This is the Kawasaki KLF250 Bayou service manual, covering the KLF250-A1, KLF250-A2, and KLF250-A3 models built from 1985 to 1987. Its 318 pages take you from routine periodic maintenance through a full engine and driveline overhaul on this four wheeler.
The manual is organized by system: fuel and carburetion, engine top end, engine right side, lubrication, crankshaft and transmission, final drive, brakes, suspension, steering, frame, and the complete electrical system. Each section gives standard values and service limits, so you know when a part is still usable and when it needs replacing.
You can set valve clearance, adjust the carburetor pilot screw and idle, check cylinder compression, torque the cylinder head correctly, and rebuild the clutch. Whether you are doing scheduled service or chasing a hard starting or running problem, this is the shop reference for keeping the Bayou 250 running.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information & Units of Measure | 4-19 | Abbreviations, Kg, Lb, Gal (Us), Km, Mile, N·m, kgf·m, kPa, PSI, Km/H |
| Standard Torque Values | 20-23 | Threads, Torque, N·m, kgf·m, ft·lb |
| Periodic Maintenance & Adjustments | 24-48 | Throttle Lever Free Play, Valve Clearance, Engine Oil, Tire Tread Depth, Standard Tire, Final Gear Case Oil, Front Brake Lever Free Play, Cam Lever Angle, Rear Brake Lever Free Play, Brake Pedal Free Play, Spark Plug Gap, Brake Light Switch Timing, Idle Speed |
| Fuel System & Carburetor | 49-75 | Carburetor Pilot Screw, Carburetor Body, Fuel Level Gauge, Float Height, Float Bowl Mating Surface, Float Valve Needle Rod |
| Cylinder Head & Valve Train | 76-93 | Rocker Arm, Rocker Shaft, Cam Height, Cylinder Compression, Cylinder Head Bolt Torque, Cylinder Head Warp, Valve/Valve Guide Clearance, Valve Seat Surface, Cylinder Inside Diameter |
| Piston & Piston Rings | 94-107 | Piston Diameter, Piston/Cylinder Clearance, Piston Ring/Groove Clearance, Piston Ring Groove Width, Piston Ring Thickness, Piston Ring End Gap |
| Clutch | 108-111 | Primary Clutch Housing, Primary Clutch Shoe Groove Depth, Friction Plate Thickness, Friction Plate Warp, Steel Plate Warp, Clutch Spring Free Length, Gear Backlash |
| Crankshaft & Transmission | 112-167 | Primary Gear, Crankshaft Diameter, Secondary Gear, Recoil Starter, Engine Lubrication System, Connecting Rod Big End Clearance, Crankshaft Runout, Connecting Rod Bend, Connecting Rod Twist, Reverse Knob Free Play, Shift Fork, Shift Drum Groove Width |
| Wheels, Tires & Steering | 168-186 | Toe-In of Front Wheels, Maximum Tire Air Pressure, Tire Air Pressure, Tire Beads |
| Final Drive & Bevel Gears | 187-216 | Drive Gear Shims, Driven Bevel Gear Shims, Bevel Gear Backlash (Front), Pinion Gear Shims, Ring Gear Shims, Bevel Gear Backlash (Rear), Cam Lever Angle (Front and Rear) |
| Brakes & Suspension | 217-267 | Front Brake Drum Inside Diameter, Rear Brake Drum Inside Diameter, Brake Shoe Lining Thickness, Brake Cam Diameter, Cam Hole Inside Diameter, Tie-Rod Length |
| Electrical System & Ignition | 268-291 | Battery, Regulator/Rectifier, Alternator, Stator Coil, Rectifier Circuit, Ignition Coil, Ignition Timing, Crankshaft Sensor, Commutator, Starter Motor Brush, Testing Relay |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder Head Bolts (M10) First Torquing | 13 N·m (1.3 kgf·m, 113 in·lb) | p. 82 |
| Cylinder Head Bolts (M6) First Torquing | 5.9 N·m (0.6 kgf·m, 52 in·lb) | p. 82 |
| Right Engine Cover Bolts torque | 8.8 N·m (0.9 kgf·m, 78 in·lb) | p. 20 |
| Engine Oil Type | API SF or SG | p. 13 |
| Engine Oil Viscosity | SAE 10W-40 | p. 13 |
| Oil Filter Cover Bolts Torque | 8.8 N·m (0.9 kgf·m, 78 in·lb) | p. 29 |
| Oil Filter Replacement | Replace with a new one | p. 29 |
| Valve Clearance (Exhaust) Standard | 0.18 ∼ 0.23 mm (0.0071 ∼ 0.0091 in.) | p. 23 |
| Valve Clearance (Inlet) Standard | 0.15 ∼ 0.20 mm (0.0059 ∼ 0.0079 in.) | p. 23 |
| Engine Oil Capacity (filter not removed) | 2.0 L (2.11 US qt) | p. 13 |
| Engine Oil Capacity (filter removed) | 2.1 L (2.22 US qt) | p. 13 |
| Engine Oil Capacity (completely dry) | 2.75 L (2.91 US qt) | p. 13 |
