2003 YAMAHA KODIAK 400 differential

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

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
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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

8-45 1. Differential case oil filler bolt
1. Boulon de remplissage du carter de différentiel
1. Perno de relleno de aceite de la caja del diferencial
1. Differential gear oil drain bolt
1. Boulon de vidange de l’huile de différentiel
1. Perno de drenaje de aceite de engranajes del diferencial
EBU01241
Differential gear oil replacement
1. Place the machine on a level surface.
2. Place a container under the differential gear
case to catch the oil.
3. Remove the oil filler bolt and oil drain bolt to
drain the oil.
4. Install the oil drain bolt, and then tighten it to
the specified torque.
Tightening torque:
Drain bolt:
10 Nm (1.0 m·kgf)
U5TE60.book Page 45 Monday, June 10, 2002 8:47 AM

8-47
5. Fill the differential gear case with the speci-
fied amount of the recommended oil.NOTE:_

Do not exceed the specified differential gear
oil quantity when filling. Overfilling will cause
the oil to seep out of the breather hose during
and after riding.


The differential gear oil level cannot be
checked. The differential gear case capacity
is greater than the recommended oil quantity,
therefore the oil level cannot be accurately
checked from the oil filler cap hole.
_
Recommended oil:
SAE 80 API “GL-4” Hypoid gear oil
Oil quantity:
0.4 L
U5TE60.book Page 47 Monday, June 10, 2002 8:47 AM

10-3
Final gear oil:
Type SAE 80 API “GL-4” Hypoid gear oil
Quantity
Periodic oil change 0.23 L
Total amount 0.25 L
Differential gear oil:
Type SAE 80 API “GL-4” Hypoid gear oil
Quantity
Periodic oil change 0.35 L
Total amount 0.40 L
Radiator capacity (including all routes): 1.32 L
Air filter: Wet type element
Fuel:
Type For Europe: Regular unleaded gasoline only
For Australia: Unleaded gasoline only
Fuel tank capacity 15 L
Fuel reserve amount 4.5 L
Carburetor:
Type/quantity BSR33/1
Manufacturer MIKUNIModel YFM400FA
U5TE60.book Page 3 Monday, June 10, 2002 8:47 AM