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Magnaflow 49 State Coverter 45005 Catalytic Converter | eBay

here's a place to purchase manuals for under $10
prolly a good idea to get one.......
http://www.midwestmanuals.com/ATVs/kawasaki-atv.htm

or here.........

1989-2006 Kawasaki Bayou 300 4x4 Service Repair Workshop Manual DOWNLOAD (1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006) - Download Recipes/Manuals

it looks very difficult to find the manual for the earlier years bayous, but here's a later model manual, i'd say of the flywheel looks the same, it'll come off the same ?
everybody on the kawasaki forums say this is the same motor, just different size bore, and different plastics, but essentually the same bike, so this manual will work for your needs.................
2003-05 Bayou 250 Service Manual.pdf

you already have the cover i was talkin about off
and whoaaa, that looks way different than the 300 lakota motor i worked on
what is the flywheel removal procedure listed in the manual you downloaded ???
maybe it's a defferent than in there ???
lemme see if i can find you a bayou manual online
hit me back with year/model/engine size
and i'll have a look after i eat and shower, just got home from fishing

the stator "cover" comes off by removing the bolts around the perimeter, now the flywheel under that cover needs a special flywheel puller, they are available on ebay for $15,
are you sure your tryin to remove the correct side ??
the stator and flywheel are located on the shifter side
no clutch involved, it's on the other side

i replied earlier, the gear that runs the timing chain is not inside the cases with the crank, but is uner the stator cover, i believe it is a couble gear, and also has the starter chain on it
pull the stator cover and flywheel/stator
i think it's behind them

the plastic guides are from the bottom case up into the top end, and they just sit in little pockets in the bottom case, you may be able to see the tips of them sticking up into the timing gear cover, and the adjuster pushes in on the rear one to keep the chain tight, they are usually black plastic

it's not the cases themselves where the crank is located, it's just the flywheel cover, theres a small gear on the shaft under the flywheel
thats where the starter gears/chain are located too
also watch that those timing chain guides stay in pace too, they like to pop out of the little notches they sit in.
i'd also remove the timing chain self adjuster, push the spring loaded pin in and "set" the set scew, this gives you more play in the chain to get it, and that top gear on easier,
then you re-install that adjuster, and loosen that "set screw" allowing the spring/pin to apply pressure to that back chain guide and self adjust the chain

hope it helps ya !!!!

check your bayou help thread