2004 YAMAHA KODIAK 450 oil filter

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 ............................................ 8-31
Final gear oil ....................................... 8-41
Differential gear oil.............................. 8-47
Cooling system ................................... 8-53
Changing the coolant.......................... 8-57
Axle boots ........................................... 8-63
Spark plug inspection ......................... 8-65
Air filter element cleaning ................... 8-71
Carburetor adjustment ........................ 8-81
Idle speed adjustment ........................ 8-83
Valve clearance adjustment ............... 8-85
Throttle lever adjustment .................... 8-87
Front brake pad inspection ................. 8-89
Rear brake pad inspection.................. 8-89
Inspecting the brake fluid level ........... 8-91
Brake fluid replacement ...................... 8-95
Front brake adjustment....................... 8-97
Rear brake lever adjustment .............. 8-99
Adjusting the rear brake light
switch ............................................. 8-103
Cable inspection and lubrication....... 8-105
8
U5ND60.book Page 2 Friday, May 10, 2002 12:10 PM

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear spring preload
adjusting ring
2. Storage box and tool kit
3. Spark plug
4. Rear brake fluid reservoir
5. Radiator cap
6. Front spring preload
adjusting ring
7. V-belt case
8. Brake pedal
9. Front spring preload
adjusting ring
10. Fuel cock
11. Air filter case
12. Fuses
13. Tail/brake light14. V-belt cooling duct check
hose
15. Coolant reservoir
16. Oil filter cartridge
17. Engine oil dipstick
18. Rear brake lever
19. Left handlebar switches
20. Starter (choke)
21. Horn switch
22. Drive select lever
23. Speedometer unit
24. Main switch
25. Fuel tank cap
26. Auxiliary DC jack
27. Right handlebar switch
28. Throttle lever
29. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5ND60.book Page 1 Friday, May 10, 2002 12:10 PM

5-15
CAUTION:_

In order to prevent clutch slippage (since
the engine oil also lubricates the clutch),
do not mix any chemical additives. Do not
use oils with a diesel specification of “CD”
or oils of a higher quality than specified. In
addition, do not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign material enters
the crankcase.
_
Oil quantity:
Periodic oil change:
2.3 L
With oil filter element replacement:
2.4 L
Total amount:
2.6 L
U5ND60.book Page 15 Friday, May 10, 2002 12:10 PM

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
km 320 1,200 2,400 2,400 4,800
hours 20 75 150 150 300
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.
•Retighten 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 month.Differential gear oil
Front brake*•Check operation/fluid leakage. (See NOTE page 8-8.)
•Correct if necessary.Rear brake*•Check operation/fluid leakage.(See NOTE page 8-8.)
•Correct if necessary.U5ND60.book Page 7 Friday, May 10, 2002 12:10 PM

8-33 1. Engine oil drain bolt
1. Boulon de vidange de l’huile
1. Perno de drenaje del aceite de motor
Engine oil and oil filter cartridge replacement
1. Remove panels E and F. (See pages 8-27–
8-29 for panel removal and installation proce-
dures.)
2. Warm up the engine for several minutes.
3. Stop the engine. Place an oil pan under the
engine to collect the used oil, and then re-
move the engine oil filler cap.
4. Remove the drain bolt and drain the oil.
U5ND60.book Page 33 Friday, May 10, 2002 12:10 PM

8-35 1. Oil filter cartridge
1. Cartouche du filtre à huile
1. Cartucho del filtro de aceite
1. Oil filter wrench
1. Clé pour filtre à huile
1. Llave para filtros de aceite
5. Remove the oil filter cartridge with an oil filter
wrench.NOTE:_ An oil filter wrench is available at a nearby
Yamaha dealer. _6. Install the drain bolt and tighten it to the spec-
ified torque.
Tightening torque:
Drain bolt:
23 Nm (2.3 m·kgf)
U5ND60.book Page 35 Friday, May 10, 2002 12:10 PM

8-37 1. Torque wrench
1. Clé dynamométrique
1. Llave de apriete
7. Apply a light coat of engine oil to the O-ring of
the new oil filter cartridge.NOTE:_ Make sure the O-ring is seated properly. _8. Install the oil filter cartridge, and then tighten
it to the specified torque with a torque
wrench.
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
U5ND60.book Page 37 Friday, May 10, 2002 12:10 PM

8-39
9. Fill the engine with sufficient oil to reach the
specified level. Install the engine oil filler cap
and tighten it.CAUTION:_

In order to prevent clutch slippage (since
the engine oil also lubricates the clutch),
do not mix any chemical additives. Do not
use oils with a diesel specification of “CD”
or oils of a higher quality than specified. In
addition, do not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign material enters
the crankcase.
_
Recommended engine oil:
See page 10-2.
Oil quantity:
Total amount:
2.6 L
Periodic oil change:
2.3 L
With oil filter cartridge replacement:
2.4 L
U5ND60.book Page 39 Friday, May 10, 2002 12:10 PM