2004 YAMAHA KODIAK 450 axle

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

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
BrakesCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-89–8-103
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13–5-15,
8-31–8-41
CoolantCheck coolant level in reservoir.
Fill with coolant if necessary.8-53–8-63
Final gear oil and
differential gear oilCheck for leakage. 5-17–5-19, 8-41–8-51
ThrottleCheck for proper throttle cable operation. 5-19, 8-87
Wheels and tiresCheck tire pressure, wear and damage.5-23–5-29,
8-109–8-111
Fittings and fastenersCheck all fittings and fasteners. 5-19
LightsCheck for proper operation. 5-21, 8-123–8-127
Axle bootsCheck for damage. 8-63
U5ND60.book Page 1 Friday, May 10, 2002 12:10 PM

7-39
TURNING YOUR ATV
To achieve maximum traction while riding off-road
in 2WD or 4WD, the two rear wheels are mounted
solidly on one axle and turn together at the same
speed. Furthermore, when riding in 4WD-LOCK
(“DIFF.LOCK”), the front wheels also turn together
at the same speed. Therefore, unless the wheel on
the inside of the turn is allowed to slip or lose some
traction, the ATV will resist turning. A special turn-
ing 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. Operate at a
slow speed and allow extra time and distance
for maneuvers when in 4WD-LOCK
(“DIFF.LOCK”). _
U5ND60.book Page 39 Friday, May 10, 2002 12:10 PM

8-8
* It is recommended that these items be serviced by a Yamaha dealer.
** Lithium-soap-based greaseNOTE:Recommended brake fluid: DOT 4
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, 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 cylinder, 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.Drive shaft universal
joint*•Lubricate.**Engine mount*
•Check for cracks or damage.Front axle boots*•Check operation.
•Replace if damaged.Fittings and Fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
km 320 1,200 2,400 2,400 4,800
hours 20 75 150 150 300
U5ND60.book Page 8 Friday, May 10, 2002 12:10 PM

8-63 1. Axle boot (× 2 each side)
1. Soufflet d’axe (× 2 de chaque côté)
1. Guardapolvo de eje (× 2 en cada lado)
12. Install the radiator cap.
13. Start the engine and let it idle for several min-
utes. Stop the engine, and then check the
coolant level in the radiator. If it is low, add
more coolant until it reaches the top of the ra-
diator.
14. Fill the coolant reservoir with coolant up to
the maximum level.
15. Install the coolant reservoir cap and check for
coolant leakage.NOTE:_ If any leakage is found, ask a Yamaha dealer to in-
spect the cooling system. _16. Install the panels and the front carrier.
EBU00862
Axle boots
Check the protective boots for holes or tears. If any
damage is found, have them replaced by a
Yamaha dealer.
U5ND60.book Page 63 Friday, May 10, 2002 12:10 PM

9-1
EBU00420
CLEANING AND STORAGE
A. CLEANING
Frequent, thorough cleaning of your machine will
not only enhance its appearance but will improve
its general performance and extend the useful life
of many components.
1. Before cleaning the machine:
a. Block off the end of the exhaust pipe to pre-
vent water entry. A plastic bag and strong
rubber band may be used.
b. Make sure the spark plug and all filler caps
are properly installed.
2. If the engine case is excessively greasy, ap-
ply degreaser with a paint brush. Do not ap-
ply degreaser to the wheel axles.
3. Rinse the dirt and degreaser off with a garden
hose. Use only enough pressure to do the
job.
U5ND60.book Page 1 Friday, May 10, 2002 12:10 PM