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1986-2006 Kawasaki Bayou 300 Service Manual

   (4 reviews)

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About This File

This service manual is for a 1986-2006 Kawasaki Bayou 300.

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Christi Enslin

   3 of 3 members found this review helpful 3 / 3 members

Yip, still have to post to get access to this file. Trouble with 300 Bayou no spark

Link to review
Anthony Thayer

   0 of 1 member found this review helpful 0 / 1 member

Very confusing website

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If you need assistance, please feel free to reach out.

  • Confused 1
Link to review
Kurtis Cosner

   0 of 1 member found this review helpful 0 / 1 member

I am working on this KLF300B shaft drive with locking rear-end, that has a hack job of wiring to at with I can not find a wiring diagram for it.... 

 Oh!! The kicker is that I have no clue to at which year it is...  Can not find a VIN number on bike frame at all... 

      Looking for some help here...        Thanks.. 

Link to review
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    • By Nickpeterkin1981
      Need help have no power to anything i can jump starter solenoid but no spark at plug no neutral lights or anything no power to anything passed the starter solenoid neutral switch is good 
    • By oxidized_black
      View File 1988-2002 Kawasaki Bayou 220 Service Manual
      1988-2002 Kawasaki Bayou 220 Service Manual
      The Kawasaki Bayou 220 is one of the most common all-terrain vehicles on off-road trails that is geared toward novice riders and families. It’s also one of the smallest and most inexpensive ATVs on the market, with a retail price under $3,500, as of 2010. The Bayou 220 is Kawasaki’s only ATV of its size. The 220’s sibling is the larger Bayou 250 equipped with a 228cc engine.
      Engine
      The Bayou 220’s engine is a 215cc, four-stroke, shaft-driven, air-cooled model. Its bore measures 2.6 inches and the stroke is 2.4 inches. It features a relatively high 9.3:1 compression ratio with fuel delivered through a Mikuni VM24SS carburetor. The electronic ignition is Kawasaki’s DC-CDI. It also features a recoil backup as a starting system. The clutch is an automatic wet multidisc model with power delivered to the wheels via a five-speed transmission, according to ATV Source.
      Chassis
      The steel frame supports a front suspension with single A-arms and twin shock absorbers, with the rear suspension a Quad-Link system with two shocks. Front wheel travel is 4.5 inches, while the rear wheel travel measures at 4.9 inches. Front and rear brakes are drums.
      Size
      The front tire size is AT21X8-9 with the rear tires measuring AT22X10-10. The ATV’s wheelbase is 43.9 inches, with an overall length of 68.7 inches. Ground clearance is 6.1 inches with the seat height measuring 28.7 inches. It weighs 403 lbs. and can tow up to 450 lbs. Its fuel tank can carry 2.6 gallons.
      Basics
      The Kawasaki Bayou 220 is not the fastest ATV on the market, but one reason the Bayou 220 has kept its price low is the lack of amenities. It features a brake light and dual headlamps with high/low beam. There is an auxiliary lighting terminal inside the front cover of the ATV and electrical accessory terminals under the seat. The instrument cluster atop the fuel tank features a fuel gauge, but not much else. There are no speedometer, odometer, hourmeter, tripmeter, high-beam indication or high-temperature light. It does have a reverse/neutral indicator light. The Bayou comes in two colors: hunter green and firecracker red.
      Features
      The front A-arm, twin shock and rear Quad-Link twin-shock suspension system is not a true fully independent system, but it allows for a comfortable ride over rough terrain without employing a complex and expensive, fully independent suspension system. The ATV features front and rear steel cargo racks. The ATV is rider-friendly with a limited adjustable throttle to help novices practice their riding skills without twisting the throttle too far and losing control of the vehicle.
      Submitter oxidized_black Submitted 12/14/2016 Category Kawasaki ATV  
    • By oxidized_black
      Also available on eManualOnline
      1988-2002 Kawasaki Bayou 220 Service Manual
      The Kawasaki Bayou 220 is one of the most common all-terrain vehicles on off-road trails that is geared toward novice riders and families. It’s also one of the smallest and most inexpensive ATVs on the market, with a retail price under $3,500, as of 2010. The Bayou 220 is Kawasaki’s only ATV of its size. The 220’s sibling is the larger Bayou 250 equipped with a 228cc engine.
      Engine
      The Bayou 220’s engine is a 215cc, four-stroke, shaft-driven, air-cooled model. Its bore measures 2.6 inches and the stroke is 2.4 inches. It features a relatively high 9.3:1 compression ratio with fuel delivered through a Mikuni VM24SS carburetor. The electronic ignition is Kawasaki’s DC-CDI. It also features a recoil backup as a starting system. The clutch is an automatic wet multidisc model with power delivered to the wheels via a five-speed transmission, according to ATV Source.
      Chassis
      The steel frame supports a front suspension with single A-arms and twin shock absorbers, with the rear suspension a Quad-Link system with two shocks. Front wheel travel is 4.5 inches, while the rear wheel travel measures at 4.9 inches. Front and rear brakes are drums.
      Size
      The front tire size is AT21X8-9 with the rear tires measuring AT22X10-10. The ATV’s wheelbase is 43.9 inches, with an overall length of 68.7 inches. Ground clearance is 6.1 inches with the seat height measuring 28.7 inches. It weighs 403 lbs. and can tow up to 450 lbs. Its fuel tank can carry 2.6 gallons.
      Basics
      The Kawasaki Bayou 220 is not the fastest ATV on the market, but one reason the Bayou 220 has kept its price low is the lack of amenities. It features a brake light and dual headlamps with high/low beam. There is an auxiliary lighting terminal inside the front cover of the ATV and electrical accessory terminals under the seat. The instrument cluster atop the fuel tank features a fuel gauge, but not much else. There are no speedometer, odometer, hourmeter, tripmeter, high-beam indication or high-temperature light. It does have a reverse/neutral indicator light. The Bayou comes in two colors: hunter green and firecracker red.
      Features
      The front A-arm, twin shock and rear Quad-Link twin-shock suspension system is not a true fully independent system, but it allows for a comfortable ride over rough terrain without employing a complex and expensive, fully independent suspension system. The ATV features front and rear steel cargo racks. The ATV is rider-friendly with a limited adjustable throttle to help novices practice their riding skills without twisting the throttle too far and losing control of the vehicle.
    • By Mouckster
      I just bought a 91 and when I went to change the oil in the rear diff it had water in it (milky oil). There are no leaks in the seals so I think it's coming in the vent tube. Thing is I can't find it. Anyone know where it is. 
       
      Thanks
       
    • By Machias_Mike
      Hi there!
      We just bought 4 acres and needed a work rig for moving stuff around and blazing trails. Been looking at buying a quad for a long time and finally got the opportunity.  Found a very good condition 1994 Kawi Bayou 300 4x4.  Runs great and seems to be in great operating condition with one little thing.
      The unit seems to have an issue with reverse.  Previous owner did tell me about it and its totally usable but the issue is annoying enough that I want to try and fix it.  Im pretty mechanical oriented so don’t think this will (hopefully) be too much of an issue.  I bought the kawasaki shop manual on ebay and should be here next Friday but wanted to get a head start on it.
       
      The issue seems to be similar to this post but I think may be more mechanical than just the switch.
      https://www.quadcrazy.com/atvforum/topic/14281-1994-bayou-220-neutral-safety-switch/
       
      Here goes!
       
      Neutral light is always on when key in on position I found that the green wire coming out of the block from neutral switch is grounded to chassis.  When plugged in to switch light never turns on no matter what gear its in (and wont start). Machine can go from 1st directly into Reverse if you don’t feather it.  This is the part that that makes me want to fix it.  I feel like its dangerous and could possibly do some damage.  It usually takes 3-4 tries to 'find' neutral.   The reverse turn knob seems to be operable and cable is connected and operates the reverse 'selector' when turned.  Springs back when released both at the switch and at the 'selector' inboard of the shifter. When in reverse the red reverse light does not illuminate Based on above and looking at the post above it seems that this would indicate that the reverse stopper is 'broken' and rotated in an 'in gear' position.  I see a few posts on here where people have said it can crack.  If I plug the green wire back in and turn machine to 'on' I can move the shifter through all gears and the neutral light and reverse light stay off.  Again, to me it seems that the 'reverse stopper' is probably broken, stuck where the switch thinks its in a forward gear and the shaft is probably just spinning inside it.
       
      Am I on the right track here?
      I wanted to get a head start on this and looking at parts diagrams it looks like the part number for the 'reverse stopper' is 13091-1443, found one on ebay for $30 shipped.  I hate buying parts before tearing it down but if this is the likely culprit I would take a $30 gamble to buy it so I can have it on hand when the manual arrives.
       
      The other question I have which I hope is an easy answer is none of the parts diagrams I have found show the bevel gear gasket part number.  Can anyone tell me what the part number is for this?
       
      Many, many thanks for the info and I promise to post pics once I have it apart.
       
       




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