2003 YAMAHA KODIAK 400 coolant level

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

4-3 1. Coolant temperature warning light “”
2. Reverse indicator light “R”
3. Four-wheel drive indicator light “”
4. Neutral indicator light “N”
1. Témoin d’avertissement de la température du liquide de
refroidissement “”
2. Témoin de marche arrière “R”
3. Témoin 4x4 “”
4. Témoin de point mort “N”
1. Luz de aviso de la temperatura del refrigerante “”
2. Luz de control de marcha atrás “R”
3. Luz de control del modo de tracción de cuatro ruedas “”
4. Luz de control de punto muerto “N”
EBU00043
Indicator lights
EBU01223
Coolant temperature warning light “”
When the coolant temperature reaches a specified
level, this light comes on to warn that the coolant
temperature is too hot. If the light comes on during
operation, stop the engine as soon as it is safe to
do so and allow the engine to cool down for about
10 minutes.
To check the coolant temperature warning light,
shift the drive select lever into neutral, turn the key
to “ON”, and then press the start switch. If the light
does not come on, have a Yamaha dealer inspect
the electrical circuit.CAUTION:_

The engine may overheat if the ATV is
overloaded. If this happens, reduce the
load to specification.


Restart after making sure that the light is
out. Continuous use while the light is on
may cause damage to the engine.
_
U5TE60.book Page 3 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

5-19
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

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 element•Clean.
•Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*•Check and adjust idle speed/starter operation.
•Adjust if necessary.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.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.
•Adjust if necessary.U5TE60.book Page 7 Monday, June 10, 2002 8:47 AM

8-51 1. Coolant reservoir cap
2. Maximum level mark
3. Minimum level mark
1. Bouchon du vase d’expansion
2. Repère de niveau maximum
3. Repère de niveau minimum
1. Tapa del depósito de refrigerante
2. Marca de nivel máximo
3. Marca de nivel mínimo
EBU01000
Cooling system
1. Check the coolant level in the reservoir when
the engine is cold as the coolant level will
vary with engine temperature. The coolant
level should be between the maximum and
minimum marks.
2. If the level is low, remove panel D. (See pag-
es 8-17–8-21 for panel removal and installa-
tion procedures.)
U5TE60.book Page 51 Monday, June 10, 2002 8:47 AM

8-53
3. Remove the reservoir cap, and then add
coolant or distilled water to raise it to the
specified level.
4. Install the panel.CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you can’t get
distilled water. _NOTE:_

If water is added, have a Yamaha dealer
check the antifreeze content of the coolant as
soon as possible.


The radiator fan operation is completely auto-
matic. It is switched on or off according to the
coolant temperature in the radiator.
_If your ATV overheats, see page 8-132 for details.Coolant reservoir capacity:
0.25 L
U5TE60.book Page 53 Monday, June 10, 2002 8:47 AM

8-55 1. Coolant drain bolt
1. Boulon de vidange du liquide de refroidissement
1. Perno de drenaje del refrigerante
1. Trough
1. Feuille de papier repliée en forme de conduit
1. Pasante
EBU00977
Changing the coolant
WARNING
_ Wait for the engine and radiator to cool before
removing the radiator cap. You could be
burned by hot fluid and steam blown out under
pressure. Always put a thick rag over the cap
when opening. Allow any remaining pressure
to escape before completely removing the cap. _1. Place the ATV on a level surface.
2. Remove panels E and F. (See pages 8-25–
8-27 for removal and installation procedures.)
3. Place a container under the engine, and then
remove the coolant drain bolt. (Use a trough
or a similar object as shown to prevent cool-
ant from spilling on the footrest.)
4. Remove the front carrier and panel C. (See
pages 8-23 and 8-25 for removal and installa-
tion procedures.)
U5TE60.book Page 55 Monday, June 10, 2002 8:47 AM