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1993 - 1999 Kawasaki Bayou KLF400 Clymer ATV Service, Repair, Maintenance Manual
1993 - 1999 Kawasaki Bayou KLF400 Clymer ATV Service, Repair, Maintenance Manual

1993 - 1999 Kawasaki Bayou KLF400 Clymer ATV Service, Repair, Maintenance Manual

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1993 - 1999 Kawasaki Bayou KLF400 Clymer ATV Service, Repair, Maintenance Manual
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 KAWASAKI ATV Repair Manual by CLYMER

Service, Repair & Maintenance:

1993-1999 Kawasaki Bayou KLF400

Every Clymer manual contains hundreds of original photographs and illustrations developed from a complete disassembly and assembly of the motorcycle. This, in addition to extensive research, allows Clymer to achieve an un-matched level of detail, accuracy & clarity.

The step-by-step instructions and two column text with large print are user friendly, bold figure numbers make it easy to quickly match instructions with illustrations and photos. Thumb tabbed chapters, numbered table of contents and extensive index make it possible to locate the desired section quickly. This manual includes a Quick Reference Data section with frequently used specifications and the following chapters:

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Service hints / Washing the vehicle / Special tips / Torque specifications / Fasteners / Lubricants / RTV gasket sealant / Gasket remover / Threadlocking compound / Expendable shop supplies / Serial numbers / Warning and information labels / Basic hand tools / Special tools / Fabricating tools / Precision measuring tools / Mechanics tips / Ball bearing replacement / Oil seals / Riding safely / Specifications Specs

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Starting the engine / Starting difficulties / Poor idle speed performance / Poor medium and high speed performance / Engine starting system / Charging system / Ignition system / Fuel system / Engine overheating / Engine Engine noises / Cylinder leak down test / Clutch / Transmission / Drive train noise / Handling / Frame noise / Brakes

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist / Service intervals schedule / Periodic lubrication / Engine oil and filter change / Engine oil flow inspection / Rear final gearcase oil change / Front final drive gearcase oil change / Control cable lubrication / Non-scheduled lubrication / Steering shaft lubrication / Rear suspension arms lubrication / Shock absorber pivot bolt lubrication / Periodic maintenance / Air filter service / Brake inspection and adjustment / Clutch adjustment / Throttle cable adjustment / Speed limiter adjuster screw / Reverse cable adjustment / Coolant change / Non-scheduled maintenance / Tune-up / Valve clearance / Compression test check / Spark plug / Air filter / Ignition timing / Pilot screw adjustment / Idle Speed Adjustment / Storage / Specifications

CHAPTER FOUR / ENGINE TOP END
Engine principles / Rocker case / Rocker arm / Camshaft / Cam chain tensioner / Cylinder head / Cam chain / Chain guides / Cylinder / Valves and components / Piston and rings / Specifications

CHAPTER FIVE / ENGINE LOWER END
Removal installation / Oil screen / Oil pump / Oil pipes / Primary gear and oil pump drive gear / Stator coil and alternator cover / Alternator cover and stator clutch / Kickstarter mechanism / Kickstarter idler gears / Crankcase and crankshaft / Break-in / Specifications

CHAPTER SIX / CLUTCH AND EXTERNAL SHIFT MECHANISM
Clutch cover / Clutch release mechanism / Clutch / One-way clutch check / External shift mechanism / Specifications

CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission troubleshooting overhaul inspection / Internal shift mechanism / Reverse stopper assembly / Neutral reverse switch / Reverse cable / Reverse lever / Reverse lever shaft / Specifications

CHAPTER EIGHT / FUEL AND EXHAUST SYSTEMS
Carburetor adjustments / Throttle cable / Choke cable replacement / Fuel tank / Fuel level gauge / Fuel valve / Air box / Exhaust system / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
Basic information / Charging system / Regulator/rectifier / Capacitor discharge ignition / IC igniter / Ignition coil / Pickup coil / Starting system / Lighting system / Cooling fan circuit / Carburetor heater circuit (1995-on UK models) / Switches / Fuse / Specifications

CHAPTER TEN / COOLING SYSTEM
Cooling system inspection / Coolant tank / Radiator and cooling fan / Cooling fan / Thermostat / Thermostatic fan switch / Water temperature switch / Water pump / Specifications

CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING
Wheel alignment / Front wheel / Front hub / Handlebar / Steering shaft / Tie rod / Steering knuckle / Control arms / Steering stopper adjustment / Shock absorber / Tires and wheels / Specifications

CHAPTER TWELVE / FRONT DRIVE MECHANISM
Front drive shaft / Front axles / Front differential / Output bevel gearcase / Output bevel gear / Specifications

CHAPTER THIRTEEN / REAR AXLE, SUSPENSION AND FINAL DRIVE
Rear wheel / Rear suspension arms / Rear shock absorbers / Left rear hub / Rear differential unit / Drive shaft / Rear axle / Specifications

CHAPTER FOURTEEN / BRAKES
Disc brake / Front caliper / Brake hose replacement / Front master cylinder / Brake disc / Brake hose replacement / Rear drum brake / Brake pedal / Rear brake cable / Parking brake cable / Bleeding the system / Specifications

CHAPTER FIFTEEN / BODY AND FRAME
Seat / Front carrier / Front guard / Rear carrier / Fuel tank cover / Front cover / Front fender / Rear fender / Mud flap / Front skid plate / Engine skip plate / Footrests / Frame / Specifications

INDEX

WIRING DIAGRAMS

Models covered: 1993 1994 1995 1996 1997 1998 1999 Kawasaki KLF400 KLF 400

Clymer Manuals Kawasaki KLF400 Bayou Manual

Specifications
Publisher: Clymer
Softcover: 400 pages
Dimensions: 10.2 x 7.0 x 0.8 inches
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