All 318 pages of this Kawasaki KLF250-A1, KLF250-A2, KLF250-A3 service manual PDF are built around one goal: restoring your Bayou 250 ATV to factory condition, from throttle cable adjustment through final drive bevel gear rebuild. Inside you get step-by-step procedures, exploded-view diagrams, and a dedicated torque table covering every fastener on the machine. Wiring diagrams and troubleshooting charts for the battery, charging circuit, and ignition system round out the electrical coverage. Torque the M10 cylinder head bolts to 13 N·m on the first pass, then final-torque to 34 N·m; run SAE 10W-40 (API SF or SG) and set your valve clearance cold before you start the engine. Your machine is down. Jump to any section by keyword or bookmark, pull it up on your phone, and get back to work.
What's Inside This Kawasaki KLF250-A1, KLF250-A2, KLF250-A3 Manual
| System | Pages | Key Topics |
|---|---|---|
| List of Abbreviations | 4-14 | Ampere(S), After Bottom Dead Center, Alternating Current, Newton(S), Horsepower, Revolution(S) per Minute |
| Units of Mass: | 15 | Kg, Lb, G, Oz |
| Units of Volume: | 15 | L, Gal (Us), Qt (Us), mL, Oz (Us), Cu in. |
| Units of Force: | 15 | N, Kg, Lb |
| Units of Length: | 15 | Km, Mile, M, Ft, Mm, In. |
| Units of Torque: | 15 | N·m, kgf·m, ft·lb, in·lb |
| Units of Pressure: | 15 | kPa, kg/cm², PSI, cmHg |
| Units of Speed: | 15 | Km/H, Mph |
| Units of Power: | 16-19 | - |
| Basic Torque for General Fasteners | 20-23 | Threads, Torque, N·m, kgf·m, ft·lb |
| Throttle Lever Free Play | 24-26 | Standard |
| Valve Clearance (When Cold) | 27-28 | Exhaust, Inlet |
| Engine Oil | 29 | Type, Viscosity, Amount |
| Tire Tread Depth | 29 | Service Limit, Front, Rear |
| Standard Tire | 30 | Front, Rear |
| Final Gear Case Oil | 31 | Type, Viscosity, Capacity |
| Front Brake Lever Free Play | 32 | Inspection, Adjustment, Brake Lever, Adjuster, Locknut |
| Cam Lever Angle | 33 | Adjustment, Inspection, Cam Lever Bolt, Cam Lever |
| Rear (Parking) Brake Lever Free Play | 32 | Inspection, Adjustment, Locknut, Adjuster |
| Brake Pedal Free Play | 33 | Inspection, Adjustment, Adjusting Bolt, Locknut |
| Spark Plug Gap | 35 | Inspection, Removal, Installation, Cleaning, Torque, Side Electrode |
| Brake Light Switch Timing | 36-47 | Adjustment, Inspection, Brake Pedal, Pedal Travel, Adjusting Nut |
| Idle Speed | 48 | Adjustment, Inspection, Throttle Cable, Tachometer, Idle Adjusting Screw |
| Carburetor Pilot Screw Setting | 49 | Adjustment, Special Tool - Pilot Screw Adjuster, Carburetor Body |
| Fuel Level | 49 | Fuel Level Inspection, Fuel Level Adjustment, Fuel Level Gauge Removal, Fuel Level Gauge Installation, Service Fuel Level, Float Height |
| Float Height | 50-75 | Float Bowl Mating Surface, Float Valve Needle Rod, Float |
| Rocker Arm Inside Diameter | 76 | Rocker Arm Inside Diameter Standard, Rocker Arm Inside Diameter Service Limit, Rocker Arm Inside Diameter Measurement |
| Rocker Shaft Diameter | 77 | Rocker Shaft Diameter Standard, Rocker Shaft Diameter Service Limit, Rocker Shaft Diameter Measurement |
| Cam Height | 78-79 | Cam Height Exhaust, Cam Height Inlet, Cam Height Standard, Cam Height Service Limit, Cam Lobe Measurement |
| Cylinder Compression (Usable Range) | 80 | Cylinder Compression Measurement, Recoil Starter, Electric Starter, Compression Too High, Wet Compression - No Change, Wet Compression - Increase |
| Compression Too High | 80 | Possible Problems, Solutions, References, Remove Carbon, Check Possible Oil Leaks to Combustion Chamber, Cylinder Head or Base Gasket Too Thin |
| Wet Compression - No Change | 80 | Possible Problems, Solutions, References, Improper Valve Clearance, Worn Valve Seats, Cylinder Head Leak |
| Wet Compression - Increase | 81 | Too Much Piston-To-Cylinder Clearance, Worn Piston Rings, Ring Grooves |
| Cylinder Head Bolt Torque | 82 | First Torquing, M10 Bolts, M6 Bolts, Final Torquing |
| Cylinder Head Warp | 83-85 | Service Limit |
| Valve/Valve Guide Clearance (Wobble Method) | 86 | Exhaust, Inlet, Standard, Service Limit |
| Valve Seat Surface Width | 86 | Exhaust, Inlet, Standard, Service Limit |
| Valve Seat Surface Outside Diameter | 87-92 | Exhaust, Inlet, Standard, Service Limit |
| Cylinder Inside Diameter | 93 | Standard, Service Limit, Difference Between Any Two Measurements |
| Piston Diameter | 94 | Standard, Service Limit |
| Piston/Cylinder Clearance | 94 | Cylinder Inside Diameter, Piston Diameter |
| Piston Ring/Groove Clearance | 94 | Top, Second |
| Piston Ring Groove Width | 95 | Top, Second, Oil |
| Piston Ring Thickness | 95 | Top, Second |
| Piston Ring End Gap | 96-107 | Top, Second, Oil |
| Primary Clutch Housing Inside Diameter | 108 | - |
| Primary Clutch Shoe Groove Depth | 109 | Primary Clutch Housing Inside Diameter |
| Friction Plate Thickness | 109 | Standard, Service Limit |
| Friction Plate Warp | 109 | Primary Clutch Housing Inside Diameter, Primary Clutch Shoe Groove Depth |
| Steel Plate Warp | 110 | - |
| Clutch Spring Free Length | 111 | - |
| Gear Backlash | 111 | - |
| Primary Gear Inside Diameter [a] | 111 | - |
| Crankshaft Diameter [a] | 111 | - |
| Secondary Gear Inside Diameter [a] | 111 | - |
| Secondary Gear Collar Diameter [B] | 112-148 | Gear Backlash, Primary Gear Inside Diameter [a], Crankshaft Diameter [a], Secondary Gear Inside Diameter [a], Recoil Starter, Engine Lubrication System, Engine Removal/Installation |
| Connecting Rod Big End Radial Clearance | 149 | Crankshaft, V Blocks, Dial Gauge, Connecting Rod, Radial Clearance, Crankshaft Assembly |
| Connecting Rod Big End Side Clearance | 150 | Crankshaft, V Blocks, Side Clearance, Connecting Rod, Thickness Gauge, Crankshaft Assembly |
| Crankshaft Runout | 151 | Crankshaft Alignment, Runout, Alignment Jig, Horizontal Misalignment, Vertical Misalignment, Big End Side Clearance |
| Connecting Rod Bend | 151 | Crankshaft, Alignment Jig, V Blocks, Surface Plate, Arbor, Connecting Rod Small End, Height Gauge |
| Connecting Rod Twist | 152-153 | Crankshaft, Alignment Jig, Arbor |
| Reverse Knob Free Play | 154-155 | Transmission, Locknuts, Adjuster |
| Shift Fork Ear Thickness | 156 | Thickness, Shift Fork Ears, Diameter, Shift Fork Guide Pin, Service Limit, Shift Fork |
| Shift Fork Guide Pin Diameter | 156 | Thickness, Shift Fork Ears, Diameter, Shift Fork Guide Pin, Service Limit, Shift Fork |
| Shift Drum Groove Width | 156 | Shift Drum Grooves, Standard, Service Limit |
| Gear Shift Fork Groove Width | 157-167 | Shift Fork Groove, Transmission Gear, Standard, Service Limit |
| Toe-In of Front Wheels | 168-171 | Front Wheels, Amount of Toe-In, Standard, Toe-In Inspection, Toe-In Adjustment |
| Maximum Tire Air Pressure (to Seat Beads When Cold) | 172 | Tire, Rim, Tire Beads, Air Pressure, Maximum Pressure |
| Tire Air Pressure (When Cold) | 173-186 | Front Tire, Rear Tire, Air Pressure, Standard |
| Drive Gear Shims | 187 | Thickness, Part Number, Output Drive Gear, Primary Shim |
| Driven Bevel Gear Shims | 188 | Thickness, Part Number, Driven Gear, Primary Shim |
| Bevel Gear Backlash (Front) | 189-199 | Driven Gear Shaft Nut, Dial Gauge, Output Drive Gear, Backlash, Standard, Service Limit |
| Pinion Gear Shims | 200 | Thickness, Part Number |
| Ring Gear Shims | 200 | Thickness, Part Number |
| Bevel Gear Backlash (Rear) | 201-210 | Standard, Service Limit |
| Cam Lever Angle (Front and Rear) | 211-216 | Standard |
| Front Brake Drum Inside Diameter | 217 | Standard, Service Limit |
| Rear Brake Drum Inside Diameter | 217 | Standard, Service Limit |
| Brake Shoe Lining Thickness (Front and Rear) | 218 | Standard, Service Limit |
| Brake Cam Diameter | 218 | Front, Rear, Standard, Service Limit |
| Cam Hole Inside Diameter | 219-236 | Front, Rear |
| Tie-Rod Length | 237-267 | Standard |
| Battery Troubleshooting Guide | 268-273 | Plates, Sediment, Voltage, Electrolyte Level, Specific Gravity |
| Regulator/Rectifier Output Voltage | 274 | Tester, Connections, Reading |
| Alternator Output Voltage | 274 | Tester, Connections, Reading |
| Stator Coil Resistance | 275 | Tester, Connections, Reading |
| Rectifier Circuit Inspection | 276-279 | W-Y1 Connections, W-Y2 Connections, W-Y3 Connections, BK/Y-Y1 Connections, BK/Y-Y2 Connections, BK/Y-Y3 Connections |
| Ignition Coil Arcing Distance | 280 | - |
| Ignition Coil Winding Resistance | 280 | Primary Windings, Secondary Windings |
| Ignition Coil Primary Peak Voltage | 281 | Standard, Ignition Coil, Crankshaft Sensor |
| Crankshaft Sensor Resistance | 282 | - |
| Connections: | 282 | Crankshaft Sensor Connector, Adapter, Hand Tester |
| Crankshaft Sensor Peak Voltage | 283 | Standard, Crankshaft Sensor |
| Ignition Timing | 284-288 | Engine Speed r/min (RPM), Slot Aligned with, Advanced Mark on Alternator Rotor |
| Commutator Diameter | 289 | Standard, Service Limit |
| Starter Motor Brush Length | 290 | Standard, Service Limit |
| Testing Relay | 291 | Hand Tester Range, Criteria, Relay Coil Terminals, Relay Switch Terminals |
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 |
Kawasaki KLF250-A1, KLF250-A2, KLF250-A3 Common Problems This Manual Covers
Kawasaki KLF250 missed tune-ups followed by hard starting, loss of power, and rough idling in cold weather p. 27
Remove the valve covers and check the clearance when the engine is cold as shown on page 27. Adjust the exhaust valves to 0.18 ~ 0.23 mm (0.0071 ~ 0.0091 in.) and the inlet valves to 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in.).
Manual Section: Valve Clearance (when cold)Engine running poorly with excessive valvetrain noise and low power output under heavy throttle load
Drain the crankcase and replace the oil filter. Torque the filter cover bolts to 8.8 N·m (0.9 kgf·m, 78 in·lb) and fill the engine with 2.75 L (2.91 US qt) of fresh oil if completely dry. See the Engine Oil section for the drain plug torque specification.
Manual Section: Engine OilEngine cranks continuously but refuses to start or misfires badly during low speed operation p. 35
Inspect the spark plug condition and verify the gap is within the specification shown in the Spark Plug section (page 35). Replace the plug if the electrodes are severely worn. Torque the new plug to the value specified in that section.
Manual Section: Spark Plug GapRecoil starter pulls too easily and the engine fails to build enough pressure to fire p. 80
Test the cylinder compression using a gauge. If readings are low, inspect the valvetrain. Check the exhaust valve guide clearance against the service limit shown in the Valve/Valve Guide Clearance section (page 86). Replace worn guides immediately.
Manual Section: Wet Compression - No ChangeFrequently Asked Questions
What are the torque specs for the Kawasaki KLF250 head bolts, cylinder, and clutch cover?
For the cylinder head, M10 bolts require a first torquing of 13 N·m (1.3 kgf·m, 113 in·lb) and a final torquing of 34 N·m (3.5 kgf·m, 25 ft·lb). M6 bolts require a first torquing of 5.9 N·m (0.6 kgf·m, 52 in·lb) and a final torquing of 9.8 N·m (1.0 kgf·m, 87 in·lb). The right engine cover bolts should be tightened to 8.8 N·m (0.9 kgf·m, 78 in·lb), and crankcase bolts to 8.8 N·m (0.9 kgf·m, 78 in·lb).
How do you adjust the carburetor on a Kawasaki Bayou KLF250?
To adjust the idle speed, warm up the engine and turn the idle adjusting screw until the idle speed is within 1300 ∼ 1400 r/min (rpm). For the pilot screw, turn it all the way in until it seats lightly, then back it out 1 1/2 turns for KLF250-A1 models or 2 1/2 turns for KLF250-A2 models.
Why does a Kawasaki KLF250 crank but not start?
If the engine cranks but does not start, possible causes include starter motor clutch trouble, a broken recoil starter spring, or the recoil starter pawl not engaging. These issues prevent the engine from turning over properly.
How to torque Kawasaki KLF250 cylinder head bolts
To torque the cylinder head bolts, apply molybdenum disulfide oil to the flange and threads of all cylinder head bolts. Tighten the M10 bolts (1 ∼ 4) to 13 N·m (1.3 kgf·m, 113 in·lb) for the first torquing, and then to 34 N·m (3.5 kgf·m, 25 ft·lb) for the final torquing. Tighten the M6 bolts (5 ∼ 6) to 5.9 N·m (0.6 kgf·m, 52 in·lb) for the first torquing, and then to 9.8 N·m (1.0 kgf·m, 87 in·lb) for the final torquing, using a criss-cross pattern.
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Does this Kawasaki KLF250 Bayou 250 service manual include wiring?
Included. The Kawasaki KLF250 Bayou 250 Service Manual covers complete wiring harness diagrams, electrical circuits, and connector pinouts.
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