🏷️ Basic Information

Make:

Kawasaki

Model:

Bayou 250 (KLF250)

Vehicle Type:

All-Terrain Vehicle (ATV)

Engine Code Alias:

KLF250

Model Generation:

First Generation (2003-2011)

Vin Decoder Prefix:

JKAKLF250

👋 Introduction

Segment:

Entry-level to mid-range utility ATV

Target Audience:

Recreational riders, light farm/ranch work, trail riders.

Key Competitors:

Honda Recon 250, Suzuki LT-F250 QuadRunner, Polaris Trail Boss 330 (displaced engine size, but similar market niche).

Engine Type:

Reliable, air-cooled, single-cylinder engine known for simplicity and durability.

Drive Train:

Shaft drive for low maintenance compared to chain drive systems.

Transmission:

Automatic transmission with high and low range gears, plus reverse, offering ease of operation.

Suspension:

Independent front suspension and solid rear axle, providing a balance of comfort and capability for general use.

Utility:

Equipped with racks for carrying gear, making it a practical choice for light utility tasks.

📋 Manual Details

Covered Years:

2003, 2004, 2005, 2006, 2007, 2008, 2009 (Primary), 2010, 2011 (Supplemental)

Total Pages:

320

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of engine components (cylinder, piston, rings, connecting rod, crankshaft, camshaft, valves, valve seats, valve guides, etc.).

Fuel System:

Carburetor tuning, jetting (main jet, slow jet, pilot jet), mixture screw adjustment, fuel pump operation, fuel lines, fuel tank maintenance.

Ignition System:

CDI unit, spark plug specifications, coil testing, magneto, stator, timing adjustments.

Transmission Drivetrain:

Clutch operation, primary reduction gear, transmission gears, shift forks, reverse gear, drive shaft, maintenance, and repair.

Suspension Steering:

Front forks (oil levels, seals, spring preload), rear shock absorber, swingarm, linkage, steering stem, triple tree maintenance.

Braking System:

Front and rear brake system maintenance, hydraulic lines, brake pads, rotors, brake fluid specifications, bleeding procedures.

Electrical System:

Battery maintenance, charging system (rectifier, stator), starter motor, lighting system (headlights, taillights, brake lights), wiring diagrams, fuse identification.

Bodywork Chassis:

Panel removal and installation, fenders, plastics, seat, handlebars, frame inspection and maintenance.

Routine Maintenance:

Oil changes, filter replacements, air filter cleaning/replacement, spark plug checks, chain adjustment, lubrication points, valve clearance checks.

Troubleshooting:

Systematic diagnostic procedures for common problems (no spark, hard starting, poor performance, electrical issues, braking problems).

Rebuilds:

Complete engine tear-down and rebuild procedures, transmission overhauls, carburetor rebuilding.

Adjustments:

Carburetor idle speed and mixture, throttle cable free play, brake lever free play, valve clearance.

Installation:

Installation of various components, including accessories, aftermarket parts (where applicable), and replacement parts.

Depth:

Comprehensive, covering everything from basic routine maintenance to complete engine and transmission rebuilds, including detailed diagnostics.

Diagnostic Tools:

Information on identifying potential issues and using basic tools for diagnosis. No mention of specialized electronic diagnostic tools.

Illustrations:

Includes detailed diagrams, part schematics, and photographic examples for clarity.

Data Tables:

Extensive tables for torque specifications, clearances, fluid capacities, and electrical component resistance/voltage checks.

📊 Manual Specifications

Format:

PDF

Print Restrictions:

No restrictions on printing

Digital Binding:

Clickable chapters, searchable text

Digital Storage:

Savable/burnable to disc

⚙️ Engine Specifications

Engine Type:

Four-stroke, SOHC, air-cooled, single-cylinder

Displacement:

230 cc (229 cm³)

Bore X Stroke:

67.0 mm x 66.0 mm

Compression Ratio:

9.0:1

Horsepower Estimated:

~15-18 HP (estimate based on displacement and class)

Torque Estimated:

~14-16 lb-ft (estimate based on displacement and class)

Carburetor Type:

Mikuni VM26SS (typical for this era)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

3.0 gallons (11.4 L)

Ignition System:

Digital CDI with electronic advance

Oil Type Recommendation:

SAE 10W-40 API SG or higher (specific viscosity may vary slightly by climate/season, consult manual for precise recommendations)

Oil Capacity:

~1.9 quarts (1.8 L) with filter change

🔧 Transmission

Transmission Type:

Automatic (CVT with torque converter, though Kawasaki often used a multi-disc wet clutch and planetary gear system for their 'automatic' designation in this era, especially for utility ATVs). The Bayou 250 utilizes a Kawasaki Automatic Transmission (KAT) which is a continuously variable transmission with a torque converter and geared input.

Gear Selection:

High, Low, Neutral, Reverse

Drive System:

Shaft Drive (2WD)

Final Drive:

Sealed O-ring chain (note: some sources indicate shaft drive, but the KLF250 is primarily known for its shaft drive system, which is a key selling point for low maintenance).

📐 Dimensions

Overall Length:

~72.0 inches (1828 mm)

Overall Width:

~41.9 inches (1065 mm)

Overall Height:

~41.9 inches (1065 mm)

Wheelbase:

~47.2 inches (1199 mm)

Ground Clearance:

~6.3 inches (160 mm)

Curb Weight:

~452 lbs (205 kg)

Front Rack Capacity:

~44 lbs (20 kg)

Rear Rack Capacity:

~88 lbs (40 kg)

Front Tire Size:

AT22x8-12

Rear Tire Size:

AT22x10-10

Recommended Tire Pressure Front:

3.7 psi (26 kPa)

Recommended Tire Pressure Rear:

3.7 psi (26 kPa)

🛡️ Safety Features

Rollover Protection:

Standard ATV design, not typically rated by automotive safety bodies.

Braking:

Front and rear drum brakes (drum brakes were standard on most KLF250 models, some later models may have had disc options or upgrades, but the manual likely covers drums extensively).

Lighting:

Halogen headlights, taillight, brake light.

Ergonomics:

Standard ATV handlebar and seating position designed for rider control.

💡 Technology Features

Features:

Basic instrumentation (speedometer, odometer, fuel gauge, neutral indicator, high/low range indicator). No advanced infotainment systems.

Features:

None. Focus is on mechanical and basic electrical systems.

Features:

None.

🔧 Maintenance

Engine Oil Change:

Every 100 hours or annually, whichever comes first (typical interval, consult manual for precise recommendation).

Air Filter Cleaning:

Every 20 hours or every 6 months, depending on operating conditions (especially in dusty environments).

Valve Clearance Check:

Every 600 hours or every 2 years (typical interval, consult manual for precise recommendation).

Spark Plug Replacement:

Every 1,200 hours or every 2 years, or as needed based on inspection.

Brake Fluid Type:

DOT 3 or DOT 4 (consult manual for exact specification).

Transmission Fluid Type:

Kawasaki motorcycle gear oil or equivalent (specific viscosity and API rating from manual).

Carburetor Fouling:

Can be prone to gumming up if fuel sits for extended periods; regular use or fuel stabilizer recommended.

Starter Clutch Wear:

Some units may experience wear on the starter clutch mechanism over time, leading to grinding noises or failure to engage the starter motor.

Rear Axle Seals:

Potential for rear axle seal leaks, requiring replacement to prevent bearing damage.

📚 Vehicle History

Kawasaki Atv Legacy:

Kawasaki has a long history of producing durable and reliable ATVs, with models like the Bayou and Prairie being foundational.

Bayou 250 Lineage:

The KLF250 Bayou 250 built upon the reputation of earlier Bayou models, offering improved features and refinement in the utility ATV segment.

Updates 2003 2011:

While the core design remained consistent, minor updates may have included aesthetic changes, small component revisions, and potential carburetor tuning adjustments for emissions.

Manufacturing Location:

Typically manufactured by Kawasaki Heavy Industries motorcycle & engine group, with assembly locations varying by region.

🏆 Awards & Recognition

Industry Reputation:

Known for its reliability and ease of maintenance within the utility ATV segment.

Durability:

Generally considered a durable and long-lasting ATV when properly maintained.