2002 YAMAHA KODIAK 400 check engine

6-9
EBU00180
Starting a warm engine
To start a warm engine, refer to the “Starting a cold
engine” section. The starter (choke) should not be
used. The throttle should be opened slightly.
EBU00182
Warming up
To get maximum engine life, always warm up the
engine before starting off. Never accelerate hard
with a cold engine! To see whether or not the en-
gine is warm, check if it responds to the throttle
normally with the starter (choke) turned off.
U5GH62.book Page 9 Monday, August 6, 2001 9:09 AM

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*•Check valve clearance.
•Adjust if necessary.
Cooling system•Check coolant leakage.
•Repair if necessary.
•Replace coolant every 24 months.Spark plug•Check condition.
•Adjust gap and clean.
•Replace if necessary.Air filter•Clean.
•Replace if necessary.Every 20~40 hours
(More often in wet or dusty areas.)
Crankcase breather
system*•Check breather hose for cracks or damage.
•Replace if necessary.Exhaust system*•Check for leakage.
•Retighten if necessary.
•Replace gasket(s) if necessary.Carburetor*•Check and adjust idle speed/starter operation.
•Adjust if necessary.Fuel line*•Check fuel hose for cracks or damage.
•Replace if necessary.Engine oil
•Replace (Warm engine before draining).Engine oil filter cartridge
•Replace.Engine oil strainer*
•Clean.Final gear oil
•Check oil level/oil leakage.
•Replace every 12 months.Differential gear oil
Front brake*•Check operation/fluid leakage/see NOTE page 8-8.
•Correct if necessary.Rear brake*•Check operation/fluid leakage/see NOTE page 8-8.
•Correct if necessary.U5GH62.book Page 7 Monday, August 6, 2001 9:09 AM

8-31 1. Engine oil dipstick
1. Jauge d’huile
1. Varilla de medición del aceite de motor
1. Maximum level mark 2. Minimum level mark
1. Repère de niveau maximum 2. Repère de niveau minimum
1. Marca de nivel máximo 2. Marca de nivel mínimo
EBU00847
Engine oil
Oil level inspection
1. Remove panel E. (See page 8-27 for panel
removal and installation procedures.)
2. Place the ATV on a level place and warm up
the engine for several minutes.
3. Stop the engine.
4. Remove the dipstick and wipe it off with a
clean rag. Insert the dipstick in the filler hole
without screwing it in.NOTE:_ Wait a few minutes until the oil level settles before
checking. _5. The oil level should be between the maxi-
mum and minimum marks. If the level is low,
fill the engine with sufficient oil to reach the
specified level.
U5GH62.book Page 31 Monday, August 6, 2001 9:09 AM

8-41
‘1. Final gear oil
2. Final gear case filler bolt
3. Proper level
1. Huile de transmission finale
2. Boulon de remplissage du carter de transmission finale
3. Niveau correct
1. Aceite de la transmisión final
2. Tapa de la caja del filtro
3. Nivel adecuado
10. Start the engine and warm it up for several
minutes. While warming up, check for oil
leakage. If oil leakage is found, stop the en-
gine immediately and check for the cause.
11. Install the panels.
EBU00825
Final gear oil
Final gear oil measurement
1. Place the machine on a level place.
2. Remove the oil filler bolt and check the oil lev-
el. It should be up to the brim of the hole. If
the level is low, add oil to raise it to the proper
level.CAUTION:_ Be sure no foreign material enters the final
gear case. _
U5GH62.book Page 41 Monday, August 6, 2001 9:09 AM

8-53 1. Coolant reservoir tank cap
2. Maximum level mark
3. Minimum level mark
1. Bouchon du vase d’expansion
2. Repère de niveau maximum
3. Repère de niveau minimum
1. Tapa del depósito de refrigerante
2. Marca de nivel máximo
3. Marca de nivel mínimo
EBU01000
Cooling system
1. Check the coolant level in the reservoir when
the engine is cold as the coolant level will
vary with engine temperature. The coolant
level should be between the maximum and
minimum marks.
2. If the level is low, remove panel D. (See page
8-17 ~ 8-19 for panel removal and installation
procedures.)
U5GH62.book Page 53 Monday, August 6, 2001 9:09 AM

8-63 1. Front axle boot (× 2 each side)
1. Soufflet d’axe avant (× 2 de chaque côté)
1. Guardapolvo de eje delantero (× 2 en cada lado)
12. Install the radiator cap.
13. Start the engine and let it idle for several min-
utes. Stop the engine, and then check the
coolant level in the radiator. If it is low, add
more coolant until it reaches the top of the ra-
diator.
14. Fill the coolant reservoir with coolant up to
the maximum level.
15. Install the coolant reservoir cap and check for
coolant leakage.NOTE:_ If any leakage is found, ask a Yamaha dealer to in-
spect the cooling system. _16. Install the panels and the front carrier.
EBU00862
Axle boots
Check the protective boots for holes or tears. If any
damage is found, have them replaced by a
Yamaha dealer.
U5GH62.book Page 63 Monday, August 6, 2001 9:09 AM

8-75 1. Connect the hose.
1. Brancher le flexible.
1. Conecte la manguera.
8. Reinstall the element to the element guide.
9. Reinstall the element assembly and parts re-
moved for access.NOTE:The air filter element should be cleaned every 20 ~
40 hours. It should be cleaned and lubricated more
often if the machine is operated in extremely dusty
areas. Each time filter element maintenance is
performed, check the air inlet to the filter case for
obstructions. Check the air cleaner rubber joint to
the carburetor and manifold fittings for an air-tight
seal. Tighten all fittings securely to avoid the pos-
sibility of unfiltered air entering the engine.CAUTION:
Never operate the engine with the air filter ele-
ment removed. This will allow unfiltered air to
enter, causing rapid engine wear and possible
engine damage. Additionally, operation with-
out the filter element will affect carburetor jet-
ting with subsequent poor performance and
possible engine overheating.
U5GH62.book Page 75 Monday, August 6, 2001 9:09 AM

8-135
EBU00724Troubleshooting chart
Starting problems or poor engine performance1. Fuel
Check if there is fuel
in the fuel tank.There is fuel.Turn the fuel cock
lever to “OFF”.No fuel.Fuel cock is
clogged.
Clean the
fuel cock. Some fuel.Turn the fuel cock
lever to “RES”.Restart the engine.
No fuel.Supply fuel.
2. Compression
Use the electric
starter to see if
there is compression.There is compression.
Compression normal.
No compression.Ask a Yamaha dealer to
inspect.
3. Ignition
Remove the
spark plug and
check electrodes.WetWipe clean with dry cloth.
DryAttach spark plug cap and
ground to chassis.Use the
electric starter.Spark is good.Ignition system is
normal.
Spark is weak.
Adjust the spark plug gap
or replace the spark plug. No spark.
Ask a Yamaha dealer to
inspect. 4. Battery
Use the electric starter.Engine turns over
quickly.Battery is good.
Engine turns over
slowly.Check the connections.Check the
fuel flow.
Turn the fuel cock
lever to “ON”.
Remove the fuel hose
from the fuel cock.
U5GH62.book Page 135 Monday, August 6, 2001 9:09 AM