2003 YAMAHA KODIAK 400 tires

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

2-13

Always be sure there are no obstacles or peo-
ple behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly.


Always use the size and type tires specified in
this manual.


Always maintain proper tire pressure as de-
scribed in this manual.


Never modify an ATV through improper instal-
lation or use of accessories.


Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow
instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for brak-
ing.
U5TE60.book Page 13 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

5-25
EBU00158
Tires
Always use the recommended tires.
WARNING
Use of improper tires on this ATV, or operation
of this ATV with improper or uneven tire pres-
sure, may cause loss of control, increasing
your risk of accident.
Pay attention to the following.
1. The tires listed below have been approved
by Yamaha Motor Co., Ltd. for this model.
Other tire combinations are not recom-
mended.(For Europe)
(For Oceania)2. The tires should be set to the recommend-
ed pressure:
Manufacturer Size Type
Front MAXXIS AT25
× 8 - 12 M911Y
Rear MAXXIS AT25
× 10 - 12 M912Y
Manufacturer Size Type
Front CHENG-SHIN AT25
× 8 - 12 C828
Rear CHENG-SHIN AT25
× 10 - 12 C828
U5TE60.book Page 25 Monday, June 10, 2002 8:47 AM

5-27

Recommended tire pressure
Front 25 kPa (0.25 kgf/cm
2, 0.25 bar)
Rear 25 kPa (0.25 kgf/cm2, 0.25 bar)


Check and adjust tire pressures when the
tires are cold.


Tire pressures must be equal on both
sides.
3. Tire pressure below the minimum speci-
fied could cause the tire to dislodge from
the rim under severe riding conditions.
The following are minimums:
Front 22 kPa (0.22 kgf/cm
2, 0.22 bar)
Rear 22 kPa (0.22 kgf/cm2, 0.22 bar)
4. Use no more than the following pressures
when seating the tire beads.
Front 250 kPa (2.5 kgf/cm2, 2.5 bar)
Rear 250 kPa (2.5 kgf/cm2, 2.5 bar)
Higher pressures may cause the tire to
burst. Inflate the tires very slowly and
carefully. Fast inflation could cause the
tire to burst.
U5TE60.book Page 27 Monday, June 10, 2002 8:47 AM

5-29 1. Low-pressure tire gauge
1. Manomètre basse pression pour pneus
1. Manómetro de baja presión
EBU00159
How to measure tire pressure
Use the low-pressure tire gauge.NOTE:The low-pressure tire gauge is included as stan-
dard equipment. Make two measurements of the
tire pressure and use the second reading. Dust or
dirt in the gauge could cause the first reading to be
incorrect.Set pressure with tires cold.
Set tire pressures to the following specifications:ACE-02EACE-02E
Recommended
pressureMinimum Maximum
Front25 kPa
(0.25 kgf/cm
2,
0.25 bar)22 kPa
(0.22 kgf/cm
2,
0.22 bar)28 kPa
(0.28 kgf/cm
2,
0.28 bar)
Rear25 kPa
(0.25 kgf/cm
2,
0.25 bar)22 kPa
(0.22 kgf/cm
2,
0.22 bar)28 kPa
(0.28 kgf/cm
2,
0.28 bar)
U5TE60.book Page 29 Monday, June 10, 2002 8:47 AM

7-15
WARNING
_ Always use the size and type tires specified in
the Owner’s Manual for this vehicle on pages
5-25–5-27. Always maintain proper tire pres-
sure as described in the Owner’s Manual on
page 5-29. Use of improper tires on this ATV,
or operation of this ATV with improper or un-
even tire pressure, may cause loss of control,
increasing your risk of an accident. _Do not operate at speeds too fast for your
skills or the conditions.
WARNING
_ Always go at a speed that is proper for the ter-
rain, visibility and operating conditions, and
your experience. Operating this ATV at speeds
too fast for your skills or the conditions in-
creases your chances of losing control of the
ATV, which can result in an accident. _
U5TE60.book Page 15 Monday, June 10, 2002 8:47 AM

7-37
With the engine idling, shift the drive select lever
into the forward “FWD” position. Apply the throttle
slowly and smoothly. The centrifugal clutch will en-
gage and you will start to accelerate. If the throttle
is applied too abruptly, the front wheels may lift off
the ground resulting in a loss of directional control.
Avoid higher speeds until you are thoroughly famil-
iar with the operation of your ATV.
When slowing down or stopping, release the throt-
tle and apply the brakes smoothly and evenly. Im-
proper use of the brakes can cause the tires to
lose traction, reducing control and increasing the
possibility of an accident.
U5TE60.book Page 37 Monday, June 10, 2002 8:47 AM