MODEL APPLICATION Year Model Beginning Frame No. 1989 KLF300-C1 JKALF8C1 oKB50001 ,or LF300C-60000 1 1990 KLF300-C2 JKALF8C1 oLB507501 ,or LF300C600951 1990 KLF300-C2A JKALF8C10LB511551 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-C7 IC7 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 JKALF8C10YB571101,JKALF8C10XB57901 or 2000 KLF300-C12 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 o:This digit in the frame number changes from one machine to another.
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 tab le of contents page. eRefe r to the sectional table of contents for the exact pages to locate the spec if ic topic o r procedure requ ired. Quick Reference Guide JL General lnfo rm at ion_____----.JD I Fuel System .:w K:iI I Engine Top End .:II L- Ell Engine Left Side Engine Right Side Engine Removal/Installation Engine Bottom End/Transmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System Appendix
KaVlasaki KLF300 All Terrain Vehicle Service Manual
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 i ng systems They are designed to give optimum per- A 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. , d";,. JI).xt't it r •. tI '! 'It ';;o¥'!. ""... ". ,..... ,," nA ...." II ." "......." "'" .. :?<''i. R if hgft°CABDCAACATDCBBDCBDCBTDCDCFOFL CONTAINSWARNINGASBESTOS Breathing asbestos dust is dangerous to health Fol low safety instructions This w,arning may app l y to any of the following components o r any assembly containing one or more of these components: Brake Shoes or Pads C l utch Friction Material Gaskets SAFETYInsulators 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. LIST OF ABBREVIATIONS ampere(s) Ib pound(s) after bottom dead center m meter(s) alternating current min minute(s) after top dead center N newton(s) before bottom dead center Pa pascal (s) bottom dead center PS horsepower before top dead center psi pound(s) per square inch degree(s) Celsius r revolut i on direct current rpm revolution(s) per minute farad(s) TDC top dead center degree(s) Fahrenheit TIR total indicator reading foot, feet V volt(s) gram(s) W watt(s) hour(s) S1 ohm(s) Readliter(s)OWNER'S MANUAL before operating
Foreword
. 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.Toget the longest life out of your vehicle : -Follow the Periodic Maintenance Chart in the Service Manual. -Be alert for problems and non-scheduled -Usemaintenance.propertools 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.Ifyou 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. o This warning symbol identifies special instruc tions 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.
NOTE o This note symbol indicates points of particular interest for more efficient and convenient operation.
This manual contains five more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information .
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
-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
(6) EdgesWatch 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.
(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) .
(7) High-Flash Point Solvent
(3) Tighten ing Generally,Sequencewheninstalling 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 .
(10) PressA 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.
(b) sparks at electrical connections which will occur when they are disconnected.
(-) 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.
Especially note the following:
(11) BallWhenBearinginstalling 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.
(2) BatteryRemoveGroundtheground
(c) damage to electrical parts.
1-2 GENERAL INFORMATION BeforeBeforeServicingstarting to service a vehicle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.
(1) DirtBefore 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
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
(4) TorqueWhen 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) ForceCommon 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.
Wire (cross-section) Name of Wire Color e: RedWire strands r 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.
(12) Oil Seal and Grease Seal
(14) Circlip, Retaining Ring
(18) InspectionWhenparts 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 Bent Dent Scratch Wear Color change Deterioration Seizure (19) SpecificationsSpecification 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.
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.
GENERAL INFORMATION 1-3
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.
(15) LubricationEnginewear
(16) Electrical Wires
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.
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 (13) Seal Guide
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.
1-4 GENERAL INFORMATION Model KLF300-AIdentification1LeftSide 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 PerformanceDimensions:ItemsOveralllengthOverallwidthOverallheightWheelbaseGroundclearanceSeatheightDryweightCurbweight:FrontRearFueltankcapacity:MinimumturningradiusEngine:TypeCoolingsystemBoreandstrokeDisplacementCompressionratioMaximumhorsepowerMaximumtorqueCarburetionsystemStartingsystemIgnitionsystemTimingadvanceIgnitiontimingSparkplugValvetiming:InletExhaustLubricationsystemEngineoil:Grade ®: U K. Models CapacityViscosity CloseCloseOpenDurationOpenDuration KL F300-A 1, A2 1,B50 226750mm1,100mmmm1,045mm1,200mm195mmkg,@ © 223 kg 109.5 kg, @ © 10B 5 kg 126.5 kg, @ © 124.5 kg B.2 L 3.0 m (Locked axle mode) 2 . 6 m (Differential mode) 4-stroke, SOHC , 1·cylinder Air 76.0cooledx64.0 mm 290 mL B.615.4 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 2r BTDC 65° 62°272°ABDCBBDC30°ATDC272°Forcedlubrication (wet sump) SE or SF class SAE 10W 30 , 10W-40, 1OW-50, 20W-40, 20W-50 1.7 L (Continued on next page.) © : Canadian Models @: U.S. Models
GENERAL INFORMATION 1-7 Items KLF300-A 1, A2 DrivePrimaryTrain:reduction system: Type Gear Reduction ratio 2 888 (78127) Clutch Transmission:type Type SecondaryPrimary Gear ratios: 1st Final drive system: Overall drive ratio Final gear case oil : Frame:TypeCaster (rake angle) CamberTrailTreadFronttire: SizeType Rear tire: SizeType Suspension : FrontRear Brake type: FrontRear Electrical Equipment: TaillightHeadlight:BatteryAlternator: TypeBulbType 3rd2nd4th5thReverseTypeReduction ratio TypeCapacityTypeWheeltravelTypeWheeltravel Rated output Voltage regulator: Type 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) Shaft4_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 DoubleL tubular 0.8°4° @lG 17 Semi-sealed830mmmmTubeless22x9_00-10Tubeless24x11.00-10Doublewishbone-link115mmTorquetube-link120mmDrum(Hydraulic)Drum(Mechanical)12V19Ahbeam12V60W12V8Wx2Three-phaseAC23.5A@9,000r/min (rpm), 14 V Short-circuit Specifications are subject to change without notice, and may not apply to every country.
Thank you very much for your reading. Please Click Here. Then Get COMPLETE IfNOTE:MANUAL.NOWAITINGthereisnoresponse to click on the link above, please download the PDF document first and then clickonit.
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 lock ing agent or liquid gasket. Letter used in the "Remarks" co lu mn means: L : App ly a non-permanent lock i ngagentto the threads. o : App ly an oil to the threads and seated surface. S : T ighten the faste ners fo ll ow in g the specified sequence. St : Stake the fasteners to prevent loosening, Fastener Engine Top End: Cylinder Head Bolts: Cylinder Bolt 6mm8mm Valve Clearance Adjusting Screw CamshaftLocknutsSprocket 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 EngineEngineRemoval/Installation:MountingBolts: 8 10mmmm 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:WheelNutsFrontHub Nuts 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.BasicTorque for General Fasteners Th r ead dia. (mm) N-m 125.41291212129.84929 78 83342512252012121717 78 3434 141085612161820 2251155_93.4N-m4.97_814-19253444-6173-98'-155165225325 kg-mTorque1.2 3.01_2 1.2 13.03.04.21.05.08.01.2253.5252.01.21.21.71.78.58.03.535 Torque 11.50.35kg-m0500_60-0_801.41.92.6354.56_27.4-10_016_017.0232333 ft-Ib 104 in-Ib 22 104 in Ib 104 in-Ib 30 87 in-Ib 36 22 9458104 in-Ib 2518.018.014.5104 in-Ib 104 in-Ib 12.012.0 61 582525 ft-Ib 30 43 in- Ib 52 69 in-Ib 10_016512519_0-25135334554-7283-115-165-240 Remarks SS L oo LL oo
GENERAL INFORMATION 1-9 Fastener Torque Remarks N-m kg-m ft-Ib FinalFrontDrive:Gear Case Bolts (8 mm) 25 2.5 18.0 Output Shaft LH Bearing Housing ,Bolts 12 1.2 104 in Ib LH Bearing Holder 98 10 0 72 St Drive Gear Nut: 14 mm (when 16 mm) 88 (93) 9.0(9.5) 65 (69) 0 Driven Gear Nut 78 8.0 58 0 Driven Gear Shaft Oil Sea l Housing Nuts 25 2.5 18.0 Front Gear Case Pl ug (Odometer Gear 20 2.0 14.5 Holder: Option) Propeller Shaft Housing Nuts 25 2.5 18.0 Axle Shaft Pipe Bolts 20 2.0 14.5 Pinion Gear Nut 78 8.0 58 0, St Ring Gear and Differential 29 3.0 22 L Gear Housing Bolts Final Gear Case Cover Bolts 25 2.5 18.0 Final Gear Case Filler Cap 29 3.0 22 Final Gear Case Drain Plug 20 2.0 14.5 Differential Shift Fork Holder Screws 6.9 0.70 61 in-Ib Brakes:Master Cylinder Clamp Bolts 11 1.1 95 in-Ib S Brake Lever Pivot Nut 5 9 0.60 52 in-Ib Wheel Cylinder Bolts 7.8 0.80 69 in-Ib Shoe Adjuster Bolts 7.8 0.80 69 in Ib Brake Panel Mounting BoltsFront: 20 2.0 14.5 Rear 29 3.0 22 Rear A xle Nuts 145 15.0 110 B rake Hose Banjo Bolts 25 2.5 18.0 Brake Pipe Nipple 20 2.0 14 5 Brake Pedal Nut 29 3.0 22 Suspension:ShockAbsorber Mounting Bolts 34 3.5 25 Suspension Arm Pivot Bolts: 10mm 34 3.5 25 12 mm 88 9.0 65 Steering:Handlebar Holder Bolts 20 2.0 14.5 S Stem Clamp Allen Bolts 20 2.0 14 . 5 Stem Bottom End Nut 29 3.0 22 Stem Bearing Housing Bolts 20 2.0 14 5 Tie-rod End Nuts 41 4.2 30 Tie-rod Adjusting Sleeve Locknuts 29 3.0 22 Knuckle Arm Pivot Nuts 41 4 . 2 30 Electrical System : Alternator Rotor Bolt 59 6 0 43 Spark Plug 27 2 8 20 Neutral and Reverse Indicator Switch LMounting Screws
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. • = Clean, adjust, lubricate, tighten, or replace parts as necessary. ChassisBrake: adjustment check ' Brake wear check ' Brake fluid level check Brake fluid change Master cylinder cup and dust seal Wheelreplacecylinder 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 c heck 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 First Service Regular Service • • • • • • 2 years 2 years 2 years • • • • • • • • • • • • • • • • • • • • • • • • • • 'Service more frequently when operated in mud, dust, or other harsh riding conditions
