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. 🏷️ Basic Information Identification Make: Kawasaki Model: KLF250 Bayou 250 Codes Chassis Code Range: Likely designated by the year, e.g., KLF250A-### for specific sub-models or configurations within the model years. 👋 Introduction Market Position Vehicle Segment: Entry-level to mid-range utility ATV (All-Terrain Vehicle). Competitive Analysis Competitors: Honda FourTrax 250, Yamaha Bear Tracker 250, Suzuki QuadSport Z250 (though some competitors may have slight differences in focus or features). Key Features Atv Attributes: Reliable and user-friendly for recreational and light utility tasks, known for its straightforward design and ease of operation. Manual Value Proposition 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. 📋 Manual Details Coverage Areas Model Years Covered: 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Total Pages: 318 Manual Type Type: Factory Service Manual / Workshop Manual / Repair Manual Language Language: English Format Format: PDF Download (Potentially Zipped) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System (Carburetion), Clutching & Belt System, Final Drive & 4WD System, Transmission Chassis And Body: Body & Steering, Brakes Electrical: Electrical System, Wiring Diagrams Procedures Included 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 Technical Depth 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. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: High quality, printable from any computer and printer. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Features Searchability: Keyword searchable for easy information retrieval. Organization: Organized and indexed for ease of use. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, air-cooled single-cylinder. Displacement: 249 cc (Cubic Centimeters) Performance Bore X Stroke: 72.0 x 61.2 mm Compression Ratio: 9.0:1 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 System Fuel Delivery: Carburetor (Likely a Keihin CVK type, specific model number would be in the manual) Fuel Type: Unleaded Gasoline Ignition Ignition System: CDI (Capacitor Discharge Ignition) Lubrication Oil Type: API SG, SF or SE classification, SAE 10W-40 recommended (Specific oil viscosity and API rating to be confirmed in manual). 🔧 Transmission Standard Transmission Type: 5-speed manual with automatic clutch Optional Optional Transmission: N/A (The Bayou 250 primarily featured the 5-speed manual). Features 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 Fluid Specifications Transmission Oil Type: Kawasaki Genuine Transmission Oil or equivalent SAE 80W-90 hypoid gear oil (Specific type and capacity to be confirmed in manual). 📐 Dimensions Exterior Length: Approx. 74.8 in (1895 mm) Width: Approx. 41.7 in (1060 mm) Height: Approx. 44.1 in (1120 mm) Weights Dry Weight: Approx. 448 lbs (203 kg) Fuel Capacity: 3.1 US gal (11.7 L) Wheelbase Wheelbase: Approx. 47.2 in (1200 mm) Ground Clearance Ground Clearance: Approx. 6.1 in (155 mm) 🛡️ Safety Features Ratings Atv Safety Standards: Designed to meet industry safety standards for ATVs of its era....