The KLF250 Bayou 250 is a reliable and user-friendly All-Terrain Vehicle (ATV) designed for recreational riding and light utility tasks. Produced for model years 2003 through 2010, this 2WD ATV features a 249cc four-stroke, SOHC, air-cooled single-cylinder engine paired with a 5-speed manual transmission and automatic clutch. Its straightforward design emphasizes ease of operation, making it a popular choice for riders seeking dependable performance. Known for its durability and practical features, the Bayou 250 has earned a reputation for being a solid entry-level to mid-range utility ATV, building on an established heritage in the ATV market.
This comprehensive factory service manual provides detailed information essential for the maintenance, repair, and troubleshooting of the KLF250 Bayou 250 for model years 2003-2010. It covers all major systems, including the engine, fuel system, powertrain, chassis, brakes, and electrical components, offering in-depth procedures for preventative maintenance, scheduled service intervals, and complete repair or overhaul of various parts. With detailed diagnostic trees, troubleshooting guidance, and technical specifications, this 318-page manual empowers both owners and professional technicians to effectively maintain the vehicle, ensuring its longevity and optimal performance. The manual is presented in English and is designed for easy navigation and information retrieval.
Chassis Code Range:
Likely designated by the year, e.g., KLF250A-### for specific sub-models or configurations within the model years.
Vehicle Segment:
Entry-level to mid-range utility ATV (All-Terrain Vehicle).
Competitors:
Honda FourTrax 250, Yamaha Bear Tracker 250, Suzuki QuadSport Z250 (though some competitors may have slight differences in focus or features).
Atv Attributes:
Reliable and user-friendly for recreational and light utility tasks, known for its straightforward design and ease of operation.
Diy Advantage:
Empowers owners to perform their own repairs and maintenance, saving money and extending the life of the ATV.
Professional Standard:
Provides the same level of detail and accuracy used by professional Kawasaki technicians.
Model Years Covered:
2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Type:
Factory Service Manual / Workshop Manual / Repair Manual
Format:
PDF Download (Potentially Zipped)
Powertrain:
Engine, Fuel System (Carburetion), Clutching & Belt System, Final Drive & 4WD System, Transmission
Chassis And Body:
Body & Steering, Brakes
Electrical:
Electrical System, Wiring Diagrams
Maintenance And Routine Service:
Preventative Maintenance, Scheduled Service Intervals, Fluid Changes, Filter Replacements, Lubrication
Repair And Rebuild:
Engine Overhaul, Transmission Repair, Brake System Overhaul, Steering System Reassembly, Clutch and Belt Replacement
Troubleshooting:
Diagnostic Procedures, Fault Finding, Symptom Analysis, Corrective Actions
Diagnostic Level:
Comprehensive, including detailed diagnostic trees and explanations of component functions.
Repair Scope:
Complete repair and rebuild information for virtually all aspects of the vehicle.
Printability:
High quality, printable from any computer and printer.
Binding:
N/A (Digital PDF)
Paper Type:
N/A (Digital PDF)
Searchability:
Keyword searchable for easy information retrieval.
Organization:
Organized and indexed for ease of use.
Engine Type:
Four-stroke, SOHC, air-cooled single-cylinder.
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
72.0 x 61.2 mm
Horsepower Estimate:
Approx. 17-18 HP (This is an estimate, official figures are not always published for this class of ATV, but typical for the displacement and configuration).
Torque Estimate:
Approx. 13-14 lb-ft (Estimate, typical for the displacement and configuration).
Fuel Delivery:
Carburetor (Likely a Keihin CVK type, specific model number would be in the manual)
Fuel Type:
Unleaded Gasoline
Ignition System:
CDI (Capacitor Discharge Ignition)
Oil Type:
API SG, SF or SE classification, SAE 10W-40 recommended (Specific oil viscosity and API rating to be confirmed in manual).
Transmission Type:
5-speed manual with automatic clutch
Optional Transmission:
N/A (The Bayou 250 primarily featured the 5-speed manual).
Drive System:
Shaft Drive (2WD) - Rear Wheel Drive (The '4WD' in the manual description likely refers to troubleshooting or general knowledge for other ATVs, but the KLF250 Bayou 250 is predominantly a 2WD model. Specific sub-models might exist, but the base is 2WD).
Clutch Type:
Wet multi-disc
Transmission Oil Type:
Kawasaki Genuine Transmission Oil or equivalent SAE 80W-90 hypoid gear oil (Specific type and capacity to be confirmed in manual).
Length:
Approx. 74.8 in (1895 mm)
Width:
Approx. 41.7 in (1060 mm)
Height:
Approx. 44.1 in (1120 mm)
Dry Weight:
Approx. 448 lbs (203 kg)
Fuel Capacity:
3.1 US gal (11.7 L)
Wheelbase:
Approx. 47.2 in (1200 mm)
Ground Clearance:
Approx. 6.1 in (155 mm)
Atv Safety Standards:
Designed to meet industry safety standards for ATVs of its era. Specific certifications would be detailed in the manual.
Braking System:
Front: Dual Hydraulic Disc Brakes, Rear: Sealed Drum Brake. Lever-actuated front brakes, foot-actuated rear brake.
Lighting:
Dual Halogen headlights, LED taillight/brake light.
Operator Safety:
Engine kill switch, parking brake.
Infotainment System:
N/A (This is a utility ATV, not equipped with infotainment systems).
Driver Assistance Features:
N/A (This is a utility ATV, not equipped with modern driver assistance features).
Connectivity Features:
N/A
Headlight Type:
Halogen (Dual)
Initial Service:
First service typically recommended at 600 miles or 6 months, whichever comes first (exact interval in manual).
Regular Maintenance:
Engine oil and filter changes every 1200 miles or 12 months, spark plug inspection/replacement, air filter cleaning/replacement, valve clearance checks, etc. (Detailed schedule in manual).
Engine Oil Capacity:
Approx. 1.5 L (1.6 US qt) without filter change, 1.7 L (1.8 US qt) with filter change (Exact capacity in manual).
Coolant:
Air-cooled engine, no coolant required.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (Consult manual for exact specification).
Common Wear Items:
Drive belt (clutch), brake pads, tires, wheel bearings, exhaust components can be subject to wear depending on usage.
Potential Issues Addressable By Manual:
Carburetor jetting or clogging, electrical connection issues, suspension component wear, general engine tune-up requirements.
Kawasaki Atv History:
Kawasaki has a long history of producing reliable ATVs, with the Bayou line being a staple for utility and recreation. The Bayou name has been associated with durable, practical ATVs.
Bayou 250 Lineage:
The KLF250 Bayou 250 represented Kawasaki's offering in the competitive 250cc utility ATV segment, building on the reputation of earlier Bayou models.
Manufacturing Location:
Typically manufactured in Japan or potentially at overseas facilities owned by Kawasaki Heavy Industries.
Production Span Of Model:
The KLF250 Bayou 250 was produced for a significant period, with the manual covering the 2003-2010 model years, indicating continued market presence and development during this time.
Atv Awards:
While specific awards for the KLF250 Bayou 250 are not widely publicized, Kawasaki ATVs have consistently been recognized for their reliability, durability, and value within the utility ATV market.
Consumer Ratings:
Generally well-regarded by owners for its dependable performance and ease of use in its class.
Emissions Compliance:
Designed to meet EPA and CARB emissions standards relevant to its model year and intended market.
