2002 YAMAHA KODIAK 400 brake fluid

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

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

5-7
EBU00671
Front and rear brakes
1. Brake levers and brake pedal
Check for correct free play in the rear brake
lever and that there is no free play in the front
brake lever. If the free play is incorrect, adjust
it. (See pages 8-97 ~ 8-101.)
Check the operation of the levers and pedal.
They should move smoothly and there
should be a firm feeling when the brakes are
applied. If not, have the machine inspected
by a Yamaha dealer.
2. Brake fluid level
Check the brake fluid level.
Add fluid if necessary. (See pages 8-91 ~
8-95.)
3. Brake fluid leakage
Check to see if any brake fluid is leaking out
of the pipe joints or master cylinder. Apply the
brakes firmly for one minute. If there is any
leaking, have the machine inspected by a
Yamaha dealer. Recommended brake fluid: DOT 4
U5GH62.book Page 7 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

8-8
* It is recommended that these items be serviced by a Yamaha dealer.NOTE:Recommended brake fluid: DOT 4
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.V-belt*•Check operation.
•Check for cracks or damage every 12 months or
2,400 km whichever comes first.Wheels*•Check balance/damage/runout.
•Repair if necessary.Wheel bearing*•Check bearing assemblies for looseness/damage.
•Replace if damaged.Front and rear
suspension*•Check operation.
•Correct if necessary.Steering system*•Check operation/Replace if damaged.
•Check toe-in/Adjust if necessary.Axle boots*•Check operation.
•Replace if damaged.Fittings and Fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U5GH62.book Page 8 Monday, August 6, 2001 9:09 AM

8-91 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
FRONT
Avant
Delantero1. Maximum level mark
1. Repère de niveau maximum
1. Marca de nivel máximoREAR
Arrière
Trasero
EBU00622
Inspecting the brake fluid level
Insufficient brake fluid may let air enter the brake
system, possibly causing the brakes to become in-
effective.
Before riding, check that the brake fluid is above
the lower level and replenish when necessary.
The rear brake fluid master cylinder reservoir is lo-
cated under panel C. (See pages 8-23 ~ 8-25 for
removal and installation procedures.)
Observe these precautions:
1. When checking the fluid level, make sure the
top of the master cylinder reservoir is level by
turning the handlebars.
2. Use only the designated quality brake fluid.
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake perfor-
mance.
Recommended brake fluid: DOT 4
U5GH62.book Page 91 Monday, August 6, 2001 9:09 AM

8-93
3. Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reac-
tion and lead to poor brake performance.
4. Be careful that water does not enter the mas-
ter cylinder reservoir when refilling. Water will
significantly lower the boiling point of the fluid
and may result in vapor lock.
5. Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
6. Have a Yamaha dealer check the cause if the
brake fluid level goes down.
U5GH62.book Page 93 Monday, August 6, 2001 9:09 AM