1988 KLF300 Service Manual PDF

The 1988 KLF300 Service Manual provides comprehensive technical information for the Kawasaki KLF300 Bayou all-terrain vehicle. This manual covers complete maintenance procedures, troubleshooting guides, repair instructions, and specifications for the 290cc four-stroke engine, transmission system, electrical components, chassis, and all mechanical systems. Below are key sections for maintenance schedules, engine service, transmission repair, electrical systems, and troubleshooting.

1. General Information 2. Maintenance Schedule 3. Engine Service 4. Transmission & Drive System 5. Electrical System 6. Chassis & Suspension 7. Fuel System 8. Brake System 9. Troubleshooting 10. Specifications 11. Wiring Diagrams

General Information

Key components: 290cc air-cooled four-stroke engine, automatic transmission with high/low range, shaft drive, independent rear suspension, front and rear hydraulic brakes.

Component	Description
Engine Type	4-stroke, air-cooled, single cylinder OHC
Displacement	290cc
Transmission	Automatic CVT with high/low range and reverse
Drive System	Shaft drive
Suspension	Independent rear suspension, telescopic front forks
Brakes	Hydraulic disc front and rear
Fuel Capacity	3.7 gallons (14 liters)
Dry Weight	419 lbs (190 kg)
Load Capacity	330 lbs (150 kg)
Towing Capacity	850 lbs (385 kg)

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Daily/Pre-ride: Check fuel, oil level, tire pressure, brakes, lights.
Every 100 hours/6 months: Change engine oil and filter, clean air filter.
Every 200 hours/12 months: Check valve clearance, spark plug, drive shaft.
Every 400 hours/24 months: Change transmission fluid, inspect brake pads.
Annual: Lubricate all fittings, check wheel bearings, inspect suspension.

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

Engine Service

Complete engine maintenance and repair procedures.

Oil change: Drain plug located bottom of crankcase, refill with 10W-40.
Valve adjustment: Intake 0.10-0.15mm, exhaust 0.15-0.20mm.
Spark plug: NGK DR8ES, gap 0.7-0.8mm.
Compression test: Should be 156 psi minimum.
Carburetor adjustment: Main jet #122.5, pilot jet #38.

CAUTION! Engine components get extremely hot. Allow to cool before servicing.

Transmission & Drive System

Transmission Type: Automatic CVT with high/low range and reverse.
Drive System: Shaft drive with universal joints.
Transmission Fluid: Type: ATF Dexron II, Capacity: 1.5 liters.
CVT Belt: Replacement interval: 2,000 hours or as needed.
Differential: Gear oil: 80W-90, Capacity: 0.25 liters.
Shift Mechanism: Cable operated with neutral safety switch.
Maintenance: Check fluid levels every 100 hours, inspect for leaks.

Electrical System

Complete electrical system specifications and troubleshooting.

Battery: 12V 14Ah, Charging system: AC magneto, Regulator/Rectifier: Solid state.

Ignition: CDI electronic ignition, Spark plug: NGK DR8ES. Lighting: Headlight 35/35W, Tail/brake light 8/27W, Turn signals 21W. Starting system: Electric start with backup recoil. Fuses: Main 30A, Headlight 10A, Signal 10A. Wiring: Color-coded harness with waterproof connectors.

Chassis & Suspension

Frame construction: Steel tube frame with box-section reinforcement.

Front suspension: Telescopic forks, travel 140mm.
Rear suspension: Independent swingarm with shocks, travel 130mm.
Wheel alignment: Toe-in 0-10mm, camber 0-1 degree.
Tire pressure: Front 3.5 psi, Rear 3.5 psi (varies by load).
Wheel bearings: Check every 200 hours for play.

Tip: Always support vehicle properly when working on suspension components.

Fuel System

Carburetor type: Mikuni VM28SS, float level: 21.5mm.

Fuel filter: Replace every 400 hours or annually.
Carburetor cleaning: Remove and clean jets every 200 hours.
Fuel pump: Mechanical type, check operation if hard starting.
Fuel lines: Inspect for cracks and replace if brittle.
Air filter: Foam element, clean with soapy water and re-oil.
Throttle cable: Adjust free play to 2-3mm at handlebar.
Choke system: Cable operated, check for smooth operation.
Fuel tank: Remove and clean sediment every 2 years.

WARNING! Gasoline is highly flammable. Work in well-ventilated area away from ignition sources.

Brake System

Hydraulic disc brakes front and rear. Front disc diameter: 184mm, Rear disc diameter: 184mm.

Troubleshooting

Common problems and solutions for the KLF300.

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel flow, spark plug, compression test.
Poor performance	Clogged air filter, carburetor	Clean air filter, adjust carburetor jets.
Transmission slipping	Worn belt, low fluid	Inspect CVT belt, check transmission fluid.
Electrical issues	Battery, stator, regulator	Test battery voltage, check stator output.
Brakes dragging	Stuck calipers, contaminated fluid	Clean calipers, flush brake fluid.

Reset: Disconnect battery for 30 minutes to reset electrical system.

Specifications

Engine: 290cc 4-stroke single cylinder OHC
Bore x Stroke: 74.0 x 66.0mm
Compression Ratio: 8.5:1
Fuel System: Mikuni VM28SS carburetor
Ignition: CDI electronic
Starting: Electric and recoil backup
Transmission: Automatic CVT with high/low/reverse
Final Drive: Shaft
Suspension Front: Telescopic forks, 140mm travel
Suspension Rear: Independent swingarm, 130mm travel
Brakes: Hydraulic disc front and rear
Tires: Front 21x7-10, Rear 22x11-10
Dimensions: L 1785mm x W 1070mm x H 1070mm
Wheelbase: 1170mm
Ground Clearance: 155mm

Wiring Diagrams

Complete color-coded wiring diagrams for entire electrical system including starting circuit, charging system, lighting, and ignition. Diagrams show wire colors, connector locations, and component identification.

Service: For technical support contact Kawasaki customer service or authorized dealers.