1988 Kawasaki Bayou 220 Service Manual

The 1988 Kawasaki Bayou 220 is a rugged ATV featuring a 216cc air-cooled four-stroke engine, automatic clutch with 5-speed transmission, shaft drive, front and rear suspension, electric start with backup recoil starter, front and rear racks, and full instrumentation. This service manual provides comprehensive information for maintenance, repair, and troubleshooting procedures.

1. General Information 2. Periodic Maintenance 3. Engine 4. Fuel System 5. Electrical System 6. Transmission & Drive 7. Suspension & Steering 8. Brakes 9. Wheels & Tires 10. Troubleshooting

General Information

Key specifications and identification data for the 1988 Kawasaki Bayou 220 ATV.

Item	Specification
Model	Bayou 220 (KAF220-A1)
Engine Type	4-stroke, air-cooled, single cylinder
Displacement	216cc
Bore x Stroke	67.0 x 61.2 mm
Compression Ratio	8.5:1
Starting System	Electric & recoil starter
Transmission	5-speed with automatic clutch
Drive System	Shaft drive
Fuel Capacity	2.6 gallons (10 liters)
Dry Weight	385 lbs (175 kg)

Periodic Maintenance

Regular maintenance schedule and procedures to ensure optimal performance and longevity.

Engine Oil: Change every 100 hours or 6 months - use SAE 10W-40
Oil Filter: Replace with every oil change
Air Filter: Clean every 50 hours, replace if damaged
Spark Plug: Clean and gap every 100 hours, replace every 200 hours
Valve Clearance: Check every 300 hours - intake: 0.10-0.15mm, exhaust: 0.15-0.20mm
Drive Shaft: Lubricate every 200 hours

WARNING! Always perform maintenance in well-ventilated area. Allow engine to cool before servicing.

Engine

Complete engine service procedures including disassembly, inspection, and reassembly.

Cylinder Head: Torque bolts to 25-30 N·m in crisscross pattern
Piston & Rings: Standard piston diameter 67.000-67.015 mm
Crankshaft: Connecting rod side clearance 0.35-0.65 mm
Camshaft: Cam height intake 33.241 mm, exhaust 32.911 mm
Valve Timing: Align timing marks during assembly
Cooling System: Air-cooled with cooling fins - keep clean

Fuel System

Carburetor service and fuel system maintenance procedures.

Carburetor Type: Mikuni VM24SS
Main Jet: #115
Pilot Jet: #35
Float Height: 18.5 ± 1.0 mm
Idle Speed: 1300 ± 100 rpm
Fuel Filter: Replace annually or if contaminated

CAUTION! Drain fuel tank before carburetor removal. Use fresh fuel to prevent contamination.

Electrical System

Electrical component specifications and troubleshooting procedures.

Component	Specification
Battery	12V 12Ah
Alternator	AC magneto 0.168 kW at 5000 rpm
Spark Plug	NGK DR8ES or equivalent
Plug Gap	0.6-0.7 mm
Ignition Timing	15° BTDC at 1500 rpm
Headlight	12V 30/30W
Fuses	Main 15A, Headlight 10A

Transmission & Drive

Transmission service and drive system maintenance.

Transmission Oil: SAE 10W-40, capacity 1.1 liters
Gear Ratios: 1st: 2.833, 2nd: 1.813, 3rd: 1.333, 4th: 1.074, 5th: 0.893
Drive Shaft: Inspect universal joints for wear
Final Drive: Hypoid gear oil SAE 80W-90
Clutch: Automatic centrifugal type - inspect shoes for wear

Tip: Check transmission oil level with ATV on level ground.

Suspension & Steering

Suspension components and steering system service procedures.

Front Suspension: Independent double wishbone with shock absorbers
Rear Suspension: Swingarm with single shock absorber
Steering System: Direct link type with handlebars
Front Wheel Alignment: Toe-in 0-10 mm
Shock Absorbers: 5-position preload adjustment
Steering Bearings: Adjust if handlebars have play

Brakes

Brake system service and adjustment procedures.

Front Brakes: Drum type, adjust via cable
Rear Brakes: Drum type with parking brake
Brake Shoes: Replace if lining thickness < 1.5 mm
Brake Adjustment: Adjust until slight drag, then back off 1/4 turn
Parking Brake: Adjust cable for proper engagement

WARNING! Test brakes after adjustment. Replace worn components immediately.

Wheels & Tires

Wheel and tire specifications and maintenance procedures.

Item	Specification
Front Tire Size	22 x 8-10
Rear Tire Size	22 x 10-10
Tire Pressure	Front: 20 kPa (0.20 kgf/cm²), Rear: 20 kPa (0.20 kgf/cm²)
Wheel Nut Torque	60-80 N·m
Lug Pattern	4/110

Troubleshooting

Common problems and their solutions for the Bayou 220.

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel flow, spark plug, compression (120+ psi)
Poor performance	Clogged air filter, carburetor	Clean air filter, service carburetor
Electrical failure	Battery, fuses, connections	Test battery voltage, check fuses, clean connections
Transmission issues	Low oil, worn clutch	Check oil level, inspect clutch shoes
Brake problems	Worn shoes, adjustment	Inspect brake shoes, adjust cables

Service Note: Use genuine Kawasaki parts for optimal performance and reliability.

Technical Support: Contact authorized Kawasaki dealer for complex repairs.