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Kawasaki KLF220 BAYOU - User Manual

Kawasaki KLF220 BAYOU
225 pages
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file:///C|/Users/Ken/Desktop/Midwest%20Manuals/index%20searchable.html[2/8/2010 3:01:03 PM]
This service manuals covers the 1988-2002 Kawasaki Bayou 220 Series.
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.
I do apologize for any confusion the supplements may cause.
This is the way Kawasaki originally set up these manuals.
I have attempted to organize and improve them as much as possible.
If you bought this manual from any other seller, they are reselling my work.
Please leave them negative feedback & email me at sales@midwestmanuals.com
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Table of Contents

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Summary

General Information

Before Servicing

Important notes and precautions to follow before starting vehicle service.

General Specifications

Technical specifications and dimensions for various KLF220 models.

Periodic Maintenance Chart

Schedule of recommended maintenance tasks and their intervals.

Fuel System

Specifications

Detailed specifications for carburetor and air cleaner elements.

Carburetor

Instructions for carburetor adjustment, inspection, cleaning, and disassembly.

Air Cleaner

Procedures for installing the air cleaner duct and cleaning the element.

Engine Top End

Specifications

Detailed specifications for cylinder head, valves, and camshaft.

Cylinder Head

Procedures for removing, installing, and disassembling the cylinder head.

Valves

Instructions for valve clearance adjustment and measuring valve-to-guide clearance.

Engine Left Side

Recoil Starter

Procedures for disassembling, assembling, and inspecting the recoil starter.

Starter Clutch

Steps for removing, installing, and inspecting the starter clutch.

Engine Right Side

Clutches

Procedures for adjusting and removing clutch components.

Lubrication System

Procedures for checking engine oil level and changing oil/filter.

Engine Removal;Installation

Engine Removal

Steps for safely removing the engine from the vehicle.

Engine Installation

Procedures for installing the engine back into the vehicle.

Engine Bottom End;Transmission

Crankcase Splitting

Procedures for splitting and assembling the crankcase halves.

Crankshaft and Connecting Rod

Service and inspection procedures for the crankshaft and connecting rod.

Wheels;Tires

Wheel Alignment

Procedures for inspecting and adjusting wheel alignment and steering centering.

Tires

Procedures for removing, installing, and inspecting tires.

Final Drive

Final Gear Case Oil

Procedures for inspecting and changing final gear case oil.

Bevel Gear Adjustment

Procedures for adjusting bevel gear backlash and tooth contact.

Brakes

Brake Adjustment

Procedures for adjusting front and rear brakes, including cam lever angle.

Brake Maintenance

Information on inspecting brake drum, shoe lining, cam, and springs.

Suspension

Shock Absorber

Procedures for removing, installing, and inspecting shock absorbers.

Suspension Arm

Steps for removing, installing, and inspecting suspension arms.

Steering

Maintenance and Inspection

Procedures for inspecting steering action, stem warp, and bearing condition.

Steering Lubrication

Instructions for lubricating steering stem, bearings, and knuckle pivots.

Frame

Fender

Procedures for removing front and rear fenders.

Electrical System

Battery

Procedures for battery removal, installation, electrolyte level, and charging.

Charging System

Inspection of alternator, stator coils, and regulator/rectifier.

Ignition System

Safety instructions and procedures for ignition coil, pickup coil, and CDI unit.

Electric Starter System

Procedures for starter motor removal, installation, disassembly, assembly, and inspection.

Appendix

Troubleshooting Guide

Guide to diagnosing and resolving common vehicle problems.

Bolt and Nut Tightening

Guidelines for checking and tightening bolts and nuts to specified torque.

Supplement - 1995 Late - 1997 Models

General Specifications

Detailed specifications for 1995-1997 models.

Supplement - 1998 - 1999 Models

General Specifications

Detailed specifications for 1998-1999 models.

Wiring Diagram

Wiring diagrams for electrical systems of specific models.

Supplement - 2000 - 2002 Models

General Specifications

Detailed specifications for 2000-2002 models.

Periodic Maintenance Chart

Maintenance schedule specific to 2000-2002 models.

Wiring Diagram

Wiring diagrams for electrical systems of specific models.

Kawasaki KLF220 BAYOU Specifications

General IconGeneral
BrandKawasaki
ModelKLF220 BAYOU
CategoryOffroad Vehicle
LanguageEnglish

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