2002 YAMAHA KODIAK 400 oil 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

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

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

8-33 1. Engine oil drain bolt
2. Oil strainer
1. Boulon de vidange de l’huile
2. Crépine à huile
1. Perno de drenaje del aceite de motor
2. Colador de aceite
Engine oil and oil filter cartridge replacement
1. Remove panels E and F. (See pages 8-27 ~
8-29 for panel removal and installation pro-
cedures.)
2. Warm up the engine for several minutes.
3. Stop the engine. Place an oil pan under the
engine and remove the dipstick.
4. Remove the drain bolt and drain the oil.
U5GH62.book Page 33 Monday, August 6, 2001 9:09 AM

8-35 1. Oil filter element
1.Élément de filtre à huile
1. Elemento del filtro de aceite
1. Oil filter wrench
1. Clé pour filtre à huile
1. Llave para filtros de aceite
5. Remove the oil filter by using an oil filter
wrench.NOTE:_ An oil filter wrench is available at a nearby
Yamaha dealer. _6. Install the drain bolt and tighten it to the spec-
ified torque.
Tightening torque:
Drain bolt:
32 Nm (3.2 m·kgf)
U5GH62.book Page 35 Monday, August 6, 2001 9:09 AM

8-37 1. Torque wrench
1. Clé dynamométrique
1. Llave de apriete
7. Apply a light coat of engine oil to the O-ring of
the new oil filter.NOTE:_ Make sure the O-ring is seated properly. _8. Install the oil filter and tighten it to the speci-
fied torque with a torque wrench.
Tightening torque:
Oil filter:
17 Nm (1.7 m·kgf)
U5GH62.book Page 37 Monday, August 6, 2001 9:09 AM

8-39
9. Fill the engine with sufficient oil to reach the
specified level. Install the dipstick and tighten
it.CAUTION:_

Do not put in any chemical additives. En-
gine oil also lubricates the clutch and addi-
tives could cause clutch slippage.


Be sure no foreign material enters the
crankcase.
_
Recommended oil:
See page 10-2.
Oil quantity:
Total amount:
2.6 L
Periodic oil change:
2.3 L
With oil filter replacement:
2.4 L
U5GH62.book Page 39 Monday, August 6, 2001 9:09 AM