2003 YAMAHA KODIAK 400 cooling

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

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

6-19
1. 0–10 hours:
Avoid continuous operation above half throt-
tle. Allow a cooling off period of five to ten
minutes after every hour of operation. Vary
the speed of the machine from time to time.
Do not operate it at one set throttle position.
2. 10–20 hours:
Avoid prolonged operation above 3/4 throttle.
Rev the machine freely but do not use full
throttle at any time.
3. After break-in:
Avoid prolonged full throttle operation. Vary
speeds occasionally.
EBU00211
Parking
When parking, stop the engine and shift into neu-
tral. Turn the fuel cock to “OFF” and apply the
parking brake.
U5VH60.book Page 19 Wednesday, August 7, 2002 12:00 PM

7-65
1. Air filter case check hose
1. Flexible de contrôle du boîtier de filtre à air
1. Manguera de comprobación de la caja del filtro de aire
Test your brakes after leaving the water. Do not
continue to ride your ATV without verifying that
you have regained proper braking ability.CAUTION:_ After riding your ATV in water, be sure to drain
the trapped water by removing the check hose
at the bottom of the air filter case and the
check hose on the V-belt cooling duct. Wash
the ATV in fresh water if it has been operated in
salt water or muddy conditions. _
U5VH60.book Page 65 Wednesday, August 7, 2002 12:00 PM

7-67 1. V-belt cooling duct check hose
1. Flexible de contrôle du conduit de refroidissement de la courroie
trapézoïdale
1. Manguera de comprobación del conducto de enfriamiento de
la correa trapezoidal
1. V-belt case drain plug
1. Boulon de vidange du carter de courroie trapézoïdale
1. Tapón de drenaje de la caja de la correa trapezoidal
1. Drive select lever box check hose
1. Flexible de contrôle du boîtier du levier de présélection
1. Manguera de comprobación de la caja de la palanca de
selección de marcha
U5VH60.book Page 67 Wednesday, August 7, 2002 12:00 PM

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.
•Tighten 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.Front brake*•Check operation/fluid leakage. (See NOTE page 8-8.)
•Correct if necessary.Rear brake•Check operation.
•Adjust if necessary.U5VH60.book Page 7 Wednesday, August 7, 2002 12:00 PM

8-45 1. Coolant reservoir cap
2. Maximum level mark
3. Minimum level mark
1. Bouchon du vase d’expansion
2. Repère de niveau maximum
3. Repère de niveau minimum
1. Tapa del depósito de refrigerante
2. Marca de nivel máximo
3. Marca de nivel mínimo
EBU01321
Cooling system
1. Place the ATV on a level surface.
2. Check the coolant level in the coolant reser-
voir when the engine is cold as the coolant
level will vary with engine temperature.NOTE:_ The coolant level should be between the minimum
and maximum level marks. _3. If the coolant is at or below the minimum level
mark, remove panel D. (See pages 8-17–8-19
for panel removal and installation proce-
dures.)
U5VH60.book Page 45 Wednesday, August 7, 2002 12:00 PM

8-51 1. Radiator cap
1. Bouchon de radiateur
1. Tapa del radiador
1. Coolant reservoir hose
1. Flexible du vase d’expansion
1. Manguera del depósito de refrigerante
5. Remove the radiator cap.
6. Remove panel D. (See pages 8-17–8-19 for
panel removal and installation procedures.)
7. Remove the coolant reservoir cap.
8. Disconnect the hose on the coolant reservoir
side, and then drain the coolant from the
coolant reservoir.
9. After draining the coolant, thoroughly flush
the cooling system with clean tap water.
10. Replace the coolant drain bolt washer if it is
damaged, and then tighten the coolant drain
bolt to the specified torque.
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf)
U5VH60.book Page 51 Wednesday, August 7, 2002 12:00 PM