2004 YAMAHA KODIAK 450 cooling

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

6-19
1. 0–10 hours:
Avoid continuous operation above half throt-
tle. Allow a cooling off period of five to ten
minutes after every hour of operation. Vary
the speed of the machine from time to time.
Do not operate it at one set throttle position.
2. 10–20 hours:
Avoid prolonged operation above 3/4 throttle.
Rev the machine freely but do not use full
throttle at any time.
3. After break-in:
Avoid prolonged full throttle operation. Vary
speeds occasionally.
EBU00612
Parking
When parking, stop the engine and shift the drive
select lever into the park position, then turn the fuel
cock to the “OFF” position.
U5ND60.book Page 19 Friday, May 10, 2002 12:10 PM

7-65
1. Air filter case check hose
1. Flexible de contrôle du boîtier de filtre à air
1. Manguera de comprobación de la caja del filtro de aire
Test your brakes after leaving the water. Do not
continue to ride your ATV without verifying that
you have regained proper braking ability.CAUTION:_ After riding your ATV in water, be sure to drain
the trapped water by removing the check hose
at the bottom of the air filter case and the
check hose on the V-belt cooling duct. Wash
the ATV in fresh water if it has been operated in
salt water or muddy conditions. _
U5ND60.book Page 65 Friday, May 10, 2002 12:10 PM

7-67 1. V-belt cooling duct check hose
1. Flexible de contrôle du conduit de refroidissement de la courroie
trapézoïdale
1. Manguera de comprobación del conducto de enfriamiento de
la correa trapezoidal
1. V-belt case drain plug
1. Boulon de vidange du carter de courroie trapézoïdale
1. Tapón de drenaje de la caja de la correa trapezoidal
1. Drive select lever box check hose
1. Flexible de contrôle du boîtier du levier de présélection
1. Manguera de comprobación de la caja de la palanca de
selección de marcha
U5ND60.book Page 67 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

8-53 1. Coolant reservoir cap
2. Maximum level mark
3. Minimum level mark
1. Bouchon du vase d’expansion
2. Repère de niveau maximum
3. Repère de niveau minimum
1. Tapa del depósito de refrigerante
2. Marca de nivel máximo
3. Marca de nivel mínimo
EBU01000
Cooling system
1. Check the coolant level in the reservoir when
the engine is cold as the coolant level will
vary with engine temperature. The coolant
level should be between the maximum and
minimum marks.
2. If the level is low, remove panel D. (See pag-
es 8-17–8-20 for panel removal and installa-
tion procedures.)
U5ND60.book Page 53 Friday, May 10, 2002 12:10 PM

8-59 1. Radiator cap
1. Bouchon du radiateur
1. Tapa del radiador
1. Coolant reservoir hose
1. Flexible du vase d’expansion
1. Manguera del depósito de refrigerante
5. Remove the radiator cap.
6. Remove the coolant reservoir cap.
7. Disconnect the hose on the coolant reservoir
side, and then drain the coolant from the
coolant reservoir.
8. After draining the coolant, thoroughly flush
the cooling system with clean tap water.
9. Replace the coolant drain bolt washer if it is
damaged, and then tighten the coolant drain
bolt to the specified torque.
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf)
U5ND60.book Page 59 Friday, May 10, 2002 12:10 PM