Kawasaki Bayou 400
Covered Models
- 1995 Kawasaki Bayou 400 – KLF400
Kawasaki Bayou 400
| GENERAL DATA | |
|---|---|
| Producer | Kawasaki |
| Modelbayou 220 | Bayou 400 |
| Year |
1995 |
Image Kawasaki Bayou 400
TEHNICAL SPECIFICATIONS
| ENGINE | |
|---|---|
| Type | SOHC single cylinder, 4-stroke, liquid-cooled |
| Displacement | 391 mL (23.9 cu in.) |
| Bore x Stroke | 81.0×76.0 mm ( (3.19×2.99in.) |
| Compression Ratio | 9.0: 1 |
| Starting System | Electric starter |
| Carburetor | Keihin CVK32 |
| Ignition System | Battery and coil (DC-CDI) |
| Ignition Timing | 10∘ BTDC @1,300 r/min (rpm)~30∘ BTDC @4,300 r/min (rpm) |
| Spark Plug | NGK DP8EA-9 or ND X24EP-U9 |
| Lubrication System | Forced lubrication (wet sump) |
| Engine Oil | SE, SF or SG class SAE 10W30, 10W40, 10W50, 20W40, or 20W50 |
| Engine Oil Capacity | 3.7 L (3.9 US qt) |
| Coolant Capacity | 2.1 L (2.2 US qt) |
| Maximum speed | 45-50 mph (72-80 km/h) |
| Power | 26 horsepower (19 kW) |
| DIMENSIONS | |
|---|---|
| Overall Length | 2,020 mm (79.53 in.) |
| Overall Width | 1,130 mm (44.49 in.) |
| Overall Height | 1,100 mm (43.31 in.) |
| Wheelbase | 1,200 mm (47.24 in.) |
| Track: Front | 850 mm (33.5 in.) |
| Track: Rear | 860 mm (33.9 in.) |
| Ground Clearance | 185 mm (7.28 in.) |
| Dry Weight | 270 kg (595 lb) |
| TRANSMISSION | |
|---|---|
| Transmission Type | 5-speed plus reverse, constant mesh, return shift |
| Drive train | Automatic with a torque converter and dual-range (Hi/Lo) forward gears, plus Reverse. |
| Drive | 4WD (Four Wheel Drive) via shaft drive with a limited-slip front differential. |
| Clutch Type: Primary | Automatic, centrifugal, wet |
| Clutch Type: Secondary | Automatic, multi disc, wet |
| Driving System | Shaft drive, 4WD |
| Primary Reduction Ratio | 2.586 (75/29) |
| Final Reduction Ratio | 6.190 (20/14 x 39/9) |
| Overall Drive Ratio | 12.242 (Top gear) |
| Gear Ratio: SL | 3.818 (42/11) |
| Gear Ratio: 1st | 2.250 (36/16) |
| Gear Ratio: 2nd | 1.523 (32/21) |
| Gear Ratio: 3rd | 1.038 (27/26) |
| Gear Ratio: 4th | 0.764 (26/34) |
| Gear Ratio: Reverse | 3.842 (30/11 x 31/22) |
| Front Final Gear Case Oil | API GL-5 for LSD SAE140 or SAE90, or SAE85 W-140 |
| Rear Final Gear Case Oil | API GL-5 SAE 90 [above 5∘C (41°F)] SAE 80 [below 5∘C (41°F)] |
| Front Final Gear Case Oil Capacity | 0.4 L (0.4 US qt) |
| Rear Final Gear Case Oil Capacity | 0.2 L (0.21 US qt) |
| CHASSIS | |
|---|---|
| Type | Tubular, double cradle |
| Caster | 2.5° |
| Trail | 12 mm (0.47 in.) |
| Maximum Torque | 32.4 N-m (3.3 kg-m, 23.9 ft-lb) @5,000 r/min (rpm) |
| Minimum Turning Radius | 3.0 m (9.8 ft) |
| Fuel Tank Capacity | 12.0 L (3.2 US gal) |
| TIRES & BRAKES | |
|---|---|
| Tire Size: Front | AT24 x 8-11 Tubeless |
| Tire Size: Rear | AT24 x 10-11 Tubeless |
| Front brakes | Dual hydraulic disc brakes, controlled by a hand lever |
| Rear brakes | Sealed mechanical drum brake, controlled by a foot pedal |
| ELECTRICS | |
|---|---|
| Battery | 12 V 19 Ah |
| Headlight | 12 V 25/25 W x 2 |
| Taillight | 12 V 8 W×2 |
| LOADING | |
|---|---|
| Front Rack | 88 lbs (40 kg) |
| Rear Rack | 154 lbs (70 kg) |
| Combined Rack Capacity | 242 lbs (110 kg) |
| Towing Capacity | 1100 lbs (499 kg) |
| SUSPENSIONS | |
|---|---|
| Front | MacPherson strut with 6.7 inches (170 mm) of travel. |
| Rear | Swingarm with a single shock and preload adjustment, offering 7.1 inches (180 mm) of travel. |
| TROUBLESHOOTING | ||
|---|---|---|
| Problem | Description | Solution |
| Engine Won’t Start | Engine cranks but doesn’t fire. | 1. Check Fuel: Ensure the fuel tank has sufficient fuel and the fuel valve is open. Check for fuel flow to the carburetor. Clean or replace the fuel filter if clogged. 2. Check Spark: Remove the spark plug, connect it to the spark plug cap, and ground it against the engine. Crank the engine to see if there’s a strong, consistent spark. Replace the spark plug if it’s fouled or there’s no spark. Check the spark plug cap and ignition coil for damage or loose connections. 3. Check Air: Ensure the air filter is clean and not obstructed. A clogged air filter can prevent the engine from starting. 4. Check Battery: Ensure the battery is fully charged and the connections are clean and tight. A weak battery may crank the engine slowly but not provide enough power for ignition. |
| Engine Cranks Slowly | The starter motor turns the engine over very slowly. | 1. Check Battery: The battery is likely weak or discharged. Try charging it or jump-starting the ATV. If it still cranks slowly, the battery may need replacement. 2. Check Battery Connections: Ensure the battery terminals and cable connections are clean and tight. Corrosion can impede current flow. 3. Check Starter Motor: The starter motor itself may be failing. Try tapping it lightly with a rubber mallet. If it doesn’t improve, the starter motor might need to be replaced. 4. Check Engine Mechanical Issues: In rare cases, internal engine problems could cause slow cranking. This would require more in-depth inspection. |
| Engine Starts but Runs Poorly/Rough Idle | Engine starts but idles erratically, stalls easily, or lacks power. | 1. Check Carburetor: The carburetor jets may be clogged or the idle mixture screw may be improperly adjusted. Clean the carburetor thoroughly. Adjust the idle mixture screw according to the service manual. 2. Check Air Filter: A dirty air filter restricts airflow and can cause poor performance. Clean or replace it. 3. Check Spark Plug: A fouled or incorrect spark plug can lead to poor running. Clean, gap, or replace the spark plug according to the service manual. 4. Check Fuel System: Ensure consistent fuel flow to the carburetor. Check for a clogged fuel filter or a restricted fuel line. 5. Check Valve Adjustment: Incorrect valve clearances can cause poor performance. Adjust the valves according to the service manual specifications. 6. Check for Air Leaks: Inspect the intake manifold and carburetor boots for cracks or loose connections that could cause air leaks. |
| Engine Overheats | The engine temperature warning light comes on or the engine starts to steam. | 1. Check Coolant Level: Ensure the coolant level in the radiator and overflow bottle is within the specified range. Add coolant if necessary. 2. Check Radiator: Ensure the radiator fins are clean and not blocked by mud or debris. Clean them carefully. 3. Check Radiator Fan: Make sure the radiator fan is operating correctly when the engine gets hot. Check the fan motor and its wiring. 4. Check Water Pump: The water pump may not be circulating coolant properly. Inspect for leaks or unusual noises. A faulty water pump may need replacement. 5. Check Thermostat: A stuck thermostat can prevent proper coolant circulation. It may need to be replaced. 6. Check for Air Pockets: Air trapped in the cooling system can cause overheating. Bleed the cooling system according to the service manual. 7. Check Oil Level: Low engine oil can contribute to overheating. Ensure the oil level is correct. |
| Transmission Problems (Hard Shifting, Won’t Shift) | Difficulty shifting gears or the transmission won’t engage a gear. | 1. Check Oil Level: Ensure the engine oil level is correct, as some ATVs use engine oil for the transmission. 2. Check Shift Linkage: Inspect the shift lever and linkage for damage, loose bolts, or obstructions. Adjust or repair as needed. 3. Check Clutch (if applicable): If your Bayou 400 has a manual clutch, ensure it’s properly adjusted and the clutch lever has the correct free play. 4. Internal Transmission Issues: If external adjustments don’t resolve the problem, there may be internal damage to the transmission, requiring professional repair. |
| Brake Problems (Weak Brakes, No Brakes) | Brakes feel spongy, require excessive lever/pedal travel, or don’t provide adequate stopping power. | 1. Check Brake Fluid Level: Ensure the brake fluid reservoir is at the correct level. Use the recommended DOT fluid. 2. Bleed the Brakes: Air in the brake lines can cause spongy or weak brakes. Bleed the brake system to remove air. 3. Inspect Brake Pads/Shoes: Check the thickness of the brake pads or shoes. Replace them if they are worn below the service limit. 4. Inspect Brake Discs/Drums: Check for damage, wear, or contamination (oil, grease) on the brake discs or drums. 5. Check Brake Lines and Hoses: Inspect for leaks, cracks, or swelling in the brake lines and hoses. 6. Check Brake Calipers/Cylinders: Ensure the calipers and wheel cylinders are not seized or leaking. Rebuild or replace if necessary. 7. Adjust Brakes (if applicable): Some older models may have adjustable drum brakes. Ensure they are properly adjusted according to the service manual. |
| Suspension Issues (Rough Ride, Poor Handling) | The ride feels harsh, the ATV bounces excessively, or handling is unstable. | 1. Check Tire Pressure: Ensure all tires are inflated to the recommended pressure. 2. Inspect Shocks/Struts: Check the shocks and struts for leaks, damage, or excessive wear. Replace if necessary. 3. Inspect Suspension Bushings: Worn or damaged bushings can cause play and poor handling. Inspect and replace as needed. 4. Check Wheel Bearings: Loose or worn wheel bearings can cause instability. Check for play in the wheels. 5. Check A-Arms and Linkages: Inspect the A-arms and suspension linkages for bends, cracks, or loose bolts. 6. Check Steering Components: Inspect tie rod ends, ball joints, and steering stem for wear or damage. |
| Electrical Issues (Lights Not Working, No Power) | Lights don’t turn on, the electric starter doesn’t work, or other electrical components fail. | 1. Check Fuses: Inspect all fuses in the fuse box. Replace any blown fuses with the correct amperage rating. 2. Check Battery Connections: Ensure the battery terminals and cable connections are clean and tight. 3. Check Wiring Harness: Inspect the wiring harness for any obvious damage, cuts, or loose connections. 4. Check Light Bulbs: Ensure the light bulbs are not burned out. Replace if necessary. 5. Check Switches: Test the functionality of the ignition switch, light switches, and other electrical switches. 6. Check Voltage Regulator/Rectifier: A faulty regulator/rectifier can cause charging problems and other electrical issues. 7. Check Stator/Alternator: The stator/alternator generates power for the electrical system. If it’s faulty, the battery may not charge. |