2002 YAMAHA KODIAK 400 engine oil

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

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

4-29 1. Drive select lever
1. Levier de présélection
1. Palanca de selección de marcha
1. Recoil starter
1. Lanceur à réenroulement
1. Arranque por tracción de cable
EBU00608
Drive select lever
The drive select lever is used to shift your machine
into the low, high, neutral, reverse and park posi-
tions. (Refer to pages 6-11 ~ 6-15 for the drive se-
lect lever operation.)
EBU00667
Recoil starter
Firmly grasp the handle and pull slightly until en-
gagement can be felt. Then pull forcefully, being
careful not to pull the rope all the way out.
WARNING
Shift the transmission in neutral or set the shift
lever to the park position before starting the
engine or the ATV could start to move unex-
pectedly, which could cause an accident.
U5GH62.book Page 29 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

5-15
EBU00947
Engine oil
Make sure the engine oil is at the specified level.
Fill with oil as necessary. (See pages 8-31 ~ 8-41
for details.)
Recommended oil:
Recommended engine oil classification:
API Service SE, SF, SG type or higher
-20˚ -10˚ 0˚
10˚20˚ 30˚40˚50˚C
10W/30
15W/4020W/4020W/50
10W/40
5W/30
U5GH62.book Page 15 Monday, August 6, 2001 9:09 AM

5-17
CAUTION:_ Be sure to use motor oils that do not contain
anti-friction modifiers. Passenger car motor
oils (often labeled “ENERGY CONSERVING II”)
contain anti-friction additives which will cause
clutch and/or starter clutch slippage, resulting
in reduced component life and poor engine
performance. _
Oil quantity:
Total amount:
2.6 L
Periodic oil change:
2.3 L
With oil filter replacement:
2.4 L
U5GH62.book Page 17 Monday, August 6, 2001 9:09 AM

6-7 a. Starter (choke) lever
1. Fully open
2. Half open
3. Closed
a. Starter (enrichisseur)
1. Complètement ouvert
2. Mi-ouvert
3. Fermé
a. Arrancador (choke)
1. Abre completamente
2. Semiabierto
3. Cerrado
NOTE:

If the engine fails to start, release the start
switch, then push the start switch again.
Pause a few seconds before the next attempt.
Each cranking should be as short as possible
to preserve battery energy. Do not crank the
engine more than 10 seconds on each at-
tempt.


If the battery is discharged, pull the recoil
starter to start the engine.
7. If the engine is started with the starter (choke)
in position
1, the starter (choke) should be
returned to position
2 to warm up the en-
gine. If the engine is started with the starter
(choke) in position
2, keep the starter
(choke) in this position to warm up the en-
gine.
8. Continue warming up the engine until it idles
smoothly and return the starter (choke) to po-
sition
3 before riding.CAUTION:
See the “Engine break-in” section prior to op-
erating the engine for the first time.
U5GH62.book Page 7 Monday, August 6, 2001 9:09 AM