Page 1

MODEL APPLICATION Beginning Frame No.

Year

Model

1989

KLF300-C1

JKALF8C1 oKB50001 ,or LF300C-60000 1

1990

KLF300-C2

JKALF8C1 oLB507501 ,or LF300C600951

1990

KLF300-C2A

1991

KLF300-C3

JKALF8C1 OMB515401, or LF300C-602101

1992

KLF300-C4

JKALF8C1 ONB521201, or LF300C-603201

1993

KLF300-C5

JKALF8C1 OPB527201 ,or LF300C-603651

1994

KLF300-C6

JKALF8C10RB532701

1995

KLF300-C7IC7 A

JKALF8C1 08B540601 ,or LF300C-604701

1996

JKLF300-C8

JKALF8C1 oTB548951 ,or LF300C-605801

1997

KLF300-C9

JKALF8C1 OVB557001, or LF300C-606501

1998

KLF300-C10

JKALF8C1 oWB563201 ,or LF300C-607501

1999

KLF300-C11

JKALF8C10XB57901

2000

KLF300-C12

JKALF8C10YB571101, or JKLF8C1 OYB576901, or JKALF300CCB609501

2001

KLF300-C13

JKALF8C1 0lB5821 01 , or JKALF300CCB61 0501

2002

KLF300-C14

JKALF8C102B590201, or JKALF300CCB611301

2003

KLF300-C15

JKALF8C1 03B593501 ,or JKALF300CCB612001

2004

KLF300-C16

JKALF8C104B596101, or JKALF300CCB612601

2005

KLF300-C17

JKALF8C105B596701, or JKALF300CCB613300

2006

KLF300C6F

JKALF300CCB613901

JKALF8C10LB511551

o:This digit in the frame number changes from one machine to another.

..cKawasaki KAWASAKI HEAVY INDUSTRIES,LTD.

111111111111111111111111111111111111111111111111111111111111111111111111111

*99924·1117·65*

Consumer Products & Machinery Company

Part No.99924-1117-65

Printed in Japan


Quick Reference Guide ¡L J

----.JD

_G_e_n_e_r_ al_l_n_ fo_r_ m_a_t_ io_n_____

I Fuel System L - - ._

_

_

I Engine Top End L . -_

_

_

_

Engine Right Side Engine Removal/Installation Engine Bottom End/Transmission

Final Drive Brakes Suspension Steering This quick reference guide will assist you in locating a desired topic or procedure.

eSend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. eRefer to the sectional table of contents for the exact pages to locate the specif ic topic or procedure requ ired.

Frame Electrical System Appendix

.:II Ell

_

Engine Left Side

Wheels/Tires

.:w K:iI

_


KaVlasaki

KLF300

All Terrain Vehicle Service Manual


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PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM

~

~

(US Model onlyl

~%

To minimize the noise emissions from this product, Kawasaki has equipped it with ~ effective intake and exhaust silenc ing systems. They are designed to give optimum perS~ formance while maintaining a low noise level. Please do not remove these systems, or alter ~ them in any which results in an increase in noise level.

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This w,arning may apply to any of the following components or any assembly containing one or

more of these components: Brake Shoes or Pads Clutch Friction Material

Gaskets Insulators WARNING CONTAINS ASBESTOS

SAFETY INSTRUCTIONS

-Operate if possible out of doors or in a well ventilated place. .Preferably use hand tools or low speed tools equipped, if necessary, with an appropriate dust extraction facility. If high speed tools are used, they should always be so equipped . • If possible, dampen before cutting or drilling . • Dampen dust and place it in properly closed receptacle and dispose of it safely.

Breathing asbestos dust is dangerous to health Fol low safety instructions

LIST OF ABBREVIATIONS A

ampere(s)

Ib

pound(s)

ABDC

after bottom dead center

m

meter(s)

AC

alternating current

min

minute(s)

ATDC

after top dead center

N

newton(s)

BBDC

before bottom dead center

Pa

pascal (s)

BDC

bottom dead center

PS

horsepower

BTDC

before top dead center

psi

pound(s) per square inch

°C

degree(s) Celsius

r

revolution

DC

direct current

rpm

revolution(s) per minute

F OF

farad(s)

TDC

top dead center

degree(s) Fahrenheit

TIR

total indicator reading

ft

foot, feet

V

volt(s)

g

gram(s)

W

watt(s)

h

hour(s)

S1

ohm(s)

L

liter(s)

Read OWNER'S MANUAL before operating

~t,.


Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used , and the use of substitute tools may adversely affect safe operation. For the duration of your warranty period, especially, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: -Follow the Periodic Maintenance Chart in the Service Manual. -Be alert for problems and non-scheduled maintenance. -Use proper tools and genuine Kawasaki vehicle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Special Tool Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. -Follow the procedures in this manual carefully. Don't take shortcuts. _ Remember to keep complete records of maintenance and repair with dates and any new parts installed.

How to Use this Manual In preparing this manual, we divided the product into its major systems. These systems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product's systems and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section. Whenever you see these WARN ING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

I WARNING. oThis warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

o This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains five more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE o This note symbol indicates points of particular interest for more efficient and convenient operation.


-Indicates a procedural step or work to be done. o lndicates a procedural sub¡step or how to do the work of the procedural step it follows . It also precedes the text of a WARNING, CAUTION , or NOTE. *Indicates a conditional step or what action to take based on the results of the test or inspec¡ tion in the procedural step or sub-step it follows. <r Indicates a conditional sub-step or what action to take based upon the results of the conditional step it follows . In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.


GENERAL INFORMATION 1-1

D General Information Table of Contents

Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • .

1·2

Model Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

General Specifications . .......................... . ..........

1-6

Torque and Locking Agent ............... . .... . _. . . . . . . . ... ..

1-8

Periodic Maintenance Chart. . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . .

1-10


1-2 GENERAL INFORMATION

Before Servicing Before eliminate criptions tations, a

starting to service a vehicle, careful reading of the applicable section is recommended to unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed deshave been included wherever necessary. Nevertheless, even a detailed account has limicertain amount of basic knowledge is also required for successful work.

Especially note the following: (1) Dirt Before removal and disassembly, clean the vehicle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the vehicle. For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground Remove the ground (-) lead from the battery before performing any disassembly operations on the vehicle. This prevents: (a) the possibility of accidentally turning the engine over while partially disassembled. (b) sparks at electrical connections which will occur when they are disconnected. (c) damage to electrical parts. (3) Tighten ing Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when .loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated . (4) Torque When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. (5) Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem . Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads. (6) Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. (7) High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name) . Always follow manufacturer and container directions regarding the use of any solvent. (B) Gasket, O-Ring Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. (9) Liquid Gasket, Non-Permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in North America is Loctite Lock'n Seal (Blue) . (10) Press A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly. (11) Ball Bearing When installing a ball bearing, the bearing race which is affected by friction should be pushed by a su itable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented . Press a ball bearing until it stops at the stop in the hole or on the shaft.


GENERAL INFORMATION 1-3 (12) Oil Seal and Grease Seal

(13)

(14)

(15)

(16)

Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction. Circlip, Retaining Ring Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Lubrication Engine wear is generally at its maximum wh il e the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum disulfide grease (MoS,) in the assembly of certain engine and chassis parts. Always check manufacturer recommendations before using such special lubricants. Electrical Wires All the electrical wires are either single-color or two-color and, with on ly a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two¡color wire is identified by first the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a "yellow/ red" wire; it would be a "red/ yellow" wire if the colors were reversed to make red the main color. Wire (cross-section)

e:

~~ ....

r '"

Name of Wire Color

Red Wire strands Yellow/ red f--

Yellow Red

(17) Replacement Parts When there is a replacement instruction , replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed. (18) Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Scratch Wear Bent Dent Color change Deterioration Seizure (19) Specifications Specification terms are defined as follows. "Standards" show dimensions or performances which brand-new parts or systems have. "Service limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.


1-4 GENERAL INFORMATION Model Identification

KLF300-A 1 Left Side View:

KLF300-A 1 Right Side View:


GENERAL INFORMATION 1-5 KLF300-A2 Left Side View

KLF300-A2 Right Side View


1-6 GENERAL INFORMATION General Specifications

Items

KL F300-A 1, A2

Dimensions: Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight : Front Rear Fuel tank capacity

1,B50 mm 1,100mm 1,045 mm 1,200 mm 195 mm 750mm 226 kg, @ © 223 kg 109.5 kg, @ © 10B.5 kg 126.5 kg, @ 124.5 kg B.2 L

©

Performance : Minimum turning radius

3.0 m (Locked axle mode) 2.6 m (Differential mode)

Engine: Type Cool i ng system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system I gn ition system Timing advance Ignition timing Spark plug Valve timing:

Inlet

Exhaust

Lubrication system Engine oil: Grade Viscosity Capacity

Open Close Duration Open Close Duration

4-stroke, SOHC, 1·cylinder Air cooled 76.0 x 64.0 mm 290 mL B.6 15.4 kW (21 PS) @7,OOO r/min (rpm). @ © 22.6 N-m (2.3 kg-m , 16.6 ft-Ib) @6,OOO r/min (rpm). @ © Carburetor, Keihin CVK32 Electric starter Battery and coil (Transistorized) Electronically advanced From 10° BTDC @1,300 r/min (rpm) to 400 BTDC @4,OOO r/min (rpm) NGK BBES, BRBES BTDC 65° ABDC 272° 62° BBDC 30° ATDC 272° Forced lubrication (wet sump) SE or SF class SAE 10W-30 , 10W-40, 1OW-50, 20W-40, 20W-50 1.7 L

2r

©®

(Continued on next page.)

®: U.K. Models

© : Canadian Models

@:

U.S. Models


GENERAL INFORMATION 1-7 Items

KLF300-A 1, A2

Drive Train: Primary reduction system: Type Reduction ratio Primary Clutch type Secondary Transmission: Type Gear ratios: 1st 2nd 3rd 4th 5th Reverse Final drive system: Type Reduction ratio Overall drive ratio Type Final gear case oil : Capacity

Gear 2_888 (78127) Auto centrifugal, wet Auto multi disc, wet 5-speed plus reverse, constant mesh, return shift 3_090 (34/11) 1_928 (27/14) 1_368 (29/19) 1_000 (23123) 0_769 (20/26) 3_072 (26/11 x 26/20) Shaft 4_886 (20/16 x 43/11) 10_858 @Top gear API GL-5 Hypoid gear oil SAE 90 (above 5° C, 41 ° F) or SAE 80 (below 5°C, 41°F) 0_3 L

Frame: Type Caster (rake angle) Camber Trail Tread Front tire: Type Size Rear tire: Type Size Front Suspension : Rear Brake type:

Type Wheel travel Type Wheel travel

Front Rear

Electrical Equipment: Battery Headlight: Type Bulb Taillight Type Alternator: Rated output Voltage regulator: Type

Double tubular 4° 0.8° @lG 17 mm 830mm Tubeless 22 x 9_00-10 Tubeless 24 x 11.00-10 Double wishbone-link 115 mm Torque tube-link 120 mm Drum (Hydraulic) Drum (Mechanical) 12 V 19 Ah Semi-sealed beam 12 V 60W 12V8Wx2 Three-phase AC 23.5 A@9,000 r/ min (rpm), 14 V Short-circuit

Specifications are subject to change without notice, and may not apply to every country.


1-8 GENERAL INFORMATION

............................................................................ Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket.

Use the basic torque table below for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. Basic Torque for General Fasteners Torque

Th read dia. (mm)

Letter used in the "Remarks" colu mn means: L : App ly a non-permanent lockingagentto the threads. o : App ly an oil to the threads and seated surface. S : Tighten the faste ners fo ll owing the specified se-

5 6 8 10 12 14 16 18 20

quence.

St : Stake the fasteners to prevent loosening,

N-m

kg-m

3.4 - 4.9 5_9 - 7_8 14 -19 25 - 34 44 -61 73 -98 115 '- 155 165 - 225 225 - 325

0.35 - 050 0_60 -0_80 1.4 - 1.9 2.6 - 35 4.5 - 6_2 7.4-10_0 11.5 - 16_0 17.0 - 23 23 - 33

ft-Ib 30 - 43 in- Ib 52 - 69 in-Ib 10_0 - 135 19_0-25 33 - 45 54 -72 83 -115 125 -165 165 -240

Torque Fastener Engine Top End: Cylinder Head Bolts:

6mm 8mm

Cylinder Bolt Valve Clearance Adjusting Screw Locknuts Camshaft Sprocket Bolt Camshaft Chain Guide Pivot Bolt Engine Left Side: Starter Clutch Allen Bolts Engine Right Side: Oil Drain Plug Primary Clutch Hub Nut Secondary Clutch Hub Nut Secondary Clutch Spring Bolts Engine Removal/Installation: 8 mm Engine Mounting Bolts: 10mm Engine Mounting Bracket Bolts Engine Bottom End/Transmission: Oil Pipe Banjo Bolts Shift Drum Stopper Bolt Shift Drum Pin Plate Bolt Shift Shaft Return Spring Pin Clutch Release Cam Pin Balancer Gear Nut Balancer Drive Gear and Oil Pump Drive Gear Nut Wheels/Tires: Wheel Nuts Front Hub Nuts

N-m

kg-m

ft-Ib

12 29 12

1.2

104 in-Ib

3.0

22

1_2

104 in-Ib

1.2

104 in-Ib

4.2 1.0

30

9.8 49

5.0

36

29 125

3.0

22

13.0

78

8.0

94 58

12

1.2

104 in-Ib

25 34 25

2.5 3.5 2.5

18.0

20 12 12

2.0 1.2 1.2

17 17 83

12 .41

Remarks

S S

87 in-Ib L

o o

25 18.0

1.7 1.7 8.5

14.5 104 in-Ib 104 in-Ib 12.0 12.0

L L

61

o

78

8.0

58

o

34 34

3.5 3.5

25 25


GENERAL INFORMATION 1-9

N-m

Torque kg-m

25 12 98 88 (93) 78 25

2.5 1.2 10.0 9.0(9.5) 8.0 2.5

72

St

65 (69) 58 18.0

0 0

20

2.0

14.5

25 20 78

2.5 2.0 8.0

18.0 14.5 58

0, St

29

3.0

22

L

25 29 20 6.9

2.5 3.0 2.0 0.70

18.0 22 14.5 61 in-Ib

11 5.9 7.8 7.8

1.1 0.60 0.80 0.80

95 52 69 69

20 29 145 25 20 29

2.0 3.0 15.0 2.5 2.0 3.0

14.5 22 110 18.0 14.5 22

Suspension: Shock Absorber Mounting Bolts Suspension Arm Pivot Bolts: 10mm 12 mm

34 34 88

3.5 3.5 9.0

25 25 65

Steering: Handlebar Holder Bolts Stem Clamp Allen Bolts Stem Bottom End Nut Stem Bearing Housing Bolts Tie-rod End Nuts Tie-rod Adjusting Sleeve Locknuts Knuckle Arm Pivot Nuts

20 20 29 20 41 29 41

2.0 2.0 3.0 2.0 4.2 3.0 4.2

14.5 14.5 22 14.5 30 22 30

59 27

6.0 2.8

43 20

-

-

-

Fastener Final Drive: Front Gear Case Bolts (8 mm) Output Shaft LH Bearing Housing ,B olts LH Bearing Holder Drive Gear Nut: 14 mm (when 16 mm) Driven Gear Nut Driven Gear Shaft Oil Sea l Housing Nuts Front Gear Case Plug (Odometer Gear Holder: Option) Propeller Shaft Housing Nuts Axle Shaft Pipe Bolts Pinion Gear Nut Ring Gear and Differential Gear Housing Bolts Final Gear Case Cover Bolts Final Gear Case Filler Cap Final Gear Case Drain Plug Differential Shift Fork Holder Screws Brakes: Master Cylinder Clamp Bolts Brake Lever Pivot Nut Wheel Cylinder Bolts Shoe Adjuster Bolts Brake Panel Mounting Bolts: Front Rear Rear A xle Nuts B rake Hose Banjo Bolts Brake Pipe Nipple Brake Pedal Nut

Electrical System : Alternator Rotor Bolt Spark Plug Neutral and Reverse Indicator Switch Mounting Screws

ft-Ib

Remarks

18.0 104 in-Ib

in-Ib in-Ib in-Ib in-Ib

S

S

L


1-10 GENERAL INFORMATION Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The first service is vitally important and must not be neglected.

First Service

Regular Service

• = Clean, adjust, lubricate, tighten, or

replace parts as necessary.

Chassis : Brake adjustment - check' Brake wear - check ' Brake fluid level - check Brake fluid - change Master cylinder cup and dust seal - replace Wheel cylinder piston seal and dust seal - replace Brake hose - replace Cable adjustment' Steering play - check Final gear case oil - change' General lubrication " Bolts and nuts - tighten Battery - check Engine: Clutch adjustment' Valve clearance - check Fuel system cleanliness - check' Air cleaner - service' Engine oil - change' Oil filter - change' Spark plug - clean and gap Spark arrester - clean

• •

• •

• 2 years 2 years 2 years

• • •

• •

• • • • • • •

• •

• •

• • • • • •

'Service more frequently when operated in mud, dust, or other harsh riding conditions.


FUEL SYSTEM 2-1

Fuel System Table of Contents Exploded View . . . . . . . . . . . . • . . . . . • . . . .

2-2

Fuel System Cleanliness Inspection . . • . . . 2-10

Specifications

.... . ... . . . . . . . . . . . . . . . .

2·3

Carburetor Removal . . . . . . . . . . . . • . . . 2-10

. _ .. __ .. _ ......• _ . . . . . . . _

2-3

Carburetor Installation

2-10

2-4

Carburetor Disassembly

2-10

Special Tool

Throttle Case and Cable . . . . . . . . Throttle Lever Free Play Inspection . . . . ..

204

Carburetor Assembly . . . . . . . .... . ... . 2·11

Throttle Cable Adjustment . . __ .... ___ .

2-4

Carburetor Cleaning . . . . . . . . ... . . . . . 2-12

Throttle Case Removal/Disassembly. . . . ..

2-4

Carburetor Inspection . ... ... . . . . . . . . 2-12

Throttle Case Assembly/Installation. . . . ..

2-4

Air Cleaner . _ . . . . . . __ .. _ . _ ... _ ...•... 2-13

Throttle Cable Removal .... __ . ______ .

2-5

Air Cleaner Element Removal . . . . . . • ... 2-13

Throttle Cable Installation . _ ... _ .... _.

2-5

Air Cleaner Element Installation . ... • ... 2-14

Throttle Case and Cable Lubrication

2·5

Air Cleaner Removal . . . . . . . . . . . . . . . . 2-14

Throttle Case Inspection .

2-6

Air Cleaner Installation .. . . . . . . . . .... 2-14

Throttle Cable Inspection.

2-6

Air Cleaner Element Cleaning . .... . .... 2-14

Choke Lever and Cable . . . . . . . . . . . . . . . .. .

2-6

Air Cleaner Element Inspection

Choke Lever and Cable Removal . . . . . . . .

2-6

and Replacement . . . . . . . . . . . . . . . . 2·15

Choke Lever and Cable Installation

2-7

Fuel Tank. _ .... __ .. __ . .• . . . . . . . . . ... 2-15

Choke Lever and Cable Lurbication

2-7

Fuel Tank Removal .. . _ . . . . . . . . . . . . . 2-15

Choke Cable Inspection. . . . . . . . . . . • ..

2-8

Fuel Tank Installation . . . . . • . . . . . . . . . 2-15

. . . . . . . . . . . . . . . . . . . . . . . . ..

2-8

Fuel Tap Removal

Carburetor Pilot Screw Adjustment. . . . ..

2-8

Fuel Tank Inspection .... _ . _ ... . .... 2-16

Idle Speed Adjustment _ . _ . . . . . . . . . ..

2-9

Fuel Tank and Tap Cleaning .... _ .. • . _ . 2-16

Fuel Level Inspection ... . . . . . . . . . . ..

2 ·9

Fuel Tap Inspection .... _ . . . . . . _ •.. . 2-16

Fuel Level Adjustment . . . . . .. .. . . . ..

2-9

Carburetor

.....

. ... _ . _ •.. _ .. • . .. 2-16


2-2 FUEL SYSTEM

Exploded View

~J

A : Apply adhesive.


FUEL SYSTEM 2-3 Specifications

Item

Standard

Throttle Lever Free Play Carburetor:

2-3mm

Make!Type

Keihin/ CVK32

Main Jet (Option)

# 130(# 125,128,132,135)

Main Air Jet

# 100

Jet Needle

N27Q

Needle Jet

#6

Pilot Jet (Option)

# 38 (# 35,40)

Pilot Air Jet

# 140

Pilot Screw

2'/, turns out

Starter Jet (Option)

# 55 (# 58 , 60)

Service Fuel Level (from the bottom edge of carburetor body) Float Height Air Cleaner Element Oil: Grade Viscosity

............................................................. ...... ......... Special Tool Alo ng with comm on ha nd tools, th e following more specialized too l is required for complete fue l system servicing.

Fuel Level Gauge: 57001·1017

0_5 mm below - 1.5 mm above 17.0 ±2 mm SE class SAE30


2-4 FUEL SYSTEM Throttle Case and Cable

Throttle Lever Free Play Inspection -Check throttle lever free play. *If free play is not within spec ifications, adjust the

throttle cable (see Throttle Cable Adjustment).

Throttle Lever Free Play Standard:

2-3mm A. Throttle Case Screws

o Pul1 the cable tip from the throttle lever catch. a loosen the locknut and unscrew the adjuster.

A. Throttle Lever Free Play B. Adjuster

C. Locknut

Throttle Cable Adjustment

A. Cable Tip

D. Throttle Lever Bolt

B. Locknut C. Ad ju ster

E. Limiter Screw

F. Grommet

_Slide the cable adjuster dust cover out of place. eTurn the adjuster until throttle lever free play is correct.

Turning the adjuster "out" (lengthening the adjuster) will reduce free play. -Slide back the dust cover.

eDisassemble the throttle case. ORemove the throttle lever bolt, lockwasher, and flat

washer, and lift the throttle lever and return spr ing from the case. The control lever pivot bushing comes

off with the lever. NOTE

Olf the throttle cable cannot be adjusted by using the adjuster at the throttle case~ use the adjuster at the carburetor. Do not forget to securely tighten the adjuster mounting nuts.

OLoosen the locknut and unscrew the throttle limiter screw. o Pull the throttle control lever out of the case.

Throttle Case Assembly/Installation Throttle Case Removal/Disassembly eRemove the throttle case. oRemove the throttle case screws and pull the case open.

oSlide the cable adjuster dust cover out of place, and take off the grommet.

_Throttle case assembly/installation is the reverse of removal/disassembly. Note the following. _Lubricate the throttle case and cable before assembly/ installation (see Throttle Case and Cable Lubrication). eBe certain that the return spring is correctly installed

on the throttle lever.


FUEL SYSTEM 2-5 -Loosen the mounting nuts at the cable lower end adjuster and free the cable from the bracket. eNote cable routing for proper installation, and pull the cable from the vehicle.

-. Throttle Cable Installation

A. Return Spring Hook

eThrottie cab le install ation is the reverse of removal. Note the following. eLubricate the throttle cable before installation (see Throttle Case and Cable Lubrication). eRoute the cab le as shown.

eTighten the throttle lever bolt to 6.9 N-m (0.7 kg-m, 61 in¡lb) of torque . eSwing the throttle co ntrol lever so that the carburetor throttle valve is fully open. Turn the throttle limiter screw until it is spaced about 1 mm away from the throttle lever stop.

I WARNING. COperation with an improperly assembled throttle case could result in an unsafe riding condition.

eAdjust the throttle cable (see Throttle Cable Adjustment). A. Throttle Cable

Throttle Cable Removal eRemove the front fender (see Front Fender Removal in the Frame chapter). eRemove and disassemble the throttle case to free the upper end of the cable from the case (see Throttle Case Removal/ Disassembly) . eSlip the cable lower end out of the pUlley.

I WARNING. <::Operation with an improperly adjusted, incorrectly

routed, or damaged cable could result in an unsafe riding condition.

eAdjust the throttle cable (see Throttle Cable Adjustment).

Throttle Case and Cable Lubrication Whenever the throttle case is disassembled, or in accordance with the Periodic Maintenance Chart, per-

A. Cable End

form the following. eApply a thin coating of multi-purpose grease to the throttle control lever pivot area and the throttle cable ends.


2~

FUEL SYSTEM

A. Apply grease. *If the lever bends, disassemble the throttle case, and clean and iubricate the throttle case (see Throttle Case and Cable Lubrication). -Examine the lever and case for cracks. Replace the case assembly if it is cracked.

Throttle Cable Inspection -With the throttle cable disconnected at the both ends, the cable should move freely within the cable housing.

A. Apply grease.

_Lubricate the throttle cable by seeping the oil between the cable and cable housing.

Cable Lubrication

*If cable movement is not fre e after lu brication (see Throttle Case and Cable Lubrication), if the cable is ¡ frayed, or if the cable housing is kinked, replace the cable.

Choke Lever and Cable

Throttle Case Inspection

Choke Lever and Cable Removal

-With the throttle cable disconnected from the throttle lever, the lever should move freely and return smoothly by spring.

-Remove th e carburetor (see Carburetor Removal). -Unscrew the starter plunger cap and pull out the starter plunger.


FUEL SYSTEM 2-7 ePull the choke lever off the housing, and free the choke cable upper end from the lever. Th.ere i!l the wave washer between the lever and the housing. eNote the choke cable routing for proper installation,

and pull the cable from the vehicle.

Choke Lever and Cable Installation -Choke cable installation is the reverse of removal. Note the following. eLubricate the choke cable before installation (see Choke Cable Lubrication). Do not lubricate the choke lever. eFit the choke cable upper end to the catch on the

A. Starter Plunger Cap

choke lever as shown.

eHold the starter plunger spring compressed, and free the choke cable lower end from the plunger.

A. Choke Cable Upper End

eRoute the choke cable as shown. A. Cable End

B. Starter Plunger

_Unscrew the choke lever mounting screw and take off

the lockwasher and fl at wa sher.

A. Choke Cable

Choke Lever and Cable Lubrication Whenever the choke cable removed, lubricate the choke cable as follows and do not lubricate the choke lever : wave washer betwee n the lever and the housing.

A. Choke Lever

B. Lever Mounting Screw


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1992 Kawasaki KLF300-C4 Bayou 4x4 Service Repair Manual  
1992 Kawasaki KLF300-C4 Bayou 4x4 Service Repair Manual  
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