2003 YAMAHA KODIAK 400 brake

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.
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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

5-5
EBU01276
Front and rear brakes
Brake levers and brake pedal

Check that there is no free play in the front
brake lever. If there is free play, have a
Yamaha dealer adjust it.


Check for correct free play in the rear brake le-
ver. If the free play is incorrect, adjust it.


Check for correct brake pedal height. If the
pedal height is incorrect, have a Yamaha deal-
er adjust it.


Check the operation of the brake levers and
pedal. They should move smoothly and there
should be a firm feeling when the brakes are
applied. If not, have a Yamaha dealer inspect
the brake system.
Brake fluid level
Check the brake fluid level. Add fluid if necessary.
(See pages 8-89–8-93.)
Recommended brake fluid: DOT 4
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5-7
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joints or brake fluid reservoirs. Apply the
brakes firmly for one minute. If there is any leak-
age, the brake system should be inspected by a
Yamaha dealer.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, in-
spect the brake pads for wear. (See page 8-87.)
WARNING
_ Always check the brakes at the start of every
ride. Do not ride the ATV if you find any prob-
lem with the brakes or you could lose braking
ability, which could lead to an accident. If a
problem cannot be corrected by the adjust-
ment procedures provided in this manual,
have a Yamaha dealer check for the cause. _
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5-23
EBU01162
Fittings and fasteners
Always check the tightness of chassis fittings and
fasteners before a ride. Take the machine to a
Yamaha dealer or refer to the Service Manual for
correct tightening torque.
EBU01003
Lights
Check the headlights and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU01170
Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper op-
eration.
U5TE60.book Page 23 Monday, June 10, 2002 8:47 AM

6-3
EBU01265
Starting a cold engine
WARNING
_ Always make sure all control cables work
smoothly before you begin riding in cold
weather. If the control cables are frozen or do
not work smoothly, you could be unable to
control the ATV, which could lead to an acci-
dent or collision. _1. Apply the rear brake lever.
2. Turn the fuel cock to “ON”.
3. Turn the main switch to “ON”, and then set
the engine stop switch to “”.
4. Shift the drive select lever into the neutral po-
sition.
U5TE60.book Page 3 Monday, June 10, 2002 8:47 AM

6-13 1. Drive select lever
a. F (Forward)
b. N (Neutral)
c. R (Reverse)
1. Levier de présélection
a. F (Marche avnt)
b. N (Point mort)
c. R (Marche arrière)
1. Palanca de selección de marcha
a. F (Marcha adelante)
b. N (Punto muerto)
c. R (Marcha atrás)
Shifting: reverse “R”
1. Bring the machine to a complete stop and re-
turn the throttle lever to the closed position.
2. Apply the parking brake.
3. Shift the drive select lever from neutral “N” to
reverse “R” and vice versa by moving the
drive select lever along the shift guide.NOTE:_ When in reverse “R”, the reverse indicator light
should be on. If the light does not come on, ask a
Yamaha dealer to inspect the machine. _4. Check behind for people or obstacles, then
release the parking brake.
5. Open the throttle lever gradually and contin-
ue to watch to the rear while backing.NOTE:_ If the drive select lever is shifted into reverse “R”
while the engine is running, the engine will stop un-
less the parking brake or rear brake lever is ap-
plied. _
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6-19
1. 0–10 hours:
Avoid continuous operation above half throt-
tle. Allow a cooling off period of five to ten
minutes after every hour of operation. Vary
the speed of the machine from time to time.
Do not operate it at one set throttle position.
2. 10–20 hours:
Avoid prolonged operation above 3/4 throttle.
Rev the machine freely but do not use full
throttle at any time.
3. After break-in:
Avoid prolonged full throttle operation. Vary
speeds occasionally.
EBU00211
Parking
When parking, stop the engine and shift into neu-
tral. Turn the fuel cock to “OFF” and apply the
parking brake.
U5TE60.book Page 19 Monday, June 10, 2002 8:47 AM