2002 YAMAHA KODIAK 400 air filter

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

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

7-65
1. Air filter case check hose
1. Flexible de contrôle du boîtier de filtre à air
1. Manguera de comprobación de la caja del filtro de aire
Test your brakes after leaving the water. Do not
continue to ride your ATV without verifying that
you have regained proper braking ability.CAUTION:_ After riding your ATV in water, be sure to 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. Wash
the ATV in fresh water if it has been operated in
salt water or muddy conditions. _
U5GH62.book Page 65 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

8-71 1. Air filter case check hose
1. Flexible de contrôle du boîtier de filtre à air
1. Manguera de comprobación de la caja del filtro de aire
1. Clip (× 4) 2. Air filter cover
1. Clip (× 4) 2. Couvercle de filtre à air
1. Retenedor (× 4) 2. Cubierta del filtro de aire
EBU00289
Air filter cleaningNOTE: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 fil-
ter case.1. Remove the seat.
2. Remove the air filter case cover.
U5GH62.book Page 71 Monday, August 6, 2001 9:09 AM

8-73 1. Air filter element
1.Élément de filtre à air
1. Elemento del filtro de aire
1. Air filter guide
1. Guide de filtre à air
1. Filtro de aire guía
3. Remove the air filter element, and separate it
from the guide.
4. Wash the element gently but thoroughly in
solvent.
WARNING
Always use parts cleaning solvent to clean the
air filter element. Never use low flash point sol-
vents or gasoline to clean the air filter element
because the engine could catch fire or ex-
plode.5. Squeeze the excess solvent out of the filter
and let it dry.CAUTION:
Do not twist the filter element when squeezing
it.6. Inspect the element. If damaged, replace it.
7. Apply SAE 10W30 motor oil to the element.NOTE:The element should be wet but not dripping.
U5GH62.book Page 73 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

10-3
Final gear oil:
Type SAE 80 API “GL-4” Hypoid gear oil
Quantity
Periodic oil change 0.19 L
Total amount 0.22 L
Differential gear oil:
Type SAE 80 API “GL-4” Hypoid gear oil
Quantity
Periodic oil change 0.35 L
Total amount 0.4 L
Air filter: Wet type element
Fuel:
Type For Europe: Regular unleaded gasoline only
For Australia: Unleaded gasoline only
Fuel tank capacity 15 L
Fuel reserve amount 4.5 L
Carburetor:
Type/quantity BSR33/1
Manufacturer MIKUNIModel YFM4FAP
U5GH62.book Page 3 Monday, August 6, 2001 9:09 AM