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1993-1999 Kawasaki KLF400 Bayou ATV Repair Manual

$24.95 $18.71

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Description

Used 1993-1999 Kawasaki KLF400 Bayou ATV Repair Manual

This Used 1993-1999 Kawasaki KLF400 Bayou ATV Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1993-1999 Kawasaki KLF400 Bayou ATVs.

Includes everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, ignition system, steering and suspension, wheels, brakes and tires, electrical system, frame and body. Features complete wiring diagrams and 376 illustrated pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Washing the vehicle / Special tips / Torque specifications / Fasteners / Lubricants / RTV gasket sealant / Gasket remover / Threadlocking compound / Expendable supplies / Serial numbers / Warning and information labels / Basic hand tools / Precision measuring tools / Special tools / Fabricating tools / Mechanic’s tips / Ball bearing replacement / Seals / Riding safety

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

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist / Service intervals / Tires and wheels / Battery / Lubricants / Cleaning solvent / Periodic lubrication / Unscheduled lubrication / Periodic maintenance / Engine tune-up / Storage

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

CHAPTER FIVE / ENGINE LOWER END
Servicing engine in frame / Engine removal / Engine 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 / Engine break-in

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

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

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

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 / Wiring diagrams

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

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

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

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

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

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

INDEX

WIRING DIAGRAMS

Additional information

Weight 1.56 lbs
Dimensions 9 × 7 × 0.4 in