2003 YAMAHA KODIAK 400 brake

8-85

Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor brake performance.


Be careful that water does not enter the brake
fluid reservoir when refilling. Water will signifi-
cantly lower the boiling point of the fluid and
may result in vapor lock.


Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid im-
mediately.


Have a Yamaha dealer check the cause if the
brake fluid level goes down.
U5VH60.book Page 85 Wednesday, August 7, 2002 12:00 PM

8-87
EBU01186
Brake fluid replacement
Complete fluid replacement should be done only
by trained Yamaha service personnel. Have a
Yamaha dealer replace the following components
during periodic maintenance or when they are
damaged or leaking.

Replace the oil seals every two years.


Replace the brake hoses every four years.
U5VH60.book Page 87 Wednesday, August 7, 2002 12:00 PM

8-89 a. Front brake lever free play
a. Jeu au levier de frein avant
a. Juego libre de la palanca de lo freno delantero
EBU01188
Front brake lever free play
The front brake lever should have a free play of
zero mm at the lever end. If not, have a Yamaha
dealer check the brake system.
WARNING
_ Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly
and that the free play is correct.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
_
U5VH60.book Page 89 Wednesday, August 7, 2002 12:00 PM

8-91 1. Adjusting nut (brake pedal cable)
2. Adjusting nut (brake lever cable)
1.Écrou de réglage (câble de la pédale de frein)
2.Écrou de réglage (câble du levier de frein)
1. Tuerca de ajuste (cable del pedal del freno)
2. Tuerca de ajuste (cable de la palanca del freno)
a. Brake pedal free play
a. Jeu à la pédale de frein arrière
a. Juego libre del pedal del freno
EBU01268
Rear brake pedal and lever adjustment
Brake pedal free play adjustment
1. Fully loosen the adjusting nut on the brake le-
ver cable at the rear wheel.
2. Turn the adjusting nut on the brake pedal ca-
ble until the free play is 20–30 mm.
U5VH60.book Page 91 Wednesday, August 7, 2002 12:00 PM

8-93 1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
1. Adjusting nut (brake lever cable) a. Gap
1.Écrou de réglage (câble du levier de frein) a.Écart
1. Tuerca de ajuste (cable de la palanca del freno)
a. Separación
Brake lever free play adjustment
1. Loosen the locknut and fully turn in the ad-
justing bolt at the brake lever.
2. Turn in the adjusting nut on brake cable to
provide a gap of 0–1 mm between the brake
camshaft lever and the pin.
U5VH60.book Page 93 Wednesday, August 7, 2002 12:00 PM

8-95 1. Locknut 2. Adjusting bolt
a. Rear brake lever free play
1. Contre-écrou 2. Boulon de réglage
a. Jeu au levier de frein arrière
1. Contratuerca 2. Perno de ajuste
a. Juego libre de la palanca del freno trasero
3. Turn the adjusting bolt at the brake lever
until the free play at the brake lever pivot is
3–5 mm.
4. Tighten the locknut.
WARNING
_ Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident. After servic-
ing:

Make sure the brakes operate smoothly
and that the free play is correct.


Make sure the brakes do not drag.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
_
U5VH60.book Page 95 Wednesday, August 7, 2002 12:00 PM

8-97 1. Rear brake light switch
2. Adjusting nut
1. Contacteur de feu stop sur frein arrière
2.Écrou de réglage
1. Interruptor de la luz del freno trasero
2. Tuerca de ajuste
EBU01259
Adjusting the rear brake light switch
The rear brake light switch, which is activated by
the brake pedal and rear brake lever, is properly
adjusted when the brake light comes on just be-
fore braking takes effect. If necessary, adjust the
brake light switch as follows.
1. Remove panel B. (See page 8-21 for panel
removal and installation procedures.)
2. Turn the adjusting nut while holding the rear
brake light switch in place. To make the brake
light come on earlier, turn the adjusting nut in
direction
a. To make the brake light come on
later, turn the adjusting nut in direction
b.
3. Install the panel.
U5VH60.book Page 97 Wednesday, August 7, 2002 12:00 PM

8-101
EBU01260
Lubricating the brake levers and brake pedal
Lubricate the pivoting parts.NOTE:_ To access the brake pedal pivot, remove panel B.
(See page 8-21 for panel removal and installation
procedures.) _
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5VH60.book Page 101 Wednesday, August 7, 2002 12:00 PM