2003 YAMAHA KODIAK 400 brake

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 and warning lights.................. 4-3
Speedometer ........................................ 4-7
Fuel gauge ........................................... 4-9
Handlebar switches ............................ 4-11
Throttle lever ...................................... 4-15
Speed limiter ...................................... 4-17
Front brake lever ................................ 4-19
Rear brake pedal and lever ................ 4-21
Parking brake ..................................... 4-23
Drive select lever ................................ 4-25
1234
Recoil starter ...................................... 4-27
Fuel tank cap ..................................... 4-27
Fuel cock............................................ 4-29
Starter (choke) ................................... 4-31
Seat.................................................... 4-33
Storage box........................................ 4-35
Front carrier ....................................... 4-37
Rear carrier ........................................ 4-37
Front shock absorber adjustment ...... 4-39
Rear shock absorber adjustment ....... 4-41
Auxiliary DC jack ................................ 4-43
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes .......................... 5-5
Fuel .................................................... 5-11
Engine oil ........................................... 5-15
Final gear oil ...................................... 5-19
Coolant............................................... 5-21
Throttle lever ...................................... 5-23
Fittings and fasteners......................... 5-25
Lights ................................................. 5-25
Switches............................................. 5-25
Tires ................................................... 5-27
How to measure tire pressure ............ 5-31
5
U5VH60.book Page 1 Wednesday, August 7, 2002 12:00 PM

Tire wear limit......................................5-33
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
Cooling system ................................... 8-45
Changing the coolant.......................... 8-49
Spark plug inspection ......................... 8-57
Air filter element cleaning ................... 8-63
V-belt cooling duct check hose ........... 8-71
Carburetor adjustment ........................ 8-73
Idle speed adjustment ........................ 8-75
Valve clearance adjustment ............... 8-77
Throttle lever adjustment .................... 8-79
Front brake pad check ........................ 8-81
Rear brake shoe inspection ................ 8-81
Brake fluid level check ........................ 8-83
Brake fluid replacement ...................... 8-87
Front brake lever free play.................. 8-89
Rear brake pedal and lever
adjustment ........................................ 8-91
8
U5VH60.book Page 2 Wednesday, August 7, 2002 12:00 PM

Adjusting the rear brake light
switch ............................................... 8-97
Cable inspection and lubrication ........ 8-99
Lubricating the brake levers and
brake pedal .................................... 8-101
Wheel removal ................................. 8-103
Wheel installation ............................. 8-105
Battery .............................................. 8-107
Battery maintenance ........................ 8-111
Fuse replacement............................. 8-113
Replacing a headlight bulb ............... 8-117
Headlight beam adjustment.............. 8-121
Tail/brake light bulb replacement ..... 8-121
Troubleshooting................................ 8-123
Troubleshooting chart....................... 8-125
CLEANING AND STORAGE .................. 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................ 10-1
CONVERSION TABLE .......................... 11-1
91011U5VH60.book Page 3 Wednesday, August 7, 2002 12:00 PM

2-11

Always check for obstacles before operating in
a new area.


Never attempt to operate over large obstacles,
such as large rocks or fallen trees. Always fol-
low proper procedures when operating over
obstacles as described in this manual.


Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such
as ice, go slowly and be very cautious in order
to reduce the chance of skidding or sliding out
of control.


Never operate an ATV in fast flowing water or
in water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.
U5VH60.book Page 11 Wednesday, August 7, 2002 12:00 PM

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear shock absorber
assembly spring preload
adjusting ring
2. Storage box and tool kit
3. Spark plug
4. Front shock absorber
assembly spring preload
adjusting ring
5. Brake pedal
6. V-belt case
7. Radiator cap
8. Fuel cock
9. Air filter case
10. Fuses
11. Tail/brake light
12. Front shock absorber
assembly spring preload
adjusting ring13. V-belt cooling duct check
hose
14. 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. Throttle lever
27. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5VH60.book Page 1 Wednesday, August 7, 2002 12:00 PM

4-19 1. Front brake lever
1. Levier de frein avant
1. Palanca del freno delantero
EBU00070
Front brake lever
The front brake lever is located on the right handle-
bar. Pull it toward the handlebar to apply the front
brake.
U5VH60.book Page 19 Wednesday, August 7, 2002 12:00 PM

4-21 1. Brake pedal
1. Pédale de frein
1. Pedal del freno
1. Rear brake lever
1. Levier de frein arrière
1. Palanca del freno trasero
EBU00073
Rear brake pedal and lever
The brake pedal is located on the right side of the
machine and the brake lever is located on the left
handlebar. Push down on the pedal or pull the le-
ver toward the handlebar to apply the rear brake.
U5VH60.book Page 21 Wednesday, August 7, 2002 12:00 PM

4-23 1. Lock plate
1. Verrou
1. Placa de bloqueo
EBU00075
Parking brake
Use the parking brake when you have to start the
engine or park the machine, especially on a slope.
Apply the rear brake lever and push down the lock
plate to apply the parking brake. Squeeze the rear
brake lever to release the parking brake.
WARNING
_

Always set the parking brake before start-
ing the engine. The ATV could start mov-
ing unexpectedly if the parking brake is not
applied. This could cause loss of control or
a collision.


Always be sure you have released the
parking brake before you begin to ride. The
brake could overheat if you ride the ATV
without releasing the parking brake. You
could lose braking performance which
could cause an accident. You could also
wear out the brakes prematurely.
_
U5VH60.book Page 23 Wednesday, August 7, 2002 12:00 PM