Kawasaki KLF400 Bayou 1993 - 1999 Clymer Owners Service & Repair Manual covers Kawasaki KLF400, 1993 through 1999 models.
● QUICK REFERENCE DATA
● 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
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
● 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
● 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
● 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
● CLUTCH AND EXTERNAL SHIFT MECHANISM
Clutch cover / Clutch release mechanism / Clutch / One-way clutch check / External shift mechanism / Specifications
● 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
● FUEL AND EXHAUST SYSTEMS
Carburetor adjustments / Throttle cable / Choke cable replacement / Fuel tank / Fuel level gauge / Fuel valve / Air box / Exhaust system / Specifications
● 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
● COOLING SYSTEM
Cooling system inspection / Coolant tank / Radiator and cooling fan / Cooling fan / Thermostat / Thermostatic fan switch / Water temperature switch / Water pump / Specifications
● FRONT SUSPENSION AND STEERING
Wheel alignment / Front wheel / Front hub / Handlebar / Steering shaft / Tie rod / Steering knuckle / Control arms / Steering stopper adjustment / Shock absorber / Tyres and wheels / Specifications
● FRONT DRIVE MECHANISM
Front drive shaft / Front axles / Front differential / Output bevel gearcase / Output bevel gear / Specifications
● 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
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
● 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
● WIRING DIAGRAMS
Clymer motorcycle & ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.
General information on Repair Manuals
Please note that workshop manuals are usually written for models sold in a specific country.
Differences in specification can exist between models sold in different countries and items such as engines can vary.
Please check that the manual will cover your model before purchase and if you are unsure please contact us first.