2004 YAMAHA KODIAK 450 differential

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

4-3 1. Differencial gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”
3. High-range indicator light “H”4. Neutral indicator light “N”
5. Reverse indicator light “R”6. Park indicator light “P”
7. Differencial gear lock indicator “”
8. Coolant temperature warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2Témoin du rapport inférieur “L”
3. Témoin du rapport supérieur “H”4. Témoin de point mort “N”
5. Témoin de marche arrière “R”
6. Témoin de stationnement “P”
7. Indicateur de blocage du différentiel “”
8. Témoin d’avertissement de la température du liquide de
refroidissement “”
1. Luz indicadora de bloqueo del diferencial “DIFF. LOCK”
2 Luz indicadora de margen bajo “L”
3. Luz indicadora de margen alto “H”
4. Luz de control de punto muerto “N”
5. Luz de control de marcha atrás “R”
6. Luz indicadora de estacionamiento “P”
7. Indicadora de bloqueo del diferencial “”
8. Luz de aviso de la temperatura del refrigerante “”
DIFF.
LOCKDIFF.
LOCK
DIFF.
LOCK
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Indicator lights
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Differential gear lock indicator light “DIFF.
LOCK”
This indicator light and the differential gear lock in-
dicator in the display flash when the differential
gear lock switch is set to the “4WD-LOCK” posi-
tion.
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Low-range indicator light “L”
This indicator light comes on when the drive select
lever is in the “L” position.
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High-range indicator light “H”
This indicator light comes on when the drive select
lever is in the “H” position.
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Neutral indicator light “N”
This indicator light comes on when the transmis-
sion is in neutral.
U5ND60.book Page 3 Friday, May 10, 2002 12:10 PM

4-21 1. On- command four- wheel drive switch “2WD”/“4WD”
2. Differential gear lock switch “4WD”/“LOCK”
1. Contacteur de commande du mode de traction “2WD”/“4WD”
2. Contacteur de blocage du différentiel “4WD”/“LOCK”
1. Selector de tracción en las cuatro ruedas “2WD”/“4WD”
2. Selector de bloqueo del diferencial “4WD”/“LOCK”
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On-command four-wheel drive and differential
gear lock switches
This ATV is equipped with an on-command four-
wheel drive switch “2WD”/“4WD” and a differential
gear lock switch “4WD”/“LOCK”. Select the appro-
priate drive according to terrain and the conditions.

Two-wheel drive (2WD): Power is supplied to
the rear wheels only.


Four-wheel drive (4WD): Power is supplied to
the rear and front wheels.


Four-wheel drive with the differential gear
locked (4WD-LOCK): Power is supplied to the
rear and front wheels when the differential gear
is locked (“DIFF.LOCK”). Unlike the 4WD
mode, all wheels turn at the same speed.
U5ND60.book Page 21 Friday, May 10, 2002 12:10 PM

4-25 1. Lever
2. On- command four- wheel drive switch “2WD”/“4WD”
1. Levier
2. Contacteur de commande du mode de traction “2WD”/“4WD”
1. Palanca
2. Selector de tracción en las cuatro ruedas “2WD”/“4WD”
1. Differential gear lock switch “4WD”/“LOCK”2. Lever
1. Contacteur de blocage du différentiel “4WD”/“LOCK”
2. Levier
1. Selector de bloqueo del diferencial “4WD”/“LOCK”
2. Palanca
On-command four-wheel drive switch
“2WD”/“4WD”
To change from 2WD to 4WD, stop the ATV, and
then set the switch to “4WD”. When the ATV is in
4WD, the 4WD indicator “” will come on in the
speedometer unit display. To change from 4WD to
2WD, stop the ATV, be sure the lever is set to po-
sition
a, and then set the switch to “2WD”.
Differential gear lock switch “4WD”/“LOCK”
To lock the differential gear in 4WD, make sure the
on-command four-wheel-drive switch is set to
“4WD”, stop the ATV, move the lever to position
b, and then set the switch to “LOCK”. When the
differential gear is locked, the differential gear lock
indicator light (“DIFF.LOCK”) will come on along
with the indicator “” in the speedometer unit
display. To release the differential gear lock, stop
the ATV and set the switch to “4WD”.
DIFF.
LOCK
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4-27
WARNING
_ Always ride at a slow speed when the ATV is in
4WD-LOCK, and allow extra time and distance
for maneuvers.
All wheels turn at the same speed when the dif-
ferential is locked, so it takes more effort to
turn the ATV. The amount of effort is more the
faster you go. You may lose control and have
an accident if you cannot make a sharp
enough turn for the speed you are traveling. _ NOTE:_

When the switch is set to “LOCK”, the differ-
ential gear lock indicator light will flash until
the differential gear is locked.


When the indicator light is flashing, turning
the handlebar back and forth will help the dif-
ferential gear lock to engage.


Riding before the differential gear lock is
properly engaged (e.g., when the indicator
light is flashing) will cause the engine speed
to be limited until engagement is complete.


When the ATV is in 4WD-LOCK, the maxi-
mum traveling speed is limited to 35 km/h.
_
U5ND60.book Page 27 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

5-19
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Differential gear oil
Make sure the differential gear oil is at the speci-
fied level. Add oil as necessary. (See pages 8-47–
8-51 for details.)
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Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
the idle position when released. Have a Yamaha
dealer repair as necessary for proper operation.
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Fittings and fasteners
Always check the tightness of chassis fittings and
fasteners before a ride. Take the machine to a
Yamaha dealer or refer to the Service Manual for
correct tightening torque.Recommended oil:
SAE 80 API “GL-4” Hypoid gear oil
U5ND60.book Page 19 Friday, May 10, 2002 12:10 PM