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 !!!! 

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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:
                
                -