2003 YAMAHA KODIAK 400 wheel

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

2-3

Never carry a passenger on an ATV.


Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways, park-
ing lots and streets.


Never operate an ATV on any public street,
road or highway, even a dirt or gravel one.


Never operate an ATV without wearing an ap-
proved motorcycle helmet that fits properly.
You should also wear eye protection (goggles
or face shield), gloves, boots, long-sleeved
shirt or jacket, and long pants.


Never consume alcohol or drugs before or
while operating this ATV.


Never operate at speeds too fast for your skills
or the conditions. Always go at a speed that is
proper for the terrain, visibility and operating
conditions, and your experience.


Never attempt wheelies, jumps, or other stunts.
U5VH60.book Page 3 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

6-21
EBU00216
Parking on a slope
WARNING
_ Avoid parking on hills or other inclines. Park-
ing on a hill or other incline could cause the
ATV to roll out of control, increasing the
chance of an accident. If you must park on an
incline, place the machine transversely across
the incline, apply the parking brake, and block
the front and rear wheels with rocks or other
objects. Do not park the ATV at all on hills that
are so steep you could not walk up them easi-
ly. _1. Bring the machine to a stop by applying the
brakes.
2. Stop the engine.
3. With the rear brake applied, apply the parking
brake.
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7-21
During operation
Always keep your feet on the footboards during
operation. Otherwise your feet may contact the
rear wheels.
WARNING
_ Always keep both hands on the handlebars
and both feet on the footboards of your ATV
during operation. Removing even one hand or
foot can reduce your ability to control the ATV
or could cause you to lose your balance and
fall off of the ATV. If you remove a foot from a
footboard, your foot or leg may come into con-
tact with the rear wheels, which could injure
you or cause an accident. _Avoid wheelies and jumping. You may lose control
of the ATV or overturn.
WARNING
_ Never attempt stunts, such as wheelies or
jumps. Don’t try to show off. _
U5VH60.book Page 21 Wednesday, August 7, 2002 12:00 PM

7-37
With the engine idling, return the starter (choke) to
the closed position and shift the drive select lever
into the forward position, then release the parking
brake. Apply the throttle slowly and smoothly. The
centrifugal clutch will engage 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 familiar 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.
U5VH60.book Page 37 Wednesday, August 7, 2002 12:00 PM

7-39
TURNING YOUR ATV
To achieve maximum traction while riding off-road,
the two rear wheels are mounted solidly on one
axle and turn together at the same speed. There-
fore, unless the wheel on the inside of the turn is
allowed to slip or lose some traction, the ATV will
resist turning. A special turning technique must be
used to allow the ATV to make turns quickly and
easily. It is essential that this skill be learned first at
low speed.
WARNING
_ Always follow proper procedures for turning
as described in this Owner’s Manual. Practice
turning at low speeds before attempting to turn
at faster speeds. Do not turn at speeds too fast
for your skills or the conditions. _
U5VH60.book Page 39 Wednesday, August 7, 2002 12:00 PM

7-41 1. Lean towards inside of turn.
2. Support your weight on the outer footboard.
1. Se pencher vers l’intérieur du virage.
2. S’appuyer sur le repose-pied extérieur.
1. Inclínese hacia el interior del giro.
2. Descanse su peso en el descansapie exterior.
As you approach a curve, slow down and begin to
turn the handlebars in the desired direction. As
you do so, put your weight on the footboard to the
outside of the turn (opposite your desired direc-
tion) and lean your upper body into the turn. Use
the throttle to maintain an even speed through the
turn. This maneuver will let the wheel on the inside
of the turn slip slightly, allowing the ATV to make
the turn properly.
This procedure should be practiced at slow speed
many times in a large off-road area with no obsta-
cles. If an incorrect technique is used, your ATV
may continue to go straight. If the ATV doesn’t
turn, come to a stop and then practice the proce-
dure again. If the riding surface is slippery or loose,
it may help to position more of your weight over the
front wheels by moving forward on the seat.
Once you have learned this technique you should
be able to perform it at higher speeds or in tighter
curves.
U5VH60.book Page 41 Wednesday, August 7, 2002 12:00 PM