2003 YAMAHA KODIAK 400 brake light

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

Cable inspection and lubrication ...... 8-105
Brake lever and brake pedal
lubrication ....................................... 8-107
Wheel removal ................................. 8-109
Wheel installation ............................. 8-111
Battery .............................................. 8-113
Battery maintenance ........................ 8-117
Fuse replacement............................. 8-119
Replacing a headlight bulb ............... 8-123
Headlight beam adjustment.............. 8-127
Tail/brake light bulb replacement ..... 8-127
Troubleshooting................................ 8-129
Troubleshooting chart....................... 8-131
CLEANING AND STORAGE .................. 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................ 10-1
CONVERSION TABLE .......................... 11-1
91011U5TE60.book Page 3 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

5-23
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

6-13 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. _
U5TE60.book Page 13 Monday, June 10, 2002 8:47 AM