1986 Kawasaki Bayou 300 Service Manual

The 1986 Kawasaki Bayou 300 is a versatile all-terrain vehicle featuring a 290cc four-stroke engine, automatic clutch with high/low range, shaft drive, front and rear racks, and electric start. This service manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for proper servicing of the ATV. Below are key sections for safety, technical specifications, maintenance procedures, troubleshooting, and repair guidelines.

General Information

Key components: 290cc air-cooled four-stroke engine, automatic transmission with high/low range and reverse, shaft drive system, front and rear cargo racks, electric start with backup recoil starter.

Specifications

• Engine: 290cc 4-stroke SOHC, air-cooled
• Bore x Stroke: 74.0 x 66.0 mm
• Compression Ratio: 8.5:1
• Carburetor: Mikuni VM24SS
• Ignition System: CDI electronic ignition
• Transmission: Automatic centrifugal clutch, 2-range sub-transmission
• Final Drive: Shaft drive
• Front Tire: 21 x 8-10
• Rear Tire: 22 x 11-10
• Oil Capacity: 1.7 quarts (1.6 liters)
• Fuel Type: Regular unleaded gasoline

Periodic Maintenance

Regular maintenance schedule for optimal performance and longevity.

1. Before Each Ride: Check fuel level, tire pressure, brakes, controls
2. Every 100 miles: Check engine oil level, clean air filter
3. Every 500 miles: Change engine oil and filter, inspect spark plug
4. Every 1000 miles: Check valve clearance, inspect drive shaft
5. Every 2000 miles: Change final drive oil, inspect brake pads
6. Seasonal: Lubricate cables and pivot points, check battery

WARNING! Always perform maintenance on level ground with engine off and cool. Use proper safety equipment.

Engine Service

Engine maintenance and repair procedures.

1. Oil Change: Warm engine, drain oil, replace filter, refill with 1.7 quarts 10W-40
2. Valve Clearance: Intake: 0.10-0.15 mm, Exhaust: 0.15-0.20 mm (cold)
3. Spark Plug: NGK DR8ES, gap 0.7-0.8 mm
4. Compression Test: Should be 120-150 psi
5. Cylinder Head: Torque bolts to 20 ft-lbs in crisscross pattern
6. Piston & Rings: Standard bore 74.00 mm, maximum oversize 74.50 mm

CAUTION! Ensure engine is completely cool before performing any service work.

Fuel System

Carburetor service and fuel system maintenance.

1. Carburetor Settings: Main jet #140, Pilot jet #40, Needle clip 3rd position
2. Float Level: 21.5 mm from carburetor body
3. Idle Speed: 1400 ± 100 rpm
4. Fuel Filter: Replace annually or every 1000 miles
5. Fuel Lines: Inspect for cracks and replace if necessary
6. Choke System: Ensure proper cable operation and enrichment

Tip: Always use fresh fuel and stabilizer if storing for extended periods.

Electrical System

Battery, charging system, and electrical component service.

Testing Procedures: Battery voltage: 12.6V+ (fully charged), Charging output: 13.5-14.5V at 3000 rpm

Drive System

Transmission, clutch, and final drive service.

1. Transmission Oil: Capacity 1.1 quarts, type 10W-40 motor oil
2. Final Drive Oil: Capacity 0.26 quarts, type 80W-90 gear oil
3. Clutch Adjustment: Automatic centrifugal type, no adjustment required
4. Drive Shaft: Inspect universal joints for wear and lubrication
5. Range Selector: Ensure smooth operation between High/Low/Reverse
6. Neutral Safety Switch: Test function for electric start safety

WARNING! Do not attempt to shift ranges while moving. Come to complete stop first.

Suspension & Steering

Front and rear suspension maintenance and steering system service.

• Front Suspension: Double A-arm with shock absorbers
• Rear Suspension: Swingarm with single shock absorber
• Steering Play: Check for excessive play in tie rods and bushings
• Wheel Alignment: Toe-in: 0-10 mm
• Shock Absorbers: Check for oil leaks and proper damping
• Wheel Bearings: Repack annually or every 1000 miles

CAUTION! Always support ATV securely with jack stands when working underneath.

Brake System

Front and rear drum brake service and adjustment.

1. Brake Adjustment: Turn adjuster nuts on brake rods for proper free play
2. Brake Shoes: Replace when lining thickness reaches 1.0 mm
3. Brake Drums: Maximum inside diameter: 150.7 mm
4. Parking Brake: Adjust cable for positive engagement
5. Brake Fluid: Not applicable - mechanical drum brakes
6. Cable Lubrication: Lubricate brake cables annually

Tip: Test brakes at low speed after adjustment to ensure proper operation.

Troubleshooting

Note: Always begin troubleshooting with simplest solutions first before major disassembly.

Wiring Diagrams

Complete electrical schematics for the 1986 Kawasaki Bayou 300.

Main Components: CDI unit, ignition coil, starter motor, voltage regulator, battery, switches, lights

Color Codes: R=Red, B=Black, W=White, G=Green, Y=Yellow, L=Blue, Br=Brown

Testing Points: Refer to specific resistance values and voltage specifications in detailed diagrams

Service Contact: For technical support or replacement parts, contact authorized Kawasaki dealers