2002 YAMAHA KODIAK 400 brake

EBU00015
1-CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ...................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION AND MACHINE
IDENTIFICATION ................................... 3-1
Identification number records .............. 3-3
Key identification number .................... 3-5
Vehicle identification number ............... 3-7
Model label ........................................... 3-9
CONTROL FUNCTIONS ........................ 4-1
Main switch .......................................... 4-1
Indicator lights ..................................... 4-3
Coolant temperature warning light
checking method ............................... 4-7
Speedometer ..................................... 4-11
Fuel gauge ........................................ 4-13
Handlebar switches ........................... 4-15
Throttle lever ..................................... 4-21
Speed limiter ..................................... 4-23
Front brake lever ............................... 4-25
Rear brake pedal and lever ............... 4-27
1234
Drive select lever .............................. 4-29
Recoil starter ..................................... 4-29
Fuel tank cap .................................... 4-31
Fuel cock ........................................... 4-33
Starter (choke) “” .......................... 4-35
Seat ................................................... 4-37
Storage box ....................................... 4-39
Front carrier ...................................... 4-39
Rear carrier ....................................... 4-39
Front shock absorber adjustment ..... 4-41
Rear shock absorber adjustment ...... 4-45
Auxiliary DC jack ............................... 4-49
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes ......................... 5-7
Fuel .................................................... 5-11
Engine oil ........................................... 5-15
Final gear oil ..................................... 5-19
Differential gear oil ............................ 5-21
Throttle lever ..................................... 5-21
Fittings and Fasteners ...................... 5-21
Lights ................................................ 5-23
Switches............................................. 5-23
5
U5GH62.book Page 1 Monday, August 6, 2001 9:09 AM

Tires ...................................................5-25
How to measure tire pressure ............5-29
Tire wear limit .....................................5-31
OPERATION ...........................................6-1
Starting a cold engine ..........................6-3
Starting a warm engine ........................6-9
Warming up ..........................................6-9
Drive select lever operation and
reverse driving ..................................6-11
Engine break-in ..................................6-17
Parking ...............................................6-19
Parking on a slope .............................6-21
Accessories and loading ....................6-23
Loading ..............................................6-27
RIDING YOUR ATV..................................7-1
Getting to know your ATV .....................7-3
Ride with care and good judgement .....7-5
Be careful where you ride ...................7-27
Turning your ATV ................................7-39
Climbing uphill.....................................7-45
Riding downhill ....................................7-55
Crossing a slope .................................7-59
Crossing through shallow water ..........7-63
Riding over rough terrain ....................7-69
Sliding and skidding ............................7-71
67
What to do if ... ................................... 7-75
What to do ... ...................................... 7-75
PERIODIC MAINTENANCE AND
ADJUSTMENT ........................................ 8-1
Owner’s manual and tool kit ................ 8-3
Periodic maintenance/lubrication ......... 8-7
Panel removal and installation ........... 8-15
Engine oil ............................................ 8-31
Final gear oil ....................................... 8-41
Differential gear oil ............................. 8-47
Cooling system .................................. 8-53
Changing the coolant.......................... 8-57
Axle boots ........................................... 8-63
Spark plug inspection ........................ 8-65
Air filter cleaning ................................ 8-71
V-belt cooling duct check hose .......... 8-77
Carburetor adjustment ....................... 8-81
Idle speed adjustment ....................... 8-83
Valve clearance adjustment .............. 8-85
Throttle lever adjustment ................... 8-87
Front brake pad inspection ................ 8-89
Rear brake pad inspection ................. 8-89
Inspecting the brake fluid level .......... 8-91
Brake fluid replacement ...................... 8-95
Front brake adjustment ...................... 8-97
Rear brake lever adjustment ............. 8-99
8
U5GH62.book Page 2 Monday, August 6, 2001 9:09 AM

Adjusting the rear brake light switch. 8-103
Cable inspection and lubrication ..... 8-105
Brake lever and brake pedal
lubrication ...................................... 8-107
Wheel removal ................................ 8-109
Wheel installation ............................. 8-111
Battery ............................................. 8-113
Battery maintenance ....................... 8-117
Fuse replacement ............................ 8-119
Replacing the headlight bulb ........... 8-123
Headlight beam adjustment ............. 8-127
Tail/brake light bulb replacement ..... 8-129
Troubleshooting ............................... 8-133
Troubleshooting chart ...................... 8-135
CLEANING AND STORAGE .................. 9-1
A. Cleaning .......................................... 9-1
B. Storage ........................................... 9-7
SPECIFICATIONS ................................ 10-1
HOW TO USE THE CONVERSION
TABLE ................................................... 11-1
91011U5GH62.book Page 3 Monday, August 6, 2001 9:09 AM

2-11

Always check for obstacles before operating in
a new area.
Never attempt to operate over large obstacles,
such as large rocks or fallen trees. Always fol-
low proper procedures when operating over
obstacles as described in this manual.


Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing 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 control.


Never operate an ATV in fast flowing water or
in water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.
U5GH62.book Page 11 Monday, August 6, 2001 9:09 AM

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear spring preload
adjusting ring
2. Storage box and tool kit
3. Spark plug
4. Rear brake fluid reservoir
5. Radiator cap
6. Front spring preload
adjusting ring
7. V-belt case
8. Rear brake pedal
9. Front spring preload
adjusting ring
10. Fuel cock
11. Air filter case
12. Fuses
13. Tail/brake light14. V-belt cooling duct check
hose
15. Coolant reservoir
16. Oil filter cartridge
17. Engine oil dipstick
18. Rear brake lever
19. Left handlebar switches
20. Starter (choke)
21. Horn switch
22. Drive select lever
23. Speedometer
24. Main switch
25. Fuel tank cap
26. Auxiliary DC jack
27. Right handlebar switch
28. Throttle lever
29. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5GH62.book Page 1 Monday, August 6, 2001 9:09 AM

4-25 1. Front brake lever
1. Levier de frein avant
1. Palanca del freno delantero
EBU00070
Front brake lever
The front brake lever is located on the right handle-
bar. Pull it toward the handlebar to apply the front
brake.
U5GH62.book Page 25 Monday, August 6, 2001 9:09 AM

4-27 1. Rear brake pedal
1. Pédale de frein arrière
1. Pedal del freno trasero
1. Rear brake lever
1. Levier de frein arrière
1. Palanca del freno trasero
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. Push down on the pedal or pull the le-
ver toward the handlebar to apply the rear brake.
U5GH62.book Page 27 Monday, August 6, 2001 9:09 AM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
BrakesCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-7 ~ 5-9,
8-89 ~ 8-95
FuelCheck fuel level.
Fill with fuel if necessary.5-11 ~ 5-13
Engine oilCheck oil level.
Fill with oil if necessary.5-15 ~ 5-17,
8-31 ~ 8-41
Coolant reservoirCheck coolant level.
Fill with coolant if necessary.8-53 ~ 8-63
Final gear oil/
Differential gear oilCheck for leakage. 5-19, 8-41 ~ 8-51
ThrottleCheck for proper throttle cable operation. 5-21, 8-87
Wheels and tiresCheck tire pressure, wear and damage.5-25 ~ 5-31,
8-109 ~ 8-111
Fittings and FastenersCheck all fittings and fasteners. 5-21
LightsCheck for proper operation. 5-23, 8-123 ~ 8-131
Axle bootsCheck for damage. 8-63
U5GH62.book Page 1 Monday, August 6, 2001 9:09 AM