2004 YAMAHA KODIAK 450 wheel

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

2-3

Never carry passenger on an ATV.


Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways, park-
ing lots and streets.


Never operate an ATV on any public street,
road or highway, even a dirt or gravel one.


Never operate an ATV without wearing an ap-
proved motorcycle helmet that fits properly.
You should also wear eye protection (goggles
or face shield), gloves, boots, long-sleeved
shirt or jacket, and long pants.


Never consume alcohol or drugs before or
while operating this ATV.


Never operate at speeds too fast for your skills
or the conditions. Always go at a speed that is
proper for the terrain, visibility and operating
conditions, and your experience.


Never attempt wheelies, jumps, or other stunts.
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”
EBU00974
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
U5ND60.book Page 25 Friday, May 10, 2002 12:10 PM

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
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

6-21
EBU00676
Parking on a slope
WARNING
Avoid parking on hills or other inclines. Park-
ing on a hill or other incline could cause the
ATV to roll out of control, increasing the
chance of an accident. If you must park on an
incline, place the machine transversely across
the incline, apply the parking brake, and block
the front and rear wheels with rocks or other
objects. Do not park the ATV at all on hills that
are so steep you could not walk up them easi-
ly.1. Bring the machine to a stop by applying the
brakes.
2. Stop the engine.
3. With the rear brake applied, shift the drive
select lever to the park position.
U5ND60.book Page 21 Friday, May 10, 2002 12:10 PM

7-21
During operation
Always keep your feet on the footboards during
operation. Otherwise your feet may contact the
rear wheels.
WARNING
_ Always keep both hands on the handlebars
and both feet on the footboards of your ATV
during operation. Removing even one hand or
foot can reduce your ability to control the ATV
or could cause you to lose your balance and
fall off of the ATV. If you remove a foot from a
footboard, your foot or leg may come into con-
tact with the rear wheels, which could injure
you or cause an accident. _Avoid wheelies and jumping. You may lose control
of the ATV or overturn.
WARNING
_ Never attempt stunts, such as wheelies or
jumps. Don’t try to show off. _
U5ND60.book Page 21 Friday, May 10, 2002 12:10 PM