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1. 02 Yamaha Kodiak 400 Service Manual Pdf

. READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM400FAR WARNING This ATV should not be ridden by anyone under 16 years of age.

LIT-11626-16-02 5TE-F8199-10. Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines.

With the purchase of this Yamaha, you can now appreciate the high degree of crafts- manship and reliability that have made Yamaha a leader in these fields. EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SE- RIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe WARNING. Please check your local riding laws and regulations before operating this machine. EBU01067 YFM400FAR OWNER’S MANUAL ©2002 by Yamaha Motor Corporation, AFFIX DEALER U.S.A. 1st edition, April 2002 LABEL HERE All rights reserved.

Any reprinting. EBU00014 CONTROL FUNCTIONS.4-1 WARNING Main switch.4-1 Indicates a potential hazard that could Indicator lights.4-2 result in serious injury or death. Speedometer.4-4 Fuel gauge.4-4 Handlebar switches.4-5 CONTENTS Throttle lever.4-8 Speed limiter.4-9 Front brake lever.4-10 LOCATION OF THE WARNING AND Rear brake pedal and lever.4-10 SPECIFICATION LABELS. Rear shock absorber Drive select lever operation and adjustment.4-20 reverse driving.

6-4 Auxiliary DC jack.4-21 Engine break-in. 6-7 Parking.6-8 PRE-OPERATION CHECKS. 5-1 Parking on a slope.6-9 Front and rear brakes. 5-2 Accessories and loading.6-10 Fuel. PERIODIC MAINTENANCE AND Brake fluid replacement.8-39 ADJUSTMENT.8-1 Front brake lever free play.8-39 Owner’s manual and tool kit.

8-1 Rear brake pedal and lever Periodic maintenance/ adjustment.8-41 lubrication.8-3 Adjusting the rear brake light Panel removal and installation.8-5 switch.8-44 Engine oil. CLEANING AND STORAGE. Cleaning.9-1 B. Storage.9-3 SPECIFICATIONS.10-1 NOISE REGULATION.11-1 MAINTENANCE RECORD. 12-1 ATV LIMITED WARRANTY.

13-1 YAMAHA EXTENDED SERVICE (Y.E.S.). EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS. Yamaha dealer. WARNING O v e r l o a d i n g t h i s AT V o r c a r r y i n g c a r g o i m p r o p e r l y c a n c h a n g e h a n d l i n g. LOADING LIMIT MAXIMUM LOADING LIMIT ( 5 0 0 k g f ) PULLING LOAD: 4900 N 1102 l b f ( 1 5 k g f ) TONGUE WEIGHT: 147 N 33 l b f 5ND-F151K-00 WARNING O v e r l o a d i n g t h i s AT V o r c a r r y i n g c a r g o i m p r o p e r l y c a n c h a n g e h a n d l i n g. EBU00924 SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars.

A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.

Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions.

Always follow proper procedures for climbing hills as described in this manual. Check the ter- rain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Always be careful when skidding or sliding.

Learn to safely control skidding or sliding by prac- ticing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con- trol. WARNING When transporting the ATV in another vehicle, be sure it is kept upright and POTENTIAL HAZARD that the fuel cock is in the “OFF” posi- Improper handling of gasoline. Otherwise, fuel may leak out of the WHAT CAN HAPPEN carburetor or fuel tank. WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.

HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation. EBU00032 D ESCRIPTION AND MACHINE IDENTIFICATION 1. Rear spring preload 13. Front spring preload adjusting ring adjusting ring 2. Spark arrester 14.

V-belt cooling duct check hose 3. Storage compartment 15. Coolant reservoir and tool kit 16. Oil filter cartridge 4. This number can be used for ordering a new when ordering spare parts from a Yamaha key. Dealer or for reference in case the vehicle is stolen.

Record the information on this la- bel in the space provided. This information will be needed to order spare parts from your Yamaha dealer.

Vehicle identification number (front left side) NOTE: The vehicle identification number is used to 1. EBU00039 C ONTROL FUNCTIONS WARNING Indicates a potential hazard that could result in serious injury or death.

EBU00942 Main switch Functions of the respective switch positions are as follows: 1. Main switch The engine can be started only at this position and the headlights and taillight come on when the light switch is on. “ON”, and then press the start switch. If the light does not come on, have a 1. Coolant temperature warning light “ ” Yamaha dealer inspect the electrical circuit. Reverse indicator light “R” 3. Four-wheel drive indicator light “ ”.

EBU00602 EBU00605 Reverse indicator light “R” Four-wheel-drive indicator light “ ” This indicator light comes on when the trans- This indicator light comes on when the 2WD/ mission is in reverse. 4WD switch is in the 4WD position. NOTE: Due to the synchronizing mechanism in the EBU00603 Neutral indicator light “N”. EBU00447 EBU00052 Speedometer Fuel gauge The speedometer shows riding speed. This The fuel gauge indicates the amount of fuel in speedometer is equipped with a trip odome- the fuel tank. When the needle reaches the ter.

The trip odometer can be reset to “0” with red line, refill the tank at the first opportunity. EBU00053 Handlebar switches CAUTION: Do not use the headlights with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. EBU00849 Engine stop switch “. EBU00607 Start switch “ ” The starter motor cranks the engine when this switch is pushed. CAUTION: See starting instructions prior to starting the engine.

(See page 6-1 for details.) 1. Four-wheel drive switch “2WD/4WD” EBU00060 On command four-wheel drive switch “2WD/4WD”. WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 2WD while the ATV is moving.

WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD in some circumstances. Changing from 2WD to 4WD or from 4WD to 2WD while moving may cause the ATV to unexpectedly handle differ- ently. Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you 1. Throttle lever can’t find or solve the problem yourself.

EBU01159 Speed limiter WARNING The speed limiter keeps the throttle from fully POTENTIAL HAZARD opening, even when the throttle lever is Improper adjustment of the speed limit- pushed to the maximum. Turning in the ad- er and throttle.

Justing screw limits the maximum engine pow- WHAT CAN HAPPEN er available and decreases the maximum The throttle cable could be damaged. EBU00070 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to ap- ply the front brake. Brake pedal 1.

Front brake lever EBU00073 Rear brake pedal and lever The brake pedal is located on the right side of the machine and the brake lever is located on the left handlebar. EBU00074 Parking brake WARNING Use the parking brake when you have to start POTENTIAL HAZARD the engine or park the machine, especially on Improper use of the parking brake. Apply the rear brake lever and push WHAT CAN HAPPEN down the lock plate to apply the parking The ATV could start moving unexpect- brake.

EBU01106 EBU01107 Drive select lever Recoil starter The drive select lever is used to shift your ma- Firmly grasp the handle and pull slightly until chine into the forward, neutral and reverse po- engagement can be felt. Then pull forcefully, sitions. EBU00092 Fuel tank cap WARNING Remove the fuel tank cap by turning it coun- POTENTIAL HAZARD terclockwise. Starting the engine without shifting into the neutral position.

WHAT CAN HAPPEN The ATV could start to move unexpect- edly, which could cause an accident. HOW TO AVOID THE HAZARD Shift the drive select lever into the neu- tral position and apply the parking brake. EBU00093 Fuel cock OFF Position The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. EBU00095 Starter (choke) “ ” RES Position Starting a cold engine requires a richer air-fuel mixture.

A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). EBU00566 Seat To install the seat, insert the projection on the To remove the seat, pull the seat lock lever front of the seat into the seat holder and push upward and pull up the seat at the rear. Down on the seat at the rear.

NOTE: Make sure that the seat is securely fitted. EBU00581 EBU00582 Storage box Front carrier Maximum load limit: 2 kg (4.4 lb) Maximum load limit: 40 kg (88 lb) CAUTION: EBU00583 To protect from damage, do not put metal Rear carrier products, like tools or sharply edged prod- ucts directly in the storage box.

If they Maximum load limit: 80 kg (176 lb) must be stored, wrap them in appropriate cushion material. Front shock absorber adjustment A special wrench can be obtained at a The spring preload can be adjusted to suit the Yamaha dealer to make this adjustment. Rider’s weight and riding conditions. Adjust the spring preload as follows. Standard position: 2 To increase the spring preload, turn the ad- justing ring in direction a. WARNING POTENTIAL HAZARD Improper shock absorber adjustment.

WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set- ting. Rear shock absorber adjustment A special wrench can be obtained at a The spring preload can be adjusted to suit the Yamaha dealer to make this adjustment. Rider’s weight and riding conditions.

Adjust the spring preload as follows: Standard position: 2 To increase the spring preload, turn the ad- justing ring in direction a. EBU00748 Auxiliary DC jack Maximum rated capacity for the The auxiliary DC jack is located at the front auxiliary DC jack: right side of the ATV. The auxiliary DC jack DC 12 V, 120 W (10 A) can be used for suitable work lights, radios, etc. Auxiliary DC jack EBU00112 WARNING Indicates a potential hazard that could result in serious injury or death. P RE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE. Check operation, free play, fluid level and fluid leakage.

5-2–5-3, Brakes. Fill with DOT 4 brake fluid if necessary. 8-37–8-44. Check fuel level.

5-4–5-5 Fuel. Always follow the inspection and main- brakes are applied. If not, have a Yamaha tenance procedures and schedules de- dealer inspect the brake system. Scribed in the Owner’s Manual. If a formance, inspect the brake pads for wear. Problem cannot be corrected by the ad- (See page 8-37.) justment procedures provided in this manual, have a Yamaha dealer check for the cause.

EBU01085 Fuel Your Yamaha engine has been designed to Make sure there is sufficient gasoline in the use regular unleaded gasoline with a pump tank. Octane number (R+M/2) of 86 or higher, or research octane number of 91 or higher. Fuel can spill, which can cause a fire hol containing methanol is not recommended and severe injury. Fuel expands when it by Yamaha because it may cause fuel system heats up. If the fuel tank is overfilled, damage or vehicle performance problems. EBU01084 Engine oil CAUTION: Make sure the engine oil is at the specified In order to prevent clutch slippage level. Add oil as necessary.

(See page 8-12.) (since the engine oil also lubricates the clutch), do not mix any chemical Recommended oil: additives. EBU00493 EBU00678 Final gear oil Differential gear oil Make sure the final gear oil is at the specified Make sure the differential gear oil is at the level. Add oil as necessary. (See pages 8-16– specified level. Add oil as necessary.

(See 8-18 for details.) pages 8-19–8-20 for details.) Recommended oil. CAUTION: WARNING Hard water or salt water is harmful to the POTENTIAL HAZARD engine. You may use distilled water if you Removing the radiator cap when the en- cannot get soft water. Gine and radiator are still hot. WHAT CAN HAPPEN Coolant reservoir capacity: You could be burned by hot fluid and 0.25 L (0.22 Imp qt, 0.26 US qt).

EBU00152 Fittings and Fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. EBU00991 Lights Check the headlights and tail/brake light to make sure they are in working condition. The following are minimums: 1.

The tires listed below have been ap- Front 22 kPa (0.22 kgf/cm, 3.2 psi) proved by Yamaha Motor Co., Ltd. Rear 22 kPa (0.22 kgf/cm, 3.2 psi) for this model. Other tire combina- tions are not recommended. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm, 36 psi) Rear 250 kPa (2.5 kgf/cm, 36 psi) Higher pressures may cause the tire to burst.

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Inflate the tires very slowly and carefully. EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measure- ments of the tire pressure and use the second reading.

Dust or dirt in the gauge could cause the first reading to be incorrect. EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. 3 mm (0.12 in) 5-13. Turn the fuel cock to “ON”.

There is a control or function you do not 3. Turn the main switch to “ON” and the en- understand, ask your Yamaha dealer. Gine stop switch to “ ”. Shift the drive select lever into the neutral. 25 °C (80 °F) and warm engine on, ask a Yamaha dealer to inspect its electric start position. Use the starter (choke) in reference to the figure: Position 1: Cold engine start- ambient temperature below 5 °C.

NOTE: CAUTION: If the engine fails to start, release the See the “Engine break-in” section prior to start switch, then push the start switch operating the engine for the first time. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery en- EBU00180 ergy. EBU01225 Drive select lever operation and reverse driving CAUTION: Before shifting, you must stop the ma- chine and return the throttle lever to its closed position. Otherwise, the transmis- sion may be damaged. Shifting: forward 1. Bring the machine to a complete stop 1.

Drive select lever should be on. If the light does not come on, 4.

Check behind for people or obstacles, ask a Yamaha dealer to inspect the ATV. Then release the parking brake. Open the throttle lever gradually and con- tinue to watch to the rear while backing. WARNING POTENTIAL HAZARD Improper operation in reverse.

WHAT CAN HAPPEN You could hit an obstacle or person be- hind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind you. For this reason, we ask that you carefully read build up of heat. If any abnormality is noticed the following material. Because the engine is during this period, consult a Yamaha dealer. Brand new, you must not put an excessive 1. 0–10 hours: load on it for the first several hours of running.

EBU00211 2. 10–20 hours: Parking Avoid prolonged operation above 3/4 When parking, stop the engine and shift into throttle. Rev the machine freely but do neutral. Turn the fuel cock to “OFF” and apply not use full throttle at any time. The parking brake. EBU00215 Parking on a slope 1. Bring the machine to a stop by applying the brakes.

Stop the engine. POTENTIAL HAZARD 3. With the rear brake applied, apply the Parking on a hill or other incline. Parking brake. WHAT CAN HAPPEN The ATV could roll out of control, in- creasing the chance of an accident. Choose only accessories designed for your dlebars which could make steering difficult, ATV.

Your Yamaha dealer has a variety of an accessory that limits your ability to move genuine Yamaha accessories. EBU00960 Loading Do not exceed the maximum tongue Cargo or a trailer can change the stability and weight. You can measure tongue weight handling of an ATV. You must use common with a bathroom scale. Put the tongue of sense and good judgment when carrying car- the loaded trailer on the scale with the go or towing a trailer.

Ride more slowly than you would without a WARNING load. The more weight you carry, the slow- POTENTIAL HAZARD er you should go. Although conditions vary, Overloading this ATV or carrying or tow- it is good practice not to exceed low range ing cargo improperly. EBU01226.

WARNING Indicates a potential hazard that could result in serious injury or death. Riding Your. WARNING Indicates a potential hazard that could result in serious injury or death. Owner’s Manual completely and understand GETTING TO KNOW YOUR ATV the operation of the controls.

Pay particular at- This ATV is for recreation and utility use. This tention to the safety information on pages section, Riding your ATV, provides general 2-1–2-6. JUDGEMENT Beginning and inexperienced operators should complete the certified training Get training if you are inexperienced. Course offered by Yamaha. They should Beginners should get training from a certified then regularly practice the skills learned instructor.

In the course and the operating tech- Become familiar with this ATV at slow speeds niques described in this Owner’s Manu. Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommenda- tions for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not rec- ommended for their age can lead to se- vere injury or death of the child. This ATV is designed to carry operator and cargo only - passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV.

Could cause an accident, resulting in harm to you and/ or your passenger. Apparel Operating without protective clothing WARNING increases your chances of severe injury in the event of an accident. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Operating this ATV without wearing an Always wear an approved motorcycle approved motorcycle helmet, eye pro- helmet that fits properly. Do not operate after consuming alcohol or WARNING drugs. POTENTIAL HAZARD Operator’s performance capability is reduced Operating this ATV after consuming al- by the influence of alcohol or drugs. Cohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment.

Could cause you to react more slowly. Pre-operation checks WARNING Always perform the pre-operation checks list- POTENTIAL HAZARD ed on page 5-1 before riding for safety and Operating this ATV with improper tires, proper care of the ATV. Or with improper or uneven tire pres- WARNING sure.

POTENTIAL HAZARD WHAT CAN HAPPEN Failure to inspect the ATV before oper. Speed limiter WARNING For riders less experienced with this model, Indicates a potential hazard that could this model is equipped with a speed limiter in result in serious injury or death. The throttle lever housing.

The speed limiter keeps the throttle from fully opening, even Do not operate at speeds too fast for your when the throttle lever is pushed to the maxi- skills or the conditions. Loading and accessories WARNING Use extra caution when riding the ATV with POTENTIAL HAZARD additional loads, such as accessories or car- Overloading this ATV or carrying or tow- go. The ATV’s handling may be adversely af- ing cargo improperly. Reduce your speed when adding WHAT CAN HAPPEN additional loads.

During operation WARNING Always keep your feet on the footboards dur- POTENTIAL HAZARD ing operation. Otherwise your feet may con- Removing hands from handlebars or tact the rear wheels. Feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can re- duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. Avoid wheelies and jumping.

You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, in- cluding an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps.

Never modify this ATV through improp- er installation or use of accessories. All parts and accessories added to this ve- hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an autho- rized ATV dealer. Exhaust system Do not touch the hot exhaust system. The exhaust system on the ATV is very hot Do not park the ATV in a place where during and following operation. To prevent others might be likely to touch it. Burns, avoid touching the exhaust system.

BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only.

Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of con. Do not ride on any public road, street, or high- way.

Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt.

Know the terrain where you ride. Ride cau- tiously in unfamiliar areas.

Stay alert for holes, rocks, or roots in the terrain, and oth- er hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an acci- dent, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills neces. When riding in an area where you might not WHAT CAN HAPPEN easily be seen, such as desert terrain, mount You could be in a collision.

You could a caution flag on the ATV. DO NOT use the be injured. Flag pole bracket as a trailer hitch.

Select a large, flat area off-road to become fa- With the engine idling, shift the drive select le- miliar with your ATV. Make sure that this area ver into the forward “FWD” position. Apply the is free of obstacles and other riders. You throttle slowly and smoothly.

TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off- Always follow proper procedures for road, the two rear wheels are mounted solidly turning as described in this Owner’s on one axle and turn together at the same Manual. Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves.

Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. CLIMBING UPHILL HOW TO AVOID THE HAZARD Use proper riding techniques to avoid vehicle Never operate the ATV on hills too steep overturns on hills. Be sure that you can ma- for the ATV or for your abilities. Practice neuver your ATV well on flat ground before at- on smaller hills before attempting large tempting any incline and then practice riding hills. WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other POTENTIAL HAZARD side of the hill. Climbing hills improperly.

WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Own- er’s Manual.

If you are climbing a hill and you find that you WARNING have not properly judged your ability to make POTENTIAL HAZARD it to the top, you should turn the ATV around Improperly crossing hills or turning on while you still have forward motion (provided hills. When crossing the side of a hill: Always follow proper procedures as de- scribed in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. If your ATV has stalled or stopped and you and rear brakes gradually, or dismount the believe you can continue up the hill, restart ATV immediately on the uphill side.

Carefully to make sure you do not lift the front WARNING wheels which could cause you to lose control. If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while rolling backwards. Apply the front brake. 4WD: Apply both front and rear brakes gradually.

When fully stopped, apply the parking brake. Dismount on uphill side or to a side if pointed straight uphill. RIDING DOWNHILL When this ATV is in 4WD, all wheels (front When riding your ATV downhill, shift your and rear) are interconnected by the drive weight as far to the rear and uphill side of the train.

This means that applying either the front ATV as possible. WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.

Always follow proper procedures for go- ing down hills as described in this Own- er’s Manual. Note: a special technique is required when braking as you go down a hill. CROSSING A SLOPE WARNING Traversing a sloping surface on your ATV re- POTENTIAL HAZARD quires you to properly position your weight to Improperly crossing hills or turning on maintain proper balance. Be sure that you hills.

Have learned the basic riding skills on flat WHAT CAN HAPPEN ground before attempting to cross a sloping Could cause loss of control or cause the. CROSSING THROUGH SHALLOW WATER Remember that wet brakes may have re- The ATV can be used to cross slow moving, duced stopping ability. Test your brakes shallow water of up to a maximum of 35 cm after leaving water. If necessary, apply (14 inches) in depth. Test your brakes after leaving the water.

Do CAUTION: not continue to ride your ATV without verifying After riding your ATV in water, be sure to that you have regained proper braking ability. Drain the trapped water by removing the check hose at the bottom of the air filter case and the check hose on the V-belt cooling duct.

V-belt cooling duct check hose (left front side of ATV) 1. Drive select lever box check hose 7-36. RIDING OVER ROUGH TERRAIN WARNING Riding over rough terrain should be done with POTENTIAL HAZARD caution. Look out for obstacles which could Improperly operating over obstacles. Cause damage to the ATV or could lead to an WHAT CAN HAPPEN upset or accident. Be sure to keep your feet Could cause loss of control or a colli- firmly mounted on the footboards at all times. SLIDING AND SKIDDING If the rear wheels of your ATV start to slide Care should be used when riding on loose or sideways, control can usually be regained (if slippery surfaces since the ATV may slide.

If there is room to do so) by steering in the direc- unexpected and uncorrected, sliding could tion of the slide. With practice, over a period of time, skill at WARNING controlled sliding can be developed. The ter- POTENTIAL HAZARD rain should be chosen carefully before at- Skidding or sliding improperly. Tempting such maneuvers, since both stability WHAT CAN HAPPEN and control are reduced. Bear in mind that You may lose control of this ATV. WHAT TO DO IF. If your ATV starts to slide sideways: This section is designed to be a reference Steer in the direction of the slide if you have guide only.

Be sure to read each section on the room. Applying the brakes or accelerat- riding techniques completely. If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to main- tain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

EBU00515 P ERIODIC MAINTENANCE AND Have a Yamaha dealer perform service if ADJUSTMENT you are not familiar with machine ser- vice. Periodic inspection, adjustment and lubrica- tion will keep your machine in the safest and EBU00535 most efficient condition possible. Safety is an Owner’s manual and tool kit. HOW TO AVOID THE HAZARD during a service operation requiring one, take Never modify this ATV through improp- your machine to a Yamaha dealer to check er installation or use of accessories. All the torque settings and adjust them as neces- parts and accessories added to this ve- sary.

EBU00261 PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY ITEM ROUTINE month months months months year. Check valve clearance.

Valves. Adjust if necessary. Check coolant leakage. Cooling system. Repair if necessary. Replace coolant every 24 months. Check condition.

Spark plug. Replace if damaged. Check all chassis fittings and fasteners. Fittings and fasteners. Correct if necessary.

It is recommended that these items be serviced by a Yamaha dealer. NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement:. EBU00614 Panel removal and installation The panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a panel has to be removed or reinstalled.

EBU00700 Panel A, D To remove 1. Remove the seat. Pull outward on the areas shown, and then pull upward. To install 1. Place the panel in its original position. Install the seat. EBU01147 Panel B To remove Remove the bolt, and then take the panel off.

To install Place the panel in the original position and in- stall the bolt. CAUTION: When installing the panel, be sure not to pinch the cables or wires. EBU00617 Panel C To remove 1. Remove the front carrier bolts and the front carrier. Remove the quick fasteners and pull up- ward. Bolt (× 2) (under fenders) 1. Bolt (× 4) 1.

Quick fastener (× 2). EBU01013 To install Panel E 1. Place the panel in the original position To remove and install the quick fasteners. Remove the bolts, and then take the panel off.

Install the front carrier and the bolts, then To install tighten to the specified torque. EBU00638 Panel F To install To remove Place the panel in its original position. Pull outward on the areas shown. Panel F 8-11. EBU01099 NOTE: Engine oil Wait a few minutes until the oil level settles Engine oil level measurement before checking.

Remove panel F. (See page 8-11 for panel removal and installation proce- 6. The oil level should be between the max- dures.) imum and minimum marks. Engine oil and oil filter cartridge replace- 5. Remove the oil filter cartridge with an oil ment filter wrench.

Remove panels E and F. (See pages 8-10 and 8-11 for panel removal and in- stallation procedures.) 2. Warm up the engine for several minutes.

Apply a light coat of engine oil to the O- NOTE: An oil filter wrench is available at a nearby ring of the new oil filter cartridge. Yamaha dealer. NOTE: Make sure the O-ring is seated properly. Install the drain bolt and tighten it to the specified torque. Fill the engine with sufficient oil to reach CAUTION: the specified level. Install the engine oil In order to prevent clutch slippage filler cap and tighten it. (since the engine oil also lubricates the clutch), do not mix any chemical Recommended engine oil: additives.

EBU01145 3. If the oil is below the brim of the filler hole, Final gear oil add sufficient oil of the recommended Final gear oil measurement type to raise it to the correct level.

Place the machine on a level surface. Final gear oil replacement 1. Remove the final gear case cover by re- moving the bolts. Final gear case drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. Final gear case cover 2.

Recommended oil: See page 5-7. Oil quantity: 0.25 L (0.22 Imp qt, 0.26 US qt) CAUTION: Be sure no foreign material enters the final gear case.

Install the oil filler bolt. Check for oil leakage. If oil leakage is found, check for the cause. EBU01241 Differential gear oil replacement 1.

Place the machine on a level surface. Place a container under the differential gear case to catch the oil. Remove the oil filler bolt and oil drain bolt to drain the oil.

Fill the differential gear case with the CAUTION: specified amount of the recommended Be sure no foreign material enters the dif- oil. Ferential gear case. Install the oil filler bolt. Do not exceed the specified differential 7. Check for oil leakage. If oil leakage is gear oil quantity when filling.

EBU01068 Cooling system 3. Remove the coolant reservoir cap, and 1. Check the coolant level in the coolant then add coolant or distilled water to raise reservoir when the engine is cold as the it to the specified level.

Coolant level will vary with engine tem- 4. Removing the radiator cap when the en- gine and radiator are still hot.

NOTE: WHAT CAN HAPPEN If water is added, have a Yamaha dealer You could be burned by hot fluid and check the antifreeze content of the cool- steam blown out under pressure. Place the ATV on a level surface. Remove panels E and F. (See pages 8-10 and 8-11 for panel removal and in- stallation procedures.) 3.

Place a container under the engine, and then remove the coolant drain bolt. (Use a trough or a similar object as shown to prevent coolant from spilling on the foot- rest.). 1. Radiator cap 1. Coolant reservoir drain hose 5. Remove the radiator cap. After draining the coolant, thoroughly 6.

Remove the coolant reservoir cap. Flush the cooling system with clean tap 7.

Disconnect the hose on the coolant res- water. Total amount: NOTE: 1.3 L (1.14 Imp qt, 1.37 US qt) If any leakage is found, have a Yamaha deal- Coolant reservoir capacity er check the cooling system. (up to the maximum level mark): 0.25 L (0.22 Imp qt, 0.26 US qt) 16. Check the protective boots for holes or tears.

If any damage is found, have them replaced 1. Remove panel A. (See pages 8-6–8-7 for by a Yamaha dealer. Panel removal and installation proce- dures.) 2. Remove the spark plug cap. Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.

If electrode erosion becomes ex- cessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug. NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. EBU01133 Air filter element cleaning NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. WARNING POTENTIAL HAZARD Using low flash point solvents or gaso- line to clean the air filter element.

WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the 1. Apply Yamaha foam air filter oil or other The air filter element should be cleaned every quality foam air filter oil to the air filter el- 20–40 hours.

It should be cleaned and lubri- ement. If foam air filter oil is not available, cated more often if the machine is operated in engine oil may be used. EBU00641 V-belt cooling duct check hose If dust or water collects in this hose, remove the hose and clean it. V-belt cooling duct check hose (Left front side of ATV) 8-32. EBU01066 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. Remove the bolts.

Remove the tailpipe by pulling it out of the muffler. Spark arrester 4. Insert the tailpipe into the muffler and align the bolt holes. The carburetor is a vital part of the engine and POTENTIAL HAZARD requires very sophisticated adjustment.

Most Improper cleaning of the spark arrester. Adjusting should be left to a Yamaha dealer Hot exhaust system who has the professional knowledge and ex- WHAT CAN HAPPEN perience to do so. To prevent this, the valve clear- crease engine speed. Ance must be adjusted regularly. This adjust- ment however, should be left to a professional Specified idle speed: Yamaha service technician.

1,450–1,550 r/min 8-35. EBU00307 Throttle lever adjustment NOTE: Adjust the engine idling speed before adjust- ing the throttle lever free play. Loosen the locknut.

Turn the adjusting bolt until the throttle le- ver free play is 3–5 mm (0.12–0.20 in). Tighten the locknut. Apply the rear brake and check the position of the in- dicator. If the indicator reaches the wear limit line, ask a Yamaha dealer to replace shoes as a set.

Wear limit: 1 mm (0.04 in). EBU00755 Brake fluid level inspection Observe these precautions: Insufficient brake fluid may let air enter the 1. When checking the fluid level, make sure brake system, possibly causing the brakes to the top of the master cylinder is level by become ineffective. The front brake lever should have a free play spilled fluid immediately. Of zero mm (zero in) at the lever end. Have a Yamaha dealer check the cause have a Yamaha dealer check the brake sys- if the brake fluid level goes down.

Make sure the brakes do not drag. Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components re- quires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU01239 Rear brake pedal and lever adjustment 2. Turn the adjusting nut on the brake pedal Brake pedal free play adjustment cable until the free play is 20–30 mm 1.

Fully loosen the adjusting nut on the (0.8–1.18 in). Brake lever cable at the rear wheel. Brake lever free play adjustment 2.

Turn in the adjusting nut on brake cable 1. Loosen the locknut and fully turn in the to provide a gap of 0–1 mm (0–0.04 in) adjusting bolt at the brake lever. Between the brake camshaft lever and the pin. Make sure the brakes do not drag.

Adjusting bolt a. Free play Replacement of brake components re- 4.

Tighten the locknut. Quires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU01120 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and rear brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If neces- sary, adjust the brake light switch as follows. Inspect cables frequently.

Replace dam- aged cables. Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil 8-45. EBU01112 Wheel removal 1. Loosen the wheel nuts.

Elevate the ATV and place a suitable stand under the frame. Remove the nuts from the wheel. Remove the wheel. Tapered nut (× 4) 8-46. EBU01121 Wheel installation 2. Lower the ATV so that the wheel is on the 1. Install the wheel and the nuts.

NOTE: Tapered nuts are used for both the front and rear wheels. Install the nut with its ta- pered side towards the wheel. Keep out of reach of chil- tery. If the battery seems to have discharged, dren.

Consult a Yamaha dealer. Antidote: EXTERNAL: Flush with water. CAUTION: INTERNAL: Drink large quantities of wa- Do not try to remove the sealing caps of ter or milk. Then turn on the switches. If CAUTION: the fuse immediately blows again, con- A special battery charger (constant volt- sult a Yamaha dealer. Age/ampere or constant voltage) is re- quired recharging sealed-type battery. Spare main fuse 1.

Headlight fuse 2. Ignition fuse 3. Auxiliary DC jack fuse 4. Four-wheel drive fuse 5.

Signaling system fuse 6. Spare fuse (× 3) Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Four-wheel drive fuse: Signaling system fuse: 8-50. EBU01063 Replacing a headlight bulb WARNING If a headlight bulb burns out, replace it as fol- POTENTIAL HAZARD lows: Using an improper fuse.

Remove the cover at the rear of the WHAT CAN HAPPEN headlight by pulling it off. An improper fuse can cause damage to the electrical system which could lead to a fire. WARNING POTENTIAL HAZARD The headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flamma- ble. HOW TO AVOID THE HAZARD 1. Tail/brake light bulb replacement If the tail/brake light bulb burns out, have a CAUTION: Yamaha dealer replace it. It is advisable to have a Yamaha dealer make this adjustment.

To raise the beam, turn the adjusting screw in direction a. EBU00412 Troubleshooting WARNING Although Yamaha machines receive a rigid in- POTENTIAL HAZARD spection before shipment from the factory, Checking the fuel system while smok- trouble may occur during operation. Any prob- ing or near an open flame. Lem in the fuel, compression, or ignition sys. Compression There is compression. Compression normal.

Use the electric starter to see if there is compression. Ask a Yamaha dealer to No compression. Ignition Wipe clean with dry cloth. Ignition system is Spark is good. Restart the engine.

If the engine overheats again, ask a Level is OK. Yamaha dealer to inspect and/or repair the cooling system. NOTE: If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible. EBU00419 C LEANING AND STORAGE CAUTION: Excessive water pressure may cause wa- A. CLEANING ter seepage and deterioration of wheel Frequent, thorough cleaning of your machine bearings, brakes, transmission seals and will not only enhance its appearance but will electrical devices.

Many expensive repair improve its general performance and extend bills have resulted from improper high the useful life of many components. Clean the seat with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after wash- 7.

Automotive type wax may be applied to ing. All painted and chrome plated surfaces. WHAT CAN HAPPEN Avoid combination cleaner-waxes. Do not apply oil to fuel) any rubber parts or the seat cover. NOTE: Use of fuel stabilizer and conditioner elimi- nates the need to drain the fuel system. Con- sult a Yamaha dealer if the fuel system needs to be drained instead. Remove the battery and charge it.

Store it in a dry place and recharge it once a month. Do not store the battery in an ex- cessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the machine. EBU00428 S PECIFICATIONS Model YFM400FAR Dimensions: Overall length 1,984 mm (78.1 in) Overall width 1,085 mm (42.7 in) Overall height 1,120 mm (44.09 in) Seat height 827 mm (32.6 in) Wheelbase 1,233 mm (48.5 in) Minimum ground clearance 245 mm (9.65 in) Minimum turning radius 3,000 mm (118.11 in) Basic weight.

Model YFM400FAR Engine oil: Type 0˚ 10˚ 30˚ 70˚ 90˚ 110˚ 130˚F 50˚ YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 -20˚ -10˚ 0˚ 20˚ 30˚ 40˚ 50˚C 10˚ Recommended engine oil classification: API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the en- gine oil also lubricates the clutch), do not mix any. Model YFM400FAR Final gear case oil: Type SAE80 API “GL-4” Hypoid gear oil Quantity: Periodic oil change 0.23 L (0.20 Imp qt, 0.24 US qt) Total amount 0.25 L (0.22 Imp qt, 0.26 US qt) Differential gear case oil: Type SAE80 API “GL-4”. Model YFM400FAR Spark plug: Type/manufacturer DR8EA / NGK Spark plug gap 0.6–0.7 mm (0.02–0.03 in) Clutch type Wet, centrifugal automatic Transmission: Primary reduction system V-belt Secondary reduction system Spur gear 39/24 × 24/18 × 33/9 (7.944) Secondary reduction ratio Transmission type V-belt automatic Operation Left hand operation.

Model YFM400FAR Brake: Front brake type Dual disc brake operation Right hand operation Rear brake type Drum brake operation Left hand and right foot operation Suspension: Front suspension Double wishbone Rear suspension Swingarm (monocross) Shock absorber: Front shock absorber Coil spring / oil damper Rear shock absorber Coil spring / oil damper Wheel travel. Model YFM400FAR Bulb voltage, wattage × quantity: 12 V, 30/30 W × 2 Headlight 12 V, 5/21 W × 1 Tail/brake light 14 V, 3 W × 1 Meter lighting 12 V, 1.7 W × 1 Neutral indicator light 12 V, 1.7 W × 1 Reverse indicator light 12 V, 1.7 W ×. EBU00430 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop- erative by any person other than for purposes of maintenance, repair, or replacement of any de- vice or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. EBU00431. M AINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to docu- ment maintenance done in accordance with the warranty. The chart below is printed only as a re- minder to you that the maintenance work is required.

02 Yamaha Kodiak 400 Service Manual Pdf

It is not acceptable proof of maintenance work. EBU00432 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 13-1. EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1. EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death. LOCATE AND READ OWNER’S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN USA 2002.04-6.0×2 CR.