Kawasaki BAYOU Workhorse KLF Service manual

Kawasaki BAYOU Workhorse KLF · service manual · 322 pages

Kawasaki BAYOU Workhorse KLF
Service manual
322 pages
ATV

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Cylinder Head Bolts (M10), first	12.8 N·m	113 in·lb	p. 23
Cylinder Head Bolts (M10), final	34 N·m	3.5 kgf·m · 25 ft·lb	p. 23
Camshaft Sprocket Bolt	34 N·m	3.5 kgf·m · 25 ft·lb	p. 23
Primary Clutch Hub Nut	127 N·m	13 kgf·m · 94 ft·lb	p. 24
Secondary Clutch Hub Nut	78 N·m	8 kgf·m · 58 ft·lb	p. 24
Balancer Drive Gear Nut	83 N·m	8.5 kgf·m · 61 ft·lb	p. 24
Balancer Gear Nut	118 N·m	12 kgf·m · 87 ft·lb	p. 24
Oil Pipe Banjo Bolts	15 N·m	1.5 kgf·m · 11 ft·lb	p. 24
Engine Drain Plug	29 N·m	3 kgf·m · 22 ft·lb	p. 24
Engine Bracket Bolts and Nuts	26 N·m	2.7 kgf·m · 20 ft·lb	p. 24
Engine Mounting Nuts	39 N·m	4 kgf·m · 29 ft·lb	p. 24
Engine Mounting Nut	29 N·m	3 kgf·m · 22 ft·lb	p. 24
Clutch Release Cam Pin	25 N·m	2.5 kgf·m · 18 ft·lb	p. 24
Return Spring Pin	25 N·m	2.5 kgf·m · 18 ft·lb	p. 24
Wheel Nuts	34 N·m	3.5 kgf·m · 25 ft·lb	p. 24
Rear Axle Nut	8.8 N·m	78 in·lb	p. 24
Rear Axle Nut	147 N·m	15 kgf·m · 108 ft·lb	p. 24
Oil Seal Housing Nuts	25 N·m	2.5 kgf·m · 18 ft·lb	p. 24
Drive Gear Nut	118 N·m	12 kgf·m · 87 ft·lb	p. 24
Cam Damper Mounting Nut	78 N·m	8 kgf·m · 58 ft·lb	p. 24
Driven Gear Shaft Nut	147 N·m	15 kgf·m · 108 ft·lb	p. 24
Bearing Retainer	108 N·m	11 kgf·m · 80 ft·lb	p. 24
Pinion Gear Nut	69 N·m	7 kgf·m · 51 ft·lb	p. 24
Propeller Shaft Housing Nuts	25 N·m	2.5 kgf·m · 18 ft·lb	p. 24
Final Gear Case Drain Bolt	20 N·m	2 kgf·m · 14 ft·lb	p. 25
Speedometer Plug	20 N·m	2 kgf·m · 14 ft·lb	p. 25
Final Gear Case Filler Cap	15 N·m	1.5 kgf·m · 11 ft·lb	p. 25
Ring Gear Cover Bolts	25 N·m	2.5 kgf·m · 18 ft·lb	p. 25
Axle Shaft Pipe Bolts	20 N·m	2 kgf·m · 14 ft·lb	p. 25
Front Axle Nut	34 N·m	3.5 kgf·m · 25 ft·lb	p. 25
Front Brake Panel Bolts	25 N·m	2.5 kgf·m · 18 ft·lb	p. 25
Rear Brake Panel Bolts	29 N·m	3 kgf·m · 22 ft·lb	p. 25
Rear Brake Drum Drain Bolts	29 N·m	3 kgf·m · 22 ft·lb	p. 25
Front Suspension Arm Pivot Bolts	88 N·m	9 kgf·m · 65 ft·lb	p. 25
Shock Absorber Mounting Bolts and Nuts	34 N·m	3.5 kgf·m · 25 ft·lb	p. 25
Steering Stem Clamp Allen Bolts	26 N·m	2.7 kgf·m · 20 ft·lb	p. 25
Stem Bottom End Nut	29 N·m	3 kgf·m · 22 ft·lb	p. 25
Tie-rod End Nuts	41 N·m	4.2 kgf·m · 30 ft·lb	p. 25
Steering Knuckle Arm Pivot Nuts	39 N·m	4 kgf·m · 29 ft·lb	p. 25
Handlebar Holder Bolts	20 N·m	2 kgf·m · 14 ft·lb	p. 25
Rear Carrier Bolts	20 N·m	2 kgf·m · 14 ft·lb	p. 25
Spark Plug	14 N·m	1.4 kgf·m · 10 ft·lb	p. 25
Starter Motor Clutch Bolts	34 N·m	3.5 kgf·m · 25 ft·lb	p. 25
Alternator Rotor Bolt	59 N·m	6 kgf·m · 43 ft·lb	p. 25
Oil Filter Change	29 N·m	3 kgf·m · 22 ft·lb	p. 32
Carburetor Holder Bolts	10.7 N·m	95 in·lb	p. 45
Throttle Lever Bolt	5.9 N·m	52 in·lb	p. 45
Cylinder Head Bolts (M6), first	5.9 N·m	52 in·lb	p. 67
Cylinder Head Bolts (M6), final	9.8 N·m	87 in·lb	p. 67
Valve Adjusting Cap Bolts	8.8 N·m	78 in·lb	p. 67
Retaining Bolt	4.4 N·m	39 in·lb	p. 67
Compression Releasing Lever Bolt	8.8 N·m	78 in·lb	p. 67
Rear Camshaft Chain Guide Bolt	9.8 N·m	87 in·lb	p. 69
Camshaft Chain Tensioner Mounting Bolts	8.8 N·m	78 in·lb	p. 69
Valve Adjusting Screw Locknuts	11.8 N·m	104 in·lb	p. 69
Rocker Shaft Retainer Screws	4.4 N·m	39 in·lb	p. 69
Camshaft Chain Guard Screws	4.4 N·m	39 in·lb	p. 69
Tensioner Body and Clamp	8.8 N·m	0.9 kgf·m · 78 in·lb	p. 75
Rotor bolt	34 N·m	3.5 kgf·m · 25 ft·lb	p. 77
Cylinder Head Bolt	13 N·m	1.3 kgf·m · 113 in·lb	p. 85
Cylinder Head Bolt	5.9 N·m	0.6 kgf·m · 52 in·lb	p. 85
Right Engine Cover Bolts	8.8 N·m	78 in·lb	p. 105
Clutch Spring Bolts	11.8 N·m	104 in·lb	p. 105
Clutch Adjusting Screw Locknut	10.7 N·m	95 in·lb	p. 105
Recoil Starter Mounting Bolts	8.8 N·m	78 in·lb	p. 119
Recoil Starter Flange Nut	11.8 N·m	104 in·lb	p. 119
Friction Plate	12 N·m	1.2 kgf·m · 104 in·lb	p. 122
Oil Pump Screws	4.4 N·m	39 in·lb	p. 127
Oil Filter Cover Bolts	8.8 N·m	78 in·lb	p. 127
Pressure relief valve	15 N·m	1.5 kgf·m · 11 ft·lb	p. 132
Rear wheel slowly	26 N·m	2.7 kgf·m · 20 ft·lb	p. 139
Rear wheel slowly	29 N·m	3 kgf·m · 22 ft·lb	p. 139
Rear wheel slowly	39 N·m	4 kgf·m · 29 ft·lb	p. 139
Crankcase Bolts	8.8 N·m	78 in·lb	p. 143
Bearing Stopper Screws	9.8 N·m	87 in·lb	p. 143
Positioning Lever Bolt	8.8 N·m	78 in·lb	p. 145
Shift Drum Pin Plate Bolt	11.8 N·m	104 in·lb	p. 145
Shift Drum Assembly	12 N·m	1.2 kgf·m · 104 in·lb	p. 160
Output Bevel Gear Case Bolts	8.8 N·m	78 in·lb	p. 181
Output Drive Gear	118 N·m	12 kgf·m · 87 ft·lb	p. 189
Axle Shaft Pipes	20 N·m	2 kgf·m · 14 ft·lb	p. 198
Ring Gear Case Cover	25 N·m	2.5 kgf·m · 18 ft·lb	p. 204
Pinion Gear Assembly and Shim	25 N·m	2.5 kgf·m · 18 ft·lb	p. 205
Pinion Gear Disassembly	108 N·m	11 kgf·m · 80 ft·lb	p. 207
Final Gear Case	69 N·m	7 kgf·m · 51 ft·lb	p. 208
Drum	34 N·m	3.5 kgf·m · 25 ft·lb	p. 217
Washer	147 N·m	15 kgf·m · 108 ft·lb	p. 219
Brake parts	29 N·m	3 kgf·m · 22 ft·lb	p. 220
Spring faces upward	34 N·m	3.5 kgf·m · 25 ft·lb	p. 228
Alternator Cover Bolts	8.8 N·m	78 in·lb	p. 259
Ignition Switch Nut	2.9 N·m	26 in·lb	p. 259
Starter Motor Mounting Bolts	8.8 N·m	78 in·lb	p. 261
Starter Motor Terminal Nut	4.9 N·m	43 in·lb	p. 261
Starter Motor Terminal Locknut	6.9 N·m	61 in·lb	p. 261
Starter Motor Bolts	3.4 N·m	30 in·lb	p. 261
Cover securely	8.8 N·m	0.9 kgf·m · 78 in·lb	p. 274
Crankshaft	59 N·m	6 kgf·m · 43 ft·lb	p. 274

Capacities

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Fuel tank	10 L		p. 16

Spark plugs

Values extracted from the document text. Check against the original before service work.

Item	Value	PDF page
VM24SS	—	p. 16
M12	—	p. 83
R37	—	p. 263

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