 5 Loosen the mounting nuts at the cable lower end adjuster and free the cable from the bracket eNote cable routing for proper installation and pull the cable from the vehicle Throttle Cable Installation eThrottie cable installation is the reverse of removal Note the following eLubricate the throttle cable before installation see Throttle Case and Cable Lubrication eRoute the cable as shown A Throttle Cable I WARNING lt Operation
16. eglected Clean adjust lubricate tighten or replace parts as necessary Chassis Brake adjustment check Brake wear check Brake fluid level check Brake fluid change Master cylinder cup and dust seal replace Wheel cylinder piston seal and dust seal replace Brake hose replace Cable adjustment Steering play check Final gear case oil change General lubrication Bolts and nuts tighten Battery check Engine Clutch adjustment Valve clearance check Fuel system cleanliness check Air cleaner service Engine oil change Oil filter change Spark plug clean and gap Spark arrester clean First Service Regular Service 2 years 2 years 2 years Service more frequently when operated in mud dust or other harsh riding conditions www midwestmanuals com FUEL SYSTEM 2 1 Fuel System Table of Contents Exploded View 2 2 Specifications 2 3 Special Tool _ __ _ _ _ Throttle Case and Cable 2 3 2 4 Throttle Lever Free Play Inspection 204 Throttle Cable Adjustment __ ___ 2 4 Throttle Case Removal Disassembly 2 4 Throttle Case Assembly Installation 2 4
17. ep complete records of main tenance and repair with dates and any new parts installed How to Use this Manual In preparing this manual we divided the product into its major systems These systems became the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a single chapter The Quick Reference Guide shows you all of the product s systems and assists in locating their chapters Each chapter in turn has its own comprehensive Table of Contents The Periodic Maintenance Chart is located in the General Information chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for example go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Spark Plug section Whenever you see these WARN I NG and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices I WARNING oThis warning symbol identifies special instruc tions or procedures which if not correctly followed could result in personal injury or loss of life o This caution symbol identifies special instruc tions or procedures which if not strictly observed could result in damage to or destruc tion
18. file C Users Ken Desktop Midwest 20Manuals index 20searchable 20OLDER html 3 16 2010 12 15 39 PM This service manual covers the 1986 2006 Bayou 300 2x4 4x4 Series Please understand that this is an older manual some pictures may be darker than most of my manuals Some models may need supplemental manuals which have blue titles Use the base manual for everything not contained in the supplement if your model or year requires a supplement This manual is fully searchable just hold down the control key and the F key to search on any word If you bought this manual from any other seller they are reselling my work Please leave them negative feedback amp email me at sales midwestmanuals com Our goal is to be one of the BEST sellers on eBay and the internet by providing you with the BEST customer service and the BEST manuals on the market Thank you for choosing us This quick reference guide will assist you in locating a desired topic or procedure eSend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page eRefer to the sectional table of contents for the exact pages to locate the specific topic or procedure required Quick Reference Guide LJ _G_e_n_e_r_al_l_n_fo_r_m_a_t_io_n _____ JD I Fuel System w L _ _ _ _ _ K iI I Engine Top End II L _ _ _ _ Ell Engine Left Side Engine Right Side Engine Remov
19. mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks 9 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s directions for cleaning and preparing surfaces where these compounds will be used Apply sparingly Excessive amounts may block engine oil passages and cause serious damage An example of a non permanent locking agent commonly available in North America is Loctite Lock n Seal Blue 10 Press A part installed using a press or driver such as a wheel bearing should first be coated with oil on its outer or inner circumference so that it will go into place smoothly 11 Ball Bearing When installing a ball bearing the bearing race which is affected by friction should be pushed by a su itable driver This prevents severe stress on the balls and races and prevents races and balls from being dented Press a ball bearing until it stops at the stop in the hole or on the shaft www midwestmanuals com GENERAL INFORMATION 1 3 12 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally damages seals When pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals should be pressed into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole 13 Seal Guide A seal guide is required
20. me color On any of the two color wires there is a greater amount of one color and a lesser amount of a second color so a two color wire is identified by first the primary color and then the secondary color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed to make red the main color Wire cross section Name of Wire Color e Red Wire strands r Yellow red f Yellow Red 17 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed These replacement parts will be damaged or lose their original function once removed 18 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 19 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service limits indicate the usable limits If the measurement shows excessive wear or dete riorated performance replace the damaged parts www midwestmanuals com 1 4 GENERAL INFORMATION Model Identification KLF300 A 1 Left Side View KLF300 A 1 Right Side View www midwestmanual
21. out of the vacuum piston from the bottom It will come out with a spring seat www midwestmanuals com
22. r causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter of turn and then remove them Where there is a tightening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated 4 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 5 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the screw heads 6 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 7 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com monly available in North America is Stoddard solvent generic name Always follow manufac turer and container directions regarding the use of any solvent B Gasket O Ring Do not reuse a gasket or O ring once it has been in service The
23. rottle Cable Adjustment Throttle Lever Free Play Standard 2 3mm A Throttle Lever Free Play C Locknut B Adjuster Throttle Cable Adjustment _Slide the cable adjuster dust cover out of place eTurn the adjuster until throttle lever free play is correct Turning the adjuster out lengthening the adjuster will reduce free play Slide back the dust cover NOTE Olf the throttle cable cannot be adjusted by using the adjuster at the throttle case use the adjuster at the carburetor Do not forget to securely tighten the adjuster mounting nuts Throttle Case Removal Disassembly eRemove the throttle case oRemove the throttle case screws and pull the case open oSlide the cable adjuster dust cover out of place and take off the grommet A Throttle Case Screws oPul1 the cable tip from the throttle lever catch a loosen the locknut and unscrew the adjuster A Cable Tip D Throttle Lever Bolt B Locknut E Limiter Screw C Adjuster F Grommet eDisassemble the throttle case ORemove the throttle lever bolt lockwasher and flat washer and lift the throttle lever and return spring from the case The control lever pivot bushing comes off with the lever OLoosen the locknut and unscrew the throttle limiter screw o Pull the throttle control lever out of the case Throttle Case Assembly Installation _Throttle case assembly installation is the reverse of removal disassembly Note the following _Lubricat
24. ry out maintenance and repair satisfactorily Whenever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be carried out only by qualified mechanics I n order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work carefully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may adversely affect safe operation For the duration of your warranty period especially we recommend that all repairs and scheduled maintenance be performed in accord ance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle Follow the Periodic Maintenance Chart in the Service Manual Be alert for problems and non scheduled maintenance Use proper tools and genuine Kawasaki vehicle parts Special tools gauges and testers that are necessary when servicing Kawasaki vehicles are introduced by the Special Tool Manual Genuine parts provided as spare parts are listed in the Parts Catalog Follow the procedures in this manual carefully Don t take shortcuts _ Remember to ke
25. s com GENERAL INFORMATION 1 5 KLF300 A2 Left Side View KLF300 A2 Right Side View www midwestmanuals com 1 6 GENERAL INFORMATION General Specifications Items Dimensions Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight Front Rear Fuel tank capacity Performance Minimum turning radius Engine Type Cool i ng system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system I gn ition system Timing advance Ignition timing Spark plug Valve timing Inlet Exhaust Lubrication system Engine oil Grade U K Models Viscosity Capacity Open Close Duration Open Close Duration KL F300 A 1 A2 1 B50 mm 1 100mm 1 045 mm 1 200 mm 195 mm 750mm 226 kg 223 kg 109 5 kg 10B 5 kg 126 5 kg 124 5 kg B 2 L 3 0 m Locked axle mode 2 6 m Differential mode 4 stroke SOHC 1 cylinder Air cooled 76 0 x 64 0 mm 290 mL B 6 15 4 kW 21 PS 7 OOO r min rpm 22 6 N m 2 3 kg m 16 6 ft Ib 6 OOO r min rpm Carburetor Keihin CVK32 Electric starter Battery and coil Transistorized Electronically advanced From 10 BTDC 1 300 r min rpm to 400 BTDC 4 OOO r min rpm NGK BBES BRBES 2r BTDC 65 ABDC 272 62 BBDC 30 ATDC 272 Forced lubrication wet sump SE or SF class SAE 10W 30 10W 40 1 OW 50 20W 40 20W 5
26. s the fuel level Float Height Standard A Tang 17 0 mm Assemble the carburetor install it on the vehicle and recheck the fuel level If the fuel level cannot be adjusted by this method the float or the float valve is damaged Float Height Measurement Keihin Carburetor 2 Float height 1 Float bowl mating surface 2 Float valve needle rod contacted but unloaded 3 Float www midwestmanuals com 2 10 FUEL SYSTEM Fuel System Cleanliness Inspection I WARNING I oGasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light eRun the lower end of the carburetor overflow tube to a suitable container eTurn out the carburetor drain plug a few turns and drain the fuel system A Drain Plug e lt heck to see if water or dirt comes out eTighten the drain plug If any water or dirt appears during the above in spection clean the fuel system see Carburetor Cleaning and Fuel Tank and Tap Cleaning Carburetor Removal eRemove the fuel tank see Fuel Tank Removal I WARNING I oGasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any
27. ter plunger cap and pull out the starter plunger www midwestmanuals com A Starter Plunger Cap eHold the starter plunger spring compressed and free the choke cable lower end from the plunger A Cable End B Starter Plunger _Unscrew the choke lever mounting screw and take off the lockwasher and fl at washer A Choke Lever B Lever Mounting Screw FUEL SYSTEM 2 7 ePull the choke lever off the housing and free the choke cable upper end from the lever Th ere i l the wave washer between the lever and the housing eNote the choke cable routing for proper installation and pull the cable from the vehicle Choke Lever and Cable Installation Choke cable installation is the reverse of removal Note the following eLubricate the choke cable before installation see Choke Cable Lubrication Do not lubricate the choke lever eFit the choke cable upper end to the catch on the choke lever as shown A Choke Cable Upper End eRoute the choke cable as shown A Choke Cable Choke Lever and Cable Lubrication Whenever the choke cable removed lubricate the choke cable as follows and do not lubricate the choke lever wave washer between the lever and the housing www midwestmanuals com 2 8 FUEL SYSTEM A Do not grease B Wave Washer Lubricate the choke cable by seeping the oil between the cable and cable housing Cable Lubrication Choke Cable Inspection With the choke cable disconnected at the bo
28. th ends the cable should move freely within the cable housing If cable movement is not free after lubricating see Choke Cable Lubrication if the cable is frayed or if the cable housing is kinked replaced the cable Carburetor Carburetor Pilot Screw Adjustment eRemove the car uretor see Carburetor Removal eTurn the carburetor pilot screw all the way in until it seats lightly CAUTIO 000 not overtighten the pilot screw or the carburetor body will be d maged and require replacement A Pilot Screw eBack the pilot screw out the specified number of turns Carburetor Pilot Screw Setting Standard Idle Speed Adjustment Adjust the pilot screw if necessary see Carburetor Pilot Screw Adjustment Start the engine and warm it up thoroughly eTurn the idle adjusting screw to obtain the slowest smooth idle speed A Idle Adjusting Screw www midwestmanuals com Fuel Level Inspection I WARN ING OGasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Park the vehicle on a level surface Connect the fuel level gauge special tool to the open end of the carburetor overflow tube A Fuel Level Gauge 57001 1017 C Drain Plug B Carburetor body bottom edge Hold the gauge vertically against the sid
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