1987 Bayou 300 Owner's & Service Manuals

The 1987 Bayou 300 is a versatile all-terrain vehicle featuring a 290cc four-stroke engine, electric start with backup recoil, shaft drive system, independent front suspension, and dual-range transmission. This comprehensive manual covers operation, maintenance, troubleshooting, and repair procedures for optimal performance and longevity. Below are key sections for specifications, operation, maintenance, troubleshooting, and service procedures.

1. Specifications 2. Operation Controls 3. Maintenance Schedule 4. Engine Service 5. Electrical System 6. Brake System 7. Suspension & Steering 8. Fuel System 9. Troubleshooting 10. Safety Information 11. Warranty & Support

Specifications

Technical specifications for the 1987 Bayou 300 ATV.

Component	Specification
Engine Type	4-stroke, air-cooled, single cylinder
Displacement	290cc
Starting System	Electric with backup recoil
Transmission	5-speed with reverse
Drive System	Shaft drive
Front Suspension	Independent double wishbone
Rear Suspension	Swingarm with shocks
Front Brakes	Dual hydraulic disc
Rear Brakes	Drum brake
Fuel Capacity	3.7 gallons
Dry Weight	462 lbs
Load Capacity	330 lbs

Operation Controls

Familiarize yourself with all controls before operation.

Ignition Switch: Key-operated with positions for OFF, ON, and START
Throttle: Right-hand thumb lever
Brakes: Left-hand lever (front), right-foot pedal (rear)
Gear Shift: Left-foot operated with positions: N-1-2-3-4-5-R
2WD/4WD Selector: Dash-mounted switch
Light Switches: Headlight, taillight controls on handlebars

WARNING! Always wear proper safety gear including helmet, eye protection, and protective clothing.

Maintenance Schedule

Regular maintenance ensures optimal performance and safety.

Interval	Service Required
After first 20 hours	Change engine oil and filter
Every 100 hours	Change engine oil and filter
Every 200 hours	Change final gear oil
Every 300 hours	Clean air filter element
Every 600 hours	Replace spark plug
Monthly	Check tire pressure and brake fluid
Before each ride	Visual inspection of controls and tires

Engine Service

Engine maintenance and repair procedures.

Oil Change: Drain plug located bottom of crankcase, refill with 10W-40
Spark Plug: NGK DR8ES, gap 0.028-0.031 inches
Valve Clearance: Intake 0.004-0.006 in, Exhaust 0.006-0.008 in
Compression: Normal range 142-171 psi
Cooling System: Keep fins clean for proper air cooling

CAUTION! Engine must be cool before performing maintenance. Use proper tools and torque specifications.

Electrical System

Battery, charging, and ignition system details.

Battery: 12V 14Ah maintenance-free
Charging System: AC magneto with rectifier/regulator
Ignition: CDI electronic ignition
Fuses: Main 20A, accessory 10A
Bulbs: Headlight 35/35W, Brake light 21/5W

Tip: Keep battery terminals clean and tight. Check electrolyte level monthly.

Brake System

Hydraulic front disc and rear drum brake maintenance.

Front Brakes: DOT 4 brake fluid, check reservoir level
Rear Brakes: Adjust cable tension for proper pedal travel
Pad Replacement: Replace when thickness below 1mm
Bleeding: Required when air enters system or fluid darkens

WARNING! Test brakes after service before riding. Replace worn components immediately.

Suspension & Steering

Front and rear suspension adjustment and maintenance.

Front Suspension: Oil capacity 180cc per fork, 10W oil
Rear Shocks: Spring preload adjustable, 5 positions
Steering: Check for play monthly, tighten if necessary
Tire Pressure: Front 3.6 psi, Rear 3.6 psi (standard load)
Wheel Bearings: Repack with grease every 200 hours

Fuel System

Carburetor and fuel delivery system service.

Fuel Filter: Replace annually or if restricted
Carburetor: Clean every 200 hours, adjust idle speed 1400±100 rpm
Fuel Lines: Inspect for cracks or leaks
Fuel Tank: Clean sediment bowl monthly

CAUTION! Work in well-ventilated area. No smoking near fuel system.

Troubleshooting

Common issues and solutions for the Bayou 300.

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, or compression issue	Check fuel flow, spark plug, compression
Poor performance	Clogged air filter, dirty carburetor	Clean/replace air filter, clean carburetor
Electrical failure	Battery, fuse, or wiring issue	Check battery voltage, fuses, connections
Brakes dragging	Stuck caliper or contaminated fluid	Clean caliper, replace brake fluid
Transmission noise	Low oil level or worn gears	Check oil level, inspect gears

Safety Information

Critical safety guidelines for ATV operation.

Always wear DOT-approved helmet, eye protection
Never carry passengers on single-rider ATV
Avoid paved surfaces; designed for off-road use
No riders under 16 years old
Complete safety training course
Inspect ATV before each use
Ride at speeds appropriate for conditions

Warranty & Support

Limited warranty and customer support information.

Limited warranty: 6 months from purchase date covering manufacturing defects. Proof of purchase required. Normal wear items excluded. For technical support contact authorized dealers or manufacturer. Parts and service available through certified dealerships. Keep maintenance records for warranty claims.

Support: Contact authorized dealers for parts and service. Technical bulletins available from manufacturer.