Kawasaki KLF 250 ATV Repair Service Manual 2003-2005

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This workshop repair service manual PDF download for the KLF 250 / BAYOU 250 / Workhorse 250 Kawasaki All Terrain Vehicle has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

KLF 250
BAYOU 250
Workhorse 250

Year Model
Beginning Frame No.

2003 KLF250-A1
JKALFMA1□3B500001,or
JKALF250AAB600001

2004 KLF250-A2
JKALFMA1□4B523201,or
JKALF250AAB601301

2005 KLF250-A3
JKALFMA1□5B534201,or
JKALF250AAB602001

TABLE OF CONTENTS :

General Information
Periodic Maintenance
Fuel System
Engine Top End
Engine Right Side
Recoil Starter
Engine Lubrication System
Engine Removal/Installation
Crankshaft/Transmission
Wheels/Tires
Final Drive
Brakes
Suspension
Steering
Frame
Electrical System
Appendix

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 99924-1284-03
Total Pages : 322

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 mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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tables
LIST OF ABBREVIATIONS
Units of Mass:
Units of Volume:
Units of Force:
Units of Length:
Units of Torque:
Units of Pressure:
Units of Speed:
Units of Power:
Basic Torque for General Fasteners
Throttle Lever Free Play
Valve Clearance (when cold)
Engine Oil
Tire Tread Depth
Standard Tire
Final Gear Case Oil
Front Brake Lever Free Play
Cam Lever Angle
Rear (Parking) Brake Lever Free Play
Brake Pedal Free Play
Cam Lever Angle
Spark Plug Gap
Brake Light Switch Timing
Idle Speed
Carburetor Pilot Screw Setting
Fuel Level
Float Height
Rocker Arm Inside Diameter
Rocker Shaft Diameter
Cam Height
Cylinder Compression (Usable Range)
Compression Too High
Wet Compression – No Change
Wet Compression – Increase
Cylinder Head Bolt Torque
Cylinder Head Warp
Valve/Valve Guide Clearance (Wobble Method)
Valve Seat Surface Width
Valve Seat Surface Outside Diameter
Cylinder Inside Diameter
Piston Diameter
Piston/Cylinder Clearance
Piston Ring/Groove Clearance
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap
Primary Clutch Housing Inside Diameter
Primary Clutch Shoe Groove Depth
Friction Plate Thickness
Friction Plate Warp
Steel Plate Warp
Clutch Spring Free length
Gear Backlash
Primary Gear Inside Diameter [A]
Crankshaft Diameter [A]
Secondary Gear Inside Diameter [A]
Secondary Gear Collar Diameter [B]
Connecting Rod Big End Radial Clearance
Connecting Rod Big End Side Clearance
Crankshaft Runout
Connecting Rod Bend
Connecting Rod Twist
Reverse Knob Free Play
Shift Fork Ear Thickness
Shift Fork Guide Pin Diameter
Shift Drum Groove Width
Gear Shift Fork Groove Width
Toe-in of Front Wheels
Maximum Tire Air Pressure (to seat beads when cold)
Tire Air Pressure (when cold)
Drive Gear Shims
Driven Bevel Gear Shims
Bevel Gear Backlash (Front)
7. Pinion Gear Shims
8. Ring Gear Shims
Bevel Gear Backlash (Rear)
Cam Lever Angle (front and rear)
Front Brake Drum Inside Diameter
Rear Brake Drum Inside Diameter
Brake Shoe Lining Thickness (Front and Rear)
Brake Cam Diameter
Cam Hole Inside Diameter
Tie-rod Length
Battery Troubleshooting Guide
Regulator/Rectifier Output Voltage
Alternator Output Voltage
Stator Coil Resistance
Rectifier Circuit Inspection
Ignition Coil Arcing Distance
Ignition Coil Winding Resistance
Ignition Coil Primary Peak Voltage
Crankshaft Sensor Resistance
Connections:
Crankshaft Sensor Peak Voltage
Ignition Timing
Commutator Diameter
Starter Motor Brush Length
Testing Relay
Testing Relay
toc
Read OWNER’S MANUAL before operating.
EMISSION CONTROL INFORMATION
1.
2.
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only)
Foreword
General Information
Before starting to perform an inspection service or carry out a
Especially note the following:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Two-Color Electrical Wire
(19)
(20)
KLF250-A1 Left Side View
KLF250-A1 Right Side View
Prefixes for Units:
Units of Temperature:
Periodic Maintenance
The scheduled maintenance must be done in accordance with this c
The following tables list the tightening torque for the major fa
Fuel System
Throttle Lever Free Play Inspection
Throttle Lever Free Play Adjustment
Fuel System Cleanliness Inspection
Air Cleaner Element Cleaning and Inspection
Air Cleaner Draining
Fuel Hose and Connection Check
Fuel Hose Replacement
Engine Top End
Valve Clearance Inspection
Spark Arrester Cleaning
Clutches
Clutch Adjustment
Torque –
Engine Lubrication System
Engine Oil Change
Torque –
Oil Filter Change
Torque –
Wheels/Tires
Tire Inspection
Final Drive
Final Gear Case Oil Change
Torque –
Torque –
Propeller Shaft Joint Boot Inspection
Brakes
Front Brake Adjustment
Rear (Parking) Brake Lever Free Play Inspection
Brake Pedal Free Play Inspection
Rear (Parking) Brake Lever and Pedal Free Play Adjustment
Steering
Steering Inspection
Electrical System
Battery Inspection
Spark Plug Cleaning / Inspection
Spark Plug Gap Inspection
Brake Light Switch Adjustment
General Lubrication
Lubrication
Cables: Lubricate with Cable Lubricant
Bolts and Nuts Tightening
Tightness Inspection
Bolts, Nuts, and Fasteners to be checked
Fuel System
Fuel Level Gauge:
Throttle Lever Free Play Inspection
Throttle Lever Free Play Adjustment
Throttle Case Removal/Disassembly
Throttle Case Assembly/Installation
Torque –
Throttle Cable Installation
Throttle Case Inspection and Lubrication
Throttle Cable Lubrication and Inspection
Choke Lever Removal
Choke Lever and Cable Installation
Choke Lever Lubrication
Choke Cable Lubrication and Inspection
Idle Speed Adjustment
Idle Speed Adjustment
Carburetor Pilot Screw Adjustment
Special Tool –
Fuel Level Inspection
Special Tool –
Fuel Level Adjustment
Fuel System Cleanliness Inspection
Carburetor Removal
Carburetor Installation
Carburetor Disassembly
Carburetor Assembly
Carburetor Cleaning
Carburetor Inspection
Air Cleaner Element Removal
Air Cleaner Element Installation
Air Cleaner Element Cleaning and Inspection
Air Cleaner Draining
Air Cleaner Housing Removal
Fuel Tank Removal
Fuel Tank Installation
Fuel Tap Removal
Fuel Tap Installation
Fuel Tank and Fuel Tap Cleaning
Fuel Tap Inspection
Fuel Level Gauge Removal
Fuel Level Gauge Installation
Fuel Level Gauge Check
Engine Top End
Piston Ring Pliers:
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Torque –
Camshaft Chain Tensioner Wear
Camshaft Sprocket Removal
Camshaft Sprocket Installation
Special Tool –
Torque –
Compression Releasing Lever Removal
Compression Releasing Lever Installation
Torque –
Torque –
Rocker Arm and Shaft Removal
Rocker Arm and Shaft Installation
Torque –
Rocker Arm and Shaft Inspection
Camshaft Removal
Camshaft Installation
Cam Wear Inspection
Camshaft Bearing Inspection
Camshaft Chain Removal
Camshaft Chain Installation
Torque –
Camshaft Chain Guide Removal
Camshaft Chain Guide Installation
Torque –
Camshaft Chain Guide Wear
Cylinder Compression Measurement
Special Tools –
Cylinder Head Removal
Cylinder Head Installation
Torque –
Cylinder Head Assembly
Torque –
Cylinder Head Cleaning
Cylinder Head Warp
Valve Clearance Inspection
Valve Clearance Adjustment
Torque –
Torque –
Valve Removal
Special Tools –
Valve Installation
Valve Visual Inspection
Valve Guide Removal
Special Tool –
Valve Guide Installation
Special Tool –
Valve-to-Guide Clearance Measurement
Valve Seat Inspection
Valve Seat Repair (Valve Lapping)
Special Tools –
Seat Cutter Operating Care:
Valve Seat Repair
Cylinder Removal
Cylinder Installation
Piston Removal
Special Tool –
Special Tool –
Piston Installation
Cylinder/Piston Wear
Piston/Cylinder Clearance
Piston Ring and Ring Groove Wear
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap Measurement
This vehicle is equipped with a spark arrester approved for off-
Spark Arrester Cleaning
Muffler Removal
Exhaust Pipe Removal
Exhaust Pipe Installation
Exhaust System Inspection
Engine Right Side
Gear Holder, m1.75:
Engine Right Side Disassembly
Special Tool –
Special Tool –
Special Tool –
Engine Right Side Assembly
Torque –
Special Tool –
Torque –
Torque –
Special Tool –
Torque –
Torque –
Torque –
Clutch Adjustment
Clutch Release Removal
Clutch Release Wear
Primary Clutch Housing Wear
Primary Clutch Shoe Lining Wear
One-way Clutch Inspection
Friction Plate Wear
Friction and Steel Plate Warp
Clutch Spring Free Length Measurement
Gear Backlash
Primary Gear/Crankshaft Wear
Secondary Gear/Collar Wear
Recoil Starter
Recoil Starter Removal
Recoil Starter Installation
Torque –
Recoil Starter Disassembly
Recoil Starter Assembly
Torque –
Recoil Starter Cleaning
Recoil Starter Inspection
Engine Lubrication System
WARNING
Oil Level Inspection
Engine Oil Change
Oil Filter Change
Bypass Valve Removal
Bypass Valve Installation
Bypass Valve Cleaning and Inspection
Oil Screen Removal
Oil Screen Installation
Oil Pressure Relief Valve Removal
Oil Pressure Relief Valve Installation
Torque –
Oil Pressure Relief Valve Inspection
Oil Pump Removal
Oil Pump Installation
Torque –
Oil Pipe Removal
Oil Pipe Installation
Torque –
Engine Removal/Installation
Engine Removal
Engine Installation
Torque –
Crankshaft/Transmission
Outside Circlip Pliers:
Crankcase Disassembly
Special Tool –
Crankcase Assembly
Sealant –
Special Tool –
Torque –
Crankshaft Removal
Crankshaft/Balancer Shaft Installation
Special Tool –
Crankshaft Disassembly
Crankshaft Assembly
Connecting Rod Big End Seizure
Connecting Rod Big End Radial Clearance
Connecting Rod Big End Side Clearance
Crankshaft Alignment
Connecting Rod Bend/Twist
External Shift Mechanism Removal
External Shift Mechanism Installation
Torque –
External Shift Mechanism Inspection
Reverse Knob Free Play Adjustment
Reverse Shift Mechanism Removal
Reverse Shift Mechanism Installation
Sealant –
Transmission Removal
Transmission Installation
Transmission Shaft Disassembly
Special Tool –
Transmission Shaft Assembly
Shift Drum Disassembly
Shift Drum Assembly
Torque –
Shift Fork Bending
Shift Fork Wear
Shift Drum Inspection
Transmission Gear Inspection
Ball and Needle Bearing Replacement
Special Tool –
Ball and Needle Bearing Wear
Oil Seal Inspection
Wheels/Tires
Jack:
Toe-in is the amount that the front wheels are closer together i
Steering Centering Inspection
Steering Centering Adjustment
Toe-in Inspection
Toe-in Adjustment
Torque –
Wheel Removal
Special Tool –
Wheel Installation
Torque –
Wheel (Rim) Inspection
Wheel (Rim) Replacement
Tire Removal
Tire Installation
Tire Inspection
Rear Left Hub Removal
Rear Left Hub Installation
Torque –
Rear Left Hub Disassembly/Assembly
Final Drive
Inside Circlip Pliers:
Output Bevel Gear Case Removal
Output Bevel Gear Case Installation
Torque –
Output Bevel Gear Case Disassembly
Special Tool –
Special Tools –
Special Tool –
Special Tool –
Output Bevel Gear Case Assembly
Special Tool –
Torque –
Torque –
Special Tools –
Torque –
Special Tool –
Output Drive Gear Removal
Special Tool –
Output Drive Gear Installation
Torque –
Special Tool –
Output Bevel Gear Adjustment
Backlash-Related Parts
Torque –
Torque –
Special Tool –
Bevel Gear Inspection
Cam Damper Inspection
Ball Bearing Inspection
Oil Seal Inspection
Propeller Shaft Removal
Special Tool –
Special Tool –
Propeller Shaft Installation
Torque –
Propeller Shaft Inspection
Propeller Shaft Joint and Pinion Gear Joint Inspection
Propeller Shaft Joint Boot Inspection
Rear Axle Removal
Rear Axle Installation
Sealant –
Torque –
Axle Shaft Pipe Disassembly
Special Tool –
Special Tool –
Special Tool –
Axle Shaft Pipe Assembly
Special Tool –
Special Tool –
Special Tool –
Special Tool –
Final Gear Case Oil Level Inspection
Torque –
Final Gear Case Oil Change
Final Gear Case Removal
Final Gear Case Installation
Torque –
Final Gear Case Disassembly
Final Gear Case Assembly
Torque –
Final Bevel Gear Adjustment
Final Gear Case (Backlash-related Parts)
Torque –
Torque –
Special Tool –
Torque –
Torque –
Pinion Gear Disassembly
Special Tool –
Special Tool –
Pinion Gear Assembly
Special Tool –
Torque –
Torque –
Bevel Gear Inspection
Ball Bearing Inspection
Oil Seal Inspection
Brakes
Front Brake Adjustment
Brake Pedal Position Inspection
Brake Pedal Position Adjustment
Rear (Parking) Brake Lever Free Play Inspection
Brake Pedal Free Play Inspection
Rear (Parking) Brake Lever and Brake Pedal Free Play Adjustment
Cam Lever Angle Adjustment (Front and Rear)
Front Brake Panel Removal/Disassembly
Front Brake Panel Assembly/Installation
Torque –
Torque –
Rear Brake Panel Removal/Disassembly
Rear Brake Panel Assembly/Installation
Torque –
Torque –
Brake Drum Seal Wear
Torque –
Brake Drum Wear
Brake Shoe Lining Wear
Brake Cam and Cam Hole Wear
Brake Shoe Spring Inspection
Brake Lubrication
Brake Cable Removal
Brake Cable Installation
Brake Cable Lubrication
Brake Pedal Installation
Suspension
Shock Absorber Removal
Rear Shock Absorber Installation
Torque –
Rear Shock Absorber Inspection
Front Suspension Arm Removal
Front Suspension Arm Installation
Torque –
Rear Suspension Arm Removal
Rear Suspension Arm Installation
Torque –
Torque –
Torque –
Suspension Arm Assembly
Suspension Arm Inspection
Front Suspension Arm Lubrication
Steering
Steering Stem Removal
Steering Stem Installation
Torque –
Torque –
Steering Knuckle Removal
Steering Knuckle Installation
Torque –
Tie-rod Removal
Tie-rod Installation
Torque –
Tie-rod End Removal
Tie-rod End Installation
Torque –
Steering Inspection
Steering Stem Warp
Steering Lubrication
Steering Stem Clamp Inspection
Steering Stem Bearing Inspection
Tie-rod End Inspection
Steering Knuckle Pivot Lubrication
Handlebar Removal
Handlebar Installation
Torque –
Frame
Seat Removal
Seat Installation
Front Fender Removal
Front Fender Installation
Torque –
Rear Fender Removal
Rear Fender Installation
Torque –
Front Guard Removal
Rear Guard Removal
Electrical System
Spark Plug Wrench, Hex 18:
Light/Dimmer Switch [A]
There are a number of important precautions that should be taken
Wiring Inspection
Special Tool –
Battery Removal
Battery Installation
Electrolyte Level Inspection
Electrolyte Specific Gravity Inspection
Initial Charging
Ordinary Charging
Battery Charging Rate/Time Table
Battery Test Charging
Special Tool –
Alternator Cover Removal
Special Tool –
Alternator Cover Installation
Sealant –
Torque –
Torque –
Alternator Rotor Removal
Special Tools –
Alternator Rotor Installation
Alternator Stator Removal
Alternator Stator Installation
Sealant –
Regulator / Rectifier Output Voltage Inspection
Special Tool –
Alternator Inspection
Special Tool –
Regulator/Rectifier Inspection
Charging System Circuit
WARNING
Spark Plug Removal/Installation
Special Tool –
Torque –
Spark Plug Cleaning/Inspection
Spark Plug Gap Inspection
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Inspection
Special Tool –
Ignition Coil Primary Peak Voltage Inspection
Special Tool –
Special Tool –
Crankshaft Sensor Removal
Crankshaft Sensor Inspection
Special Tool –
Crankshaft Sensor Peak Voltage Inspection
Special Tool –
Recommended Tool –
Alternator Rotor Inspection
Ignition Timing Test
Special Tool –
Ignition System Circuit
Starter Motor Removal
Starter Motor Installation
Torque –
Starter Motor Disassembly
Starter Motor Assembly
Torque –
Torque –
Commutator Cleaning/Inspection
Armature Inspection
Starter Motor Brush Length
Brush Assembly Inspection
Brush Plate and Terminal Bolt Inspection
Starter Relay Inspection
Starter Circuit Relay Inspection
Electric Starter Circuit
Starter Motor Clutch Removal
Special Tool –
Starter Motor Clutch Installation
Torque –
Starter Motor Clutch Inspection
Torque Limiter Inspection
Headlight Beam Vertical Adjustment
Headlight Bulb Replacement
Taillight Bulb Replacement
Neutral and Reverse Indicator Light Bulb Replacement
Lighting System Circuit
Brake Light Switch Adjustment
Switch Inspection
Front Brake Light Switch Connections
Rear Brake Light Switch Connections
20 A Main Fuse Removal
Fuse Inspection
Appendix
NOTE
Engine Doesn’t Start, Starting Difficulty:
Starter motor not rotating:
Starter motor rotating but engine doesn’t turn over:
Recoil starter not operating
Engine won’t turn over:
No fuel flow:
Engine flooded:
Fuel/air mixture incorrect:
No spark; spark weak:
Compression Low:
Poor Running at Low Speed:
Spark weak:
Fuel/air mixture incorrect:
Compression low:
Other:
Poor Running or No Power at High Speed:
Firing incorrect:
Fuel/air mixture incorrect:
Compression low:
Knocking:
Miscellaneous:
Overheating:
Firing incorrect:
Fuel/air mixture incorrect:
Compression high:
Engine load faulty:
Lubrication inadequate:
Rear final gear case overheating:
Clutch Operation Faulty:
Clutch slipping:
Clutch not disengaging properly
Gear Shifting Faulty:
Doesn’t go into gear; shift pedal doesn’t return:
Jumps out of gear:
Overshifts:
Abnormal Engine Noise:
Knocking:
Piston Slap:
Valve noise:
Other noise:
Abnormal Drive Train Noise:
Clutch noise:
Transmission noise:
Drive train noise:
Abnormal Frame Noise:
Shock absorber noise:
Brake noise:
Other noise:
Exhaust Smokes Excessively:
White smoke:
Black Smoke:
Brown smoke:
Handling and/or Stability Unsatisfactory
Handlebar hard to turn:
Handlebar shakes or excessively vibrates:
Handlebar pulls to one side:
Shock absorption unsatisfactory:
Brake Doesn’t Hold
Battery Discharged:
Battery Overcharged:

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