2003 YAMAHA KODIAK 400 brake light

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

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

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

4-27 1. Recoil starter
1. Lanceur à réenroulement
1. Arranque por tracción de cable
1. Fuel tank cap
1. Bouchon du réservoir de carburant
1. Tapón del depósito de combustible
EBU01264
Recoil starter
Firmly grasp the handle and pull slightly until en-
gagement can be felt. Then pull forcefully, being
careful not to pull the rope all the way out.
WARNING
_ Shift the drive select lever into the neutral po-
sition and apply the parking brake before start-
ing the engine or the ATV could start to move
unexpectedly, which could cause an accident. _
EBU00092
Fuel tank cap
Remove the fuel tank cap by turning it counter-
clockwise.
U5VH60.book Page 27 Wednesday, August 7, 2002 12:00 PM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-9,
8-81–8-89
Rear brakeCheck operation, condition and free play.
Adjust if necessary.5-5–5-9,
8-81, 8-91–8-95
FuelCheck fuel level.
Fill with fuel if necessary.5-11–5-13
Engine oilCheck oil level.
Fill with oil if necessary.5-15–5-17,
8-29–8-39
CoolantCheck coolant level in reservoir.
Fill with coolant if necessary.5-21–5-23,
8-45–8-55
Final gear oilCheck for leakage. 5-19, 8-39–8-43
ThrottleCheck for proper throttle cable operation. 5-23, 8-79
Wheels and tiresCheck tire pressure, wear and damage.5-27–5-33,
8-103–8-105
Fittings and fastenersCheck all fittings and fasteners. 5-25
Lights and switchesCheck for proper operation.5-25, 8-97,
8-117–8-121
U5VH60.book Page 1 Wednesday, August 7, 2002 12:00 PM

5-25
EBU01162
Fittings and fasteners
Always check the tightness of chassis fittings and
fasteners before a ride. Take the machine to a
Yamaha dealer or refer to the Service Manual for
correct tightening torque.
EBU01003
Lights
Check the headlights and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU01170
Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper op-
eration.
U5VH60.book Page 25 Wednesday, August 7, 2002 12:00 PM

6-13 1. Drive select lever
a. F (Forward)
b. N (Neutral)
c. R (Reverse)
1. Levier de présélection
a. F (Marche avant)
b. N (Point mort)
c. R (Marche arrière)
1. Palanca de selección de marcha
a. F (Avance)
b. N (Punto muerto)
c. R (Marcha atrás)
Shifting: reverse
1. Bring the machine to a complete stop and re-
turn the throttle lever to the closed position.
2. Apply the parking brake.
3. Shift the gear from neutral to reverse and vice
versa by moving the drive select lever along
the shift guide.NOTE:_ When in reverse, the reverse indicator light should
be on. If the light does not come on, ask a Yamaha
dealer to inspect the machine. _4. Check behind for people or obstacles, then
release the parking brake.
5. Open the throttle lever gradually and contin-
ue to watch to the rear while backing.NOTE:_ If the drive select lever is shifted into reverse while
the engine is running, the engine will stop unless
the parking brake or rear brake lever is applied. _
U5VH60.book Page 13 Wednesday, August 7, 2002 12:00 PM

8-8
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.NOTE:Recommended brake fluid: DOT 4
Brake fluid replacement:
1. When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake
fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.V-belt*•Check operation.
•Check for cracks or damage.Wheels*•Check balance/damage/runout.
•Repair if necessary.Wheel bearing*•Check bearing assemblies for looseness/damage.
•Replace if damaged.Front and rear
suspension*•Check operation.
•Correct if necessary.Steering system*•Check operation./Replace if damaged.
•Check toe-in./Adjust if necessary.Fittings and fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.Lights and switches*•Check operation.
•Adjust headlight beam.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U5VH60.book Page 8 Wednesday, August 7, 2002 12:00 PM