1988-2002 Kawasaki Bayou 220 KLF220 Service & Repair Manual

Kawasaki KLF220 BAYOU All Terrain Vehicle Service Manual

This quick reference guide will assist you in locating a desired topic or procedure. -Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. -Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required. Quick Reference Guide General Information 1 2 End 3 4 5 ine Removal/Installation 6 ine Bottom EndlTransmission 7 8 9 10 11 12 13 14 15 nt - 1995 Late - 1997 Models 16 lement - 1998 - 1999 Models 17 lement - 2000 - 2002 Models 18

LIST OF ABBREV IATIONS A ampere(s) Ib pound(s) ABOC after bottom dead center m meter(s) AC alternating current min minute(s) ATOC after top dead center N newton(s) BBOC before bottom dead center Pa pascal(s) BOC bottom dead center PS horsepower BTDC before top dead center psi pound (s) per square inch °C degree(s) Celsius r revolution DC direct current rpm revolution(s) per minute F farad(s) TOC top dead center OF degree(s) Fahrenheit TIR total indicator reading ft foot, feet V volt(s) 9 gram(s) W watt(s) h hour(s) n ohm(s) L liter(s) Read OWNER'S MANUAL before operating

~ "~~w.~",.",w.~" .. .. ~ ... ~ ... -, ·Y .~ .. ... t. .;¥.,,~ ••. •• ~ ... !\. :;¥.";¥. .. _ ..... ... ;r:~ ... ? .;¥."~"~" .~,. -,,!-jf~. ~.1I-~-VJl e.lf:.tf~~f. .~. ,- .~iL.~1l..~ii:. •• • ~it. ~.u:. • .~........ • ••• ~.. • .. ~. .y;.!Y';- ..... "".~fllr._~...11 .y..::Y<io .. ';: ... .1I!r. .. !o-.. ,,- .y;:.- .- .. .• .... .,r,; .... *-\ PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM *: ~ IUS Model only I ::r.: •• ~ ~t ~: To minimize the noise emissions from this product, Kawasaki has equipped it with !\~: ;:":: effective intake and exhaust silencing systems. They are designed to give optimum per- ~: :-i!\ formance while maintaining a low noise level. Please do not remove these systems, or alter ~! ~ them in anY which results in an increase in noise level. !\o::; ..... ~ ~;Ko$~ti:.$~~~p.:~~~~:~'f.U.'f.U.'f.!-!~~:;w.~~~~'f..U.~~~~ .~., ............ ,.. ............. , •• ".. •• :."~; .. , ..... " ......... :>~:>:;:;:.'~;~; ............... ,. .... :~ .... ~~; ......... .. WARNING CONTAINS ASBESTOS Breathing asbestos dun is dlngerous to health Follow safety instructions This warning may apply to any of the following components or any assembly containing one or more of these components:- Brake Shoes or Pads Clutch Friction Material Gaskets Insulators SAFETY INSTRUCTIONS e{)perate if possible out of doors or in a well ventilated place. .Preferably use hand tools or low speed tools equipped, if necessary. with an appropriate dust extraction facility. If high speed tools are used, they should always be so equipped. elf possible, dampen before cutting or drilling . -Dampen dust and place it in properly closed receptacle and dispose of it safely.

Foreword 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 de- sires 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. When- ever the owner has insufficient experience or doubts his ability to do the work, all adjust- ments, maintenance, and repair should be car- ried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work care- fully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may ad- versely affect safe operation. For the duration of the warranty period , we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: • Follow the Periodic Maintenance Chart in the Service Manual. • Be alert for problems and non-scheduled maintenance. • Use proper tools and genuine Kawasaki Vehi- cle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Man- ual. Genuine parts provided as spare parts are listed in the Parts Catalog. • Follow the procedures in this manual care- fully. Don't take shortcuts. • Remember to keep complete records of maintenance and repair with dates and any new parts installed. How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual's chapters. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Ta- ble of Contents, For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. A WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per- sonal injury, or loss of life. CAUTiON This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE o This note symbol indicates points of particular interest for more efficient and con- venient operation. .Indicates a procedural step or work to be done, Olndicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE, * Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1 General Information Table of Contents Before SelVicing _. . .. . .. ....... ........ . ...... _. _ ......... _ 1-2 Model Identification . ... . .. •.. .. ........... _. . . . . . . . . . . . . . . . 1-4 General Specifications . . .. . ............... . ...... . ........ .. 1-5 Periodic Maintenance Chart . .... . ...... .. : . . . . . . . . . . . . . . . . • . . 1-7 Torque and Locking Agent . . .... . ... _ ... . .. ........ .. .. . . : . . . 1-8 Cable and Hamess Routing.. . . . . . ... . ... . . . . ... . . . . . . . . .. . . .. 1-10

1-2 GENERAL .INFORMATION Before Servicing Before starting to service a vehicle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed des- criptions have been included wherever necessary. Nevertheless, even a detailed account has limi- tations, a certain amount of basic knowledge is also required for successful work. Especially note the following: (1) Dirt Before removal and disassembly, clean the vehicle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the vehicle. For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground Remove the ground (-) lead 'from the battery before performing any disassembly operations on the vehicle. This prevents:' (a) the possibility of accidentally turning the engine over wh ile partially disassembled. (b) sparks at electric~1 connections which will occur when they are disconnected. (c) damage to electrical parts. (3) Tighten ing Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them evenly in a cross pattern. Th is is to avoid distortion of the part and / or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated. (4) Torque When torque values are given in this Service Manual, use them. Either' too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. (5) Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads. , (6) Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands wi th gloves or a piece of thick cloth when lifting the engine or turning it over. (7) High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name) . Always follow manufacturer and container directions regarding the use of any solvent. (8) Gasket, O-Ring Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. (9) Liquid Gasket, Non-Permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in North America is Loctite Lock'n Seal (Blue). (10) Press 'A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly. (11) Ball Bearing When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented . Press a ball bearing until it stops at the stop in the hole or on the shaft.

GENERAL INFORMATION 1-3 (12) Oil Seal and Grease 'Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. (13) Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction. (14) Circlip, Retaining Ring Replace any circlips and .retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. (15) Lubrication Engine wear is generally at its maximum while the e~gine is warming up and 'before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubriCative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended . This'manual makes reference to molybdenum disulfide grease (MoS,) in the assembly of certain engine and chassis parts_ Always check manufacturer recommendations before using such special lubricants. (16) Electrical Wires All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and thim the secondary color. For example, a yellow wire with thin red stripes is referred to as a ·yellow/red" wire; it would be a "red/yellow" wire if the colors were reversed to make red the main color. Wire (cross-section) Name of Wire Color Red Wire strands Yellow/red Yellow Red (17) Replacement Parts When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed. (18) Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent Dent . Scratch Wear Color change Deterioration Seizure (19) Specifications Specification tenms are defined as follows. "Standards" show dimensions or performances which brand-new parts or systems have. "Service limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

1988-2002 Kawasaki Bayou 220 KLF220 Service & Repair Manual

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