2002 YAMAHA KODIAK 400 tires

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

2-13

Always be sure there are no obstacles or peo-
ple behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly.


Always use the size and type tires specified in
this manual.


Always maintain proper tire pressure as de-
scribed in this manual.


Never modify an ATV through improper instal-
lation or use of accessories.


Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow
instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for brak-
ing.
U5GH62.book Page 13 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

5-25
EBU00158
Tires
Always use the recommended tires.
WARNING
Use of improper tires on this ATV, or operation
of this ATV with improper or uneven tire pres-
sure, may cause loss of control, increasing
your risk of accident.
Pay attention to the following.
1. The tires listed below have been approved
by Yamaha Motor Co., Ltd. for this model.
Other tire combinations are not recom-
mended.(For Europe)
(For Oceania)2. The tires should be set to the recommend-
ed pressure:
Manufacturer Size Type
Front DUNLOP AT25
× 8 - 12 KT123
Rear DUNLOP AT25
× 10 - 12 KT127
Manufacturer Size Type
Front CHENG-SHIN AT25
× 8 - 12 C828
Rear CHENG-SHIN AT25
× 10 - 12 C828
U5GH62.book Page 25 Monday, August 6, 2001 9:09 AM

5-27

Recommended tire pressure
Front 25 kPa (0.25 kgf/cm
2, 0.25 bar)
Rear 25 kPa (0.25 kgf/cm2, 0.25 bar)


Check and adjust tire pressures when the
tires are cold.


Tire pressures must be equal on both sides.
3. Tire pressure below the minimum speci-
fied could cause the tire to dislodge from
the rim under severe riding conditions.
The following are minimums:
Front 22 kPa (0.22 kgf/cm
2, 0.22 bar)
Rear 22 kPa (0.22 kgf/cm2, 0.22 bar)
4. Use no more than the following pressures
when seating the tire beads.
Front 250 kPa (2.5 kgf/cm2, 2.5 bar)
Rear 250 kPa (2.5 kgf/cm2, 2.5 bar)
Higher pressures may cause the tire to
burst. Inflate the tires very slowly and
carefully. Fast inflation could cause the
tire to burst.
U5GH62.book Page 27 Monday, August 6, 2001 9:09 AM

5-29 1. Low-pressure tire gauge
1. Manomètre basse pression pour pneus
1. Manómetro de baja presión
EBU00159
How to measure tire pressure
Use the low-pressure tire gauge.NOTE:The low-pressure tire gauge is included as stan-
dard equipment. Make two measurements of the
tire pressure and use the second reading. Dust or
dirt in the gauge could cause the first reading to be
incorrect.Set pressure with tires cold.
Set tire pressures to the following specifications:ACE-02EACE-02E
Recommended
pressureMinimum Maximum
Front25 kPa
(0.25 kgf/cm
2,
0.25 bar)22 kPa
(0.22 kgf/cm
2,
0.22 bar)28 kPa
(0.28 kgf/cm
2,
0.28 bar)
Rear25 kPa
(0.25 kgf/cm
2,
0.25 bar)22 kPa
(0.22 kgf/cm
2,
0.22 bar)28 kPa
(0.28 kgf/cm
2,
0.28 bar)
U5GH62.book Page 29 Monday, August 6, 2001 9:09 AM

7-15
WARNING
_ Always use the size and type tires specified in
the Owner’s Manual for this vehicle on pages
5-25 ~ 5-27. Always maintain proper tire pres-
sure as described in the Owner’s Manual on
page 5-29. Use of improper tires on this ATV,
or operation of this ATV with improper or un-
even tire pressure, may cause loss of control,
increasing your risk of an accident. _Do not operate at speeds too fast for your
skills or the conditions.
WARNING
_ Always go at a speed that is proper for the ter-
rain, visibility and operating conditions, and
your experience. Operating this ATV at speeds
too fast for your skills or the conditions in-
creases your chances of losing control of the
ATV, which can result in an accident. _
U5GH62.book Page 15 Monday, August 6, 2001 9:09 AM

7-37
With the engine idling, shift the drive select lever
into the low “L” or the high “H” position. Apply the
throttle slowly and smoothly. The centrifugal clutch
will engage and you will start to accelerate. If the
throttle is applied too abruptly, the front wheels
may lift off the ground resulting in a loss of direc-
tional control. Avoid higher speeds until you are
thoroughly familiar with the operation of your ATV.
When slowing down or stopping, release the throt-
tle and apply the brakes smoothly and evenly. Im-
proper use of the brakes can cause the tires to
lose traction, reducing control and increasing the
possibility of an accident.CAUTION:_ Do not shift from low to high or vice versa with-
out coming to a complete stop. Damage to the
engine or drive train may occur. _
U5GH62.book Page 37 Monday, August 6, 2001 9:09 AM