2004 YAMAHA KODIAK 450 check engine

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

3-1
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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

4-29 1. Throttle lever
1. Levier d’accélération
1. Palanca de aceleración
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Throttle lever
Once the engine is running, movement of the
throttle lever will increase the engine speed.
Regulate the speed of the machine by varying the
throttle position. Because the throttle is spring-
loaded, the machine will decelerate, and the en-
gine will return to an idle any time the hand is re-
moved from the throttle lever.
Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.
WARNING
Malfunction of the throttle could make it diffi-
cult to speed up or slow down when you need
to. This could cause an accident. Check the
operation of the throttle lever before you start
the engine. If the throttle does not work
smoothly, check for the cause. Correct the
problem before riding the ATV or consult a
Yamaha dealer.
U5ND60.book Page 29 Friday, May 10, 2002 12:10 PM

5-1
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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

6-9
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Starting a warm engine
To start a warm engine, refer to the “Starting a cold
engine” section. The starter (choke) should not be
used. The throttle should be opened slightly.
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Warming up
To get maximum engine life, always warm up the
engine before starting off. Never accelerate hard
with a cold engine! To see whether or not the en-
gine is warm, check if it responds to the throttle
normally with the starter (choke) turned off.
U5ND60.book Page 9 Friday, May 10, 2002 12:10 PM

8-7
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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

8-8
* 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

8-31 1. Engine oil filler cap
1. Bouchon de remplissage d’huile de moteur
1. Tapa de relleno de aceite de motor
1. Maximum level mark 2. Minimum level mark
1. Repère de niveau maximum 2. Repère de niveau minimum
1. Marca de nivel máximo 2. Marca de nivel mínimo
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Engine oil
Engine oil level measurement
1. Remove panel F. (See page 8-29 for panel
removal and installation procedures.)
2. Place the ATV on a level surface and warm
up the engine for several minutes.
3. Stop the engine.
4. Remove the engine oil filler cap and wipe off
the dipstick with a clean rag.
5. Insert the dipstick in the filler hole without
screwing it in.NOTE:_ Wait a few minutes until the oil level settles before
checking. _6. The oil level should be between the maxi-
mum and minimum marks. If the level is low,
fill the engine with sufficient oil to reach the
specified level.
U5ND60.book Page 31 Friday, May 10, 2002 12:10 PM