🏷️ Basic Information

Make:

Kawasaki

Model:

KLF250

Year:

2003

Model Nickname:

Bayou 250

Vehicle Type:

ATV (All-Terrain Vehicle)

👋 Introduction

Market Segment:

Entry-level to mid-range utility ATV market, popular for recreational riding, light farm work, and trail use.

Target Audience:

New ATV riders, recreational riders, small farm operators, and DIY mechanics seeking to maintain and repair their KLF250.

Competitors:

Honda FourTrax 300/350, Yamaha Timberwolf 250, Suzuki LT-F250 QuadRunner.

Vehicle Highlights:

Reliable air-cooled engine, rugged chassis, dependable shaft drive, comfortable riding position, versatile for various terrains.

Manual Value Proposition:

Provides essential knowledge for owners to perform routine maintenance, troubleshoot common issues, and carry out repairs, extending the lifespan and performance of their ATV.

📋 Manual Details

Manual Type:

Service Manual

Language:

English

Format:

Digital (Likely PDF)

Page Count:

Approximately 300-400 pages (typical for a comprehensive service manual of this era)

📖 Manual Coverage

Engine:

Complete engine overhaul, disassembly, assembly, tuning, diagnostics, lubrication system, cooling system (air-cooled), ignition system, fuel system.

Transmission:

Manual gearbox, clutch operation and adjustment, internal components, lubrication.

Drivetrain:

Shaft drive, final drive housing, universal joints, axle components, bearing service.

Suspension:

Front and rear suspension system, shock absorbers, swingarm, bushings, linkage maintenance.

Brakes:

Front and rear drum brake systems, brake cable adjustment, linkage, hydraulic fluid (if applicable for parking brake), troubleshooting.

Electrical System:

Wiring diagrams, lighting system, ignition system components, battery, starter motor, charging system (alternator), troubleshooting electrical faults.

Fuel System:

Carburetor identification, disassembly, cleaning, adjustment, fuel lines, fuel petcock, fuel tank.

Cooling System:

Air-cooled system management, cylinder head cooling fins, heat dissipation.

Frame And Bodywork:

Frame inspection, body panel removal and installation, seat, fenders, handlebars, controls.

Wheels And Tires:

Tire pressure recommendations, wheel bearing service, rim maintenance.

Maintenance:

Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug checks, valve clearance checks.

Troubleshooting:

Diagnostic flowcharts for common problems, identifying and resolving issues related to starting, running, braking, and electrical systems.

Repair:

Detailed step-by-step instructions for component disassembly, repair, reassembly, and adjustment across all covered systems.

Inspection:

Pre-ride inspection guidelines, thorough inspection procedures for critical components.

Specifications Setting:

Torque specifications for fasteners, engine timing, ignition timing, carburetor jetting, valve clearances, and other critical adjustments.

Depth Level:

Comprehensive - Covers everything from basic rider maintenance to full engine rebuilds and detailed electrical system troubleshooting.

Diagrams Illustrations:

Includes detailed exploded views, wiring diagrams, and step-by-step photographic illustrations.

Diagnostic Tools:

Provides guidance on using standard hand tools and potentially specialized tools for certain procedures.

📊 Manual Specifications

Digital Format:

PDF

Searchable Text:

Likely Yes, for ease of navigation and quick information retrieval.

Printable:

Likely Yes, allowing users to print specific sections or the entire manual.

Resolution Quality:

High-resolution scans ensuring clarity of text and diagrams.

Print Quality:

N/A (Digital Format)

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Four-stroke, SOHC, air-cooled

Displacement:

249 cc (249 cubic centimeters)

Bore X Stroke:

68.5 mm x 68.0 mm

Compression Ratio:

9.0:1

Valve Configuration:

SOHC (Single Overhead Camshaft) with 2 valves

Horsepower:

Estimated 16-18 HP (manufacturer typically doesn't publish specific HP figures for ATVs, but this is a common range for this engine size).

Torque:

Estimated 14-16 lb-ft (similar to horsepower, typical estimate).

Carburetor:

Mikuni VM26 (single carburetor)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

Approximately 2.5 gallons (9.5 liters)

🔧 Transmission

Transmission Type:

5-speed manual with reverse

Clutch Type:

Wet, multi-plate

Final Drive:

Sealed O-ring chain, Shaft drive (typically refers to the transfer case from transmission to rear axle)

Gear Ratios:

Specific gear ratios will be detailed in the manual.

📐 Dimensions

Overall Length:

Approximately 73.4 inches (1865 mm)

Overall Width:

Approximately 40.6 inches (1030 mm)

Overall Height:

Approximately 43.1 inches (1095 mm)

Wheelbase:

Approximately 47.2 inches (1200 mm)

Ground Clearance:

Approximately 6.7 inches (170 mm)

Curb Weight:

Approximately 440 lbs (200 kg)

Gross Vehicle Weight Rating:

Will be specified in the manual, typically around 750-850 lbs.

🛡️ Safety Features

Atv Safety Standards:

Designed to meet applicable industry safety standards for ATVs.

Braking System:

Front and rear drum brakes, parking brake.

Lighting:

Headlight, taillight, brake light.

Chassis Design:

Stable chassis design for off-road stability.

Operator Safety:

Emphasis on proper riding techniques and protective gear, as detailed in owner's manuals and often referenced in service manuals.

💡 Technology Features

Infotainment Features:

N/A (Basic Utility ATV, no integrated infotainment systems).

Driver Assistance Features:

N/A (Basic Utility ATV, no electronic driver assistance systems).

Connectivity Features:

N/A (Basic Utility ATV, no electronic connectivity).

🔧 Maintenance

Engine Oil Change:

Every 1000 km or 6 months, whichever comes first.

Air Filter Cleaning:

Every 500 km or monthly, more frequently in dusty conditions.

Spark Plug Check:

Every 1000 km or annually.

Valve Clearance Check:

Every 3000 km or 2 years.

Brake Adjustment:

Check and adjust as needed, typically before each ride or every 250 km.

Engine Oil Type:

API SG or SH, SAE 10W-40 viscosity (check manual for specific ambient temperature recommendations).

Engine Oil Capacity:

Approximately 1.5 liters (1.6 US qt) without filter change, 1.6 liters (1.7 US qt) with filter change.

Final Drive Oil Type:

SAE 80 hypoid gear oil (check manual for specific API classification).

Final Drive Oil Capacity:

Approximately 0.15 liters (0.16 US qt).

Common Wear Items:

Brake shoes and cables, wheel bearings, carburetor jets (clogging), rear shock bushings, starter motor brushes.

Carburetor Performance:

Can be prone to jetting issues or clogging if fuel quality is poor or it sits for extended periods.

Cooling System Maintenance:

Importance of keeping air cooling fins clean for optimal engine temperature management.

📚 Vehicle History

Kawasaki Atv History:

Kawasaki has a long-standing history in the ATV market, dating back to the early 1980s, with the Bayou line being a significant contributor to their off-road presence.

Klf250 Development:

The KLF250 Bayou 250 evolved from earlier Kawasaki 250cc utility ATVs, focusing on simplicity, durability, and affordability. It often shared components and design philosophies with other Kawasaki models of its era.

Production Period:

The KLF250 Bayou was produced for many years, with the 2003 model being part of a successful and enduring generation of this utility ATV.

🏆 Awards & Recognition

Industry Awards:

While specific awards for the 2003 KLF250 are not widely documented, the Bayou line consistently received positive reviews for its reliability, value, and capability within its class during its production run.

Consumer Ratings:

Generally rated highly by owners for its dependability and ease of maintenance.

Safety Certifications:

Compliant with relevant industry safety certifications for its model year.