2003 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
Speedometer ........................................ 4-7
Fuel gauge ........................................... 4-9
Handlebar switches ............................ 4-11
Throttle lever ...................................... 4-17
Speed limiter ...................................... 4-19
Front brake lever ................................ 4-21
Rear brake pedal and lever ................ 4-23
Parking brake ..................................... 4-25
Drive select lever ................................ 4-27
1234
Recoil starter ...................................... 4-29
Fuel tank cap ..................................... 4-29
Fuel cock............................................ 4-31
Starter (choke) ................................... 4-33
Seat.................................................... 4-35
Storage box........................................ 4-37
Front carrier ....................................... 4-39
Rear carrier ........................................ 4-39
Front shock absorber adjustment ...... 4-41
Rear shock absorber adjustment ....... 4-45
Auxiliary DC jack ................................ 4-47
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Final gear oil ...................................... 5-17
Differential gear oil ............................. 5-19
Coolant............................................... 5-19
Throttle lever ...................................... 5-21
Fittings and fasteners......................... 5-23
Lights ................................................. 5-23
Switches............................................. 5-23
Tires ................................................... 5-25
5
U5TE60.book Page 1 Monday, June 10, 2002 8:47 AM

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
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
What to do if ........................................7-75
What to do...........................................7-75
67
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 ............................................ 8-29
Final gear oil ....................................... 8-39
Differential gear oil replacement ......... 8-45
Cooling system ................................... 8-51
Changing the coolant.......................... 8-55
Axle boots ........................................... 8-61
Spark plug inspection ......................... 8-63
Air filter element cleaning ................... 8-69
V-belt cooling duct check hose ........... 8-77
Carburetor adjustment ........................ 8-79
Idle speed adjustment ........................ 8-81
Valve clearance adjustment ............... 8-83
Throttle lever adjustment .................... 8-85
Front brake pad inspection ................. 8-87
Rear brake shoe inspection ................ 8-87
Brake fluid level check ........................ 8-89
Brake fluid replacement ...................... 8-93
Front brake lever free play.................. 8-95
Rear brake pedal and lever
adjustment ........................................ 8-97
Adjusting the rear brake light
switch ............................................. 8-103
8
U5TE60.book Page 2 Monday, June 10, 2002 8:47 AM

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear spring preload
adjusting ring
2. Storage compartment
and tool kit
3. Spark plug
4. Front spring preload
adjusting ring
5. Rear brake pedal
6. V-belt case
7. Radiator cap
8. Fuel cock
9. Air filter case
10. Fuses
11. Tail/brake light
12. Front spring preload
adjusting ring
13. V-belt cooling duct check
hose14. Coolant reservoir
15. Oil filter cartridge
16. Engine oil dipstick
17. Rear brake lever
18. Left handlebar switches
19. Starter (choke)
20. Horn switch
21. Drive select lever
22. Speedometer
23. Main switch
24. Fuel tank cap
25. Auxiliary DC jack
26. Right handlebar
switches
27. Throttle lever
28. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5TE60.book Page 1 Monday, June 10, 2002 8:47 AM

4-29 1. Recoil starter
1. Lanceur à réenroulement
1. Arranque por tracción de cable
1. Fuel tank cap
1. Bouchon du réservoir de carburant
1. Tapón del depósito de combustible
EBU01264
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 drive select lever into the neutral po-
sition and apply the parking brake before start-
ing the engine or the ATV could start to move
unexpectedly, which could cause an accident. _
EBU00092
Fuel tank cap
Remove the fuel tank cap by turning it counter-
clockwise.
U5TE60.book Page 29 Monday, June 10, 2002 8:47 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.5-5–5-7,
8-87–8-103
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13–5-15,
8-29–8-39
CoolantCheck coolant level in reservoir.
Fill with coolant if necessary.8-51–8-61
Final gear oil and
differential gear oilCheck for leakage. 5-17–5-19, 8-39–8-49
ThrottleCheck for proper throttle cable operation. 5-21, 8-85
Wheels and tiresCheck tire pressure, wear and damage.5-25–5-31,
8-109–8-111
Fittings and fastenersCheck all fittings and fasteners. 5-23
LightsCheck for proper operation. 5-23, 8-123–8-127
Axle bootsCheck for damage. 8-61
U5TE60.book Page 1 Monday, June 10, 2002 8:47 AM

5-13
EBU01180
Engine oil
Make sure the engine oil is at the specified level.
Fill with oil as necessary. (See pages 8-29–8-39
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
U5TE60.book Page 13 Monday, June 10, 2002 8:47 AM

5-15
CAUTION:_

In order to prevent clutch slippage (since
the engine oil also lubricates the clutch),
do not mix any chemical additives. Do not
use oils with a diesel specification of “CD”
or oils of a higher quality than specified. In
addition, do not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign material enters
the crankcase.
_
Oil quantity:
Periodic oil change:
2.3 L
With oil filter element replacement:
2.4 L
Total amount:
2.6 L
U5TE60.book Page 15 Monday, June 10, 2002 8:47 AM

5-19
EBU00678*
Differential gear oil
Make sure the differential gear oil is at the speci-
fied level. Add oil as necessary. (See pages 8-45–
8-49 for details.)
EBU01244
Coolant
Check the coolant level in the coolant reservoir
when the engine is cold. (The coolant level will
vary with engine temperature.) The coolant level is
satisfactory if it is between the upper and lower
level marks on the coolant reservoir. If the coolant
level is at or below the lower level mark, add tap
water (soft water) to bring the level up to the upper
level mark. Change the coolant every two years.
(See pages 8-51–8-61 for details.) Recommended oil:
SAE 80 API “GL-4” Hypoid gear oil
U5TE60.book Page 19 Monday, June 10, 2002 8:47 AM