Kawasaki KLF400 Bayou (1993 - 1999)

This Kawasaki KLF400 Bayou manual is 400 pages.

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

KLF400 Bayou (1993-1999)