2004 YAMAHA KODIAK 450 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 lights ...................................... 4-3
Speedometer unit ................................. 4-9
Fuel gauge ......................................... 4-15
Handlebar switches ............................ 4-17
Throttle lever ...................................... 4-29
Speed limiter ...................................... 4-31
Front brake lever ................................ 4-33
Rear brake pedal and lever ................ 4-35
Drive select lever ................................ 4-37
Recoil starter ...................................... 4-37
1234
Fuel tank cap ..................................... 4-39
Fuel cock............................................ 4-41
Starter (choke) ................................... 4-43
Seat.................................................... 4-45
Storage compartment ........................ 4-47
Front carrier ....................................... 4-49
Rear carrier ........................................ 4-49
Front shock absorber adjustment ...... 4-51
Rear shock absorber adjustment ....... 4-55
Auxiliary DC jack ................................ 4-59
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Final gear oil ...................................... 5-17
Differential gear oil ............................. 5-19
Throttle lever ...................................... 5-19
Fittings and fasteners......................... 5-19
Lights ................................................. 5-21
Switches............................................. 5-21
Tires ................................................... 5-23
How to measure tire pressure ............ 5-27
Tire wear limit..................................... 5-29
5
U5ND60.book Page 1 Friday, May 10, 2002 12:10 PM

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

Brake lever and brake pedal
lubrication ....................................... 8-107
Wheel removal ................................. 8-109
Wheel installation ............................. 8-111
Battery .............................................. 8-113
Battery maintenance ........................ 8-117
Fuse replacement............................. 8-119
Replacing a headlight bulb ............... 8-123
Headlight beam adjustment.............. 8-127
Tail/brake light bulb replacement ..... 8-127
Troubleshooting................................ 8-129
Troubleshooting chart....................... 8-131
CLEANING AND STORAGE .................. 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................ 10-1
CONVERSION TABLE .......................... 11-1
91011U5ND60.book Page 3 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

4-17 1. Light switch “//OFF”
2. Engine stop switch “”/“”
3. Start switch “”
4. Horn switch “”
1. Contacteur d’éclairage “//OFF”
2. Coupe-circuit du moteur “”/“”
3. Contacteur du démarreur “”
4. Contacteur de l’avertisseur “”
1. Interruptor de luces “//OFF”
2. Interruptor de paro del motor “”/“”
3. Interruptor de arranque “”
4. Interruptor de la bocina “”
EBU00053
Handlebar switches
EBU01058
Light switch “/ /OFF”
Set the switch to the “” position to turn on the
low beam and the tail/brake light. Set the switch to
the “” position to turn on the high beam and the
tail/brake light. Set the switch to the “OFF” position
to turn off all the lights.CAUTION:_ Do not use the headlights with the engine
turned off for more than thirty minutes. The
battery may discharge to the point that the
starter motor will not operate properly. If this
should happen, remove the battery and re-
charge it. _
EBU00849
Engine stop switch “”/“”
Make sure that the engine stop switch is in the
“” position. The engine stop switch controls ig-
nition and can be used at all times to stop the en-
gine, especially in an emergency. The engine will
not start or run when the engine stop switch is
turned to “”.
U5ND60.book Page 17 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

5-21
EBU01003
Lights
Check the headlights and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU01082
Switches
Check the operation of all switches. Repair as nec-
essary for proper operation.
U5ND60.book Page 21 Friday, May 10, 2002 12:10 PM

6-5 a. Starter (choke) lever
1. Fully open
2. Half open
3. Closed
a. Starter (enrichisseur)
1. Complètement ouvert
2. Mi-ouvert
3. Fermé
a. Arrancador (choke)
1. Abre completamente
2. Semiabierto
3. Cerrado
NOTE:

When the drive select lever is in the neutral or
park position, if either indicator light does not
come on, ask a Yamaha dealer to inspect its
electric circuit.


The engine can be started in any gear if the
rear brake lever is applied. However, it is rec-
ommended to shift into neutral or park before
starting the engine.
5. Use the starter (choke) in reference to the fig-
ure:
Position
1: Cold engine start-
ambient temperature below 5 °C.
Position
2: Cold engine start-
ambient temperature at 0 °C–30 °C
and warming up position.
Position
3: Cold engine start-
ambient temperature above 25 °C
and warm engine start position.
6. Completely close the throttle lever and start
the engine by pushing the start switch.
U5ND60.book Page 5 Friday, May 10, 2002 12:10 PM