2005 YAMAHA KODIAK 450 check engine

8-7
EBU02621
PERIODIC MAINTENANCE/LUBRICATION
NOTE:_

For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.


For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. How-
ever, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be
followed.
_
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
Valves*Check valve clearance.
Adjust if necessary.
Cooling systemCheck coolant leakage.
Repair if necessary.
Replace coolant every 24 months.Spark plugCheck condition.
Adjust gap and clean.
Replace if necessary.Air filter elementClean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*Check starter (choke).
Adjust engine idling speed.Crankcase breather
system*Check breather hose for cracks or damage.
Replace if necessary.Exhaust system*Check for leakage.
Tighten if necessary.
Replace gasket(s) if necessary.U1D960.book Page 7 Wednesday, June 23, 2004 3:59 PM

8-8
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 8-9.)
Correct if necessary.Rear brake*Check operation/fluid leakage.(See NOTE page 8-9.)
Correct if necessary.Select lever safety system
cable*Check operation.
Adjust if necessary.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.Rear upper and lower
knuckle pivots*Lubricate with lithium-soap-based grease.Drive shaft universal
joint*Lubricate with lithium-soap-based grease.Engine mount*
Check for cracks or damage.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
U1D960.book Page 8 Wednesday, June 23, 2004 3:59 PM

8-33 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
EBU10992
Engine oil and oil filter cartridge
The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter cartridge replaced at the intervals
specified in the periodic maintenance and lubrica-
tion chart.
To check the engine oil level
1. Remove panel F. (See page 8-31 for panel
removal and installation procedures.)
2. Place the ATV on a level surface.
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Wait a few minutes until the oil settles.
5. Remove the engine oil filler cap and wipe off
the dipstick with a clean rag.
6. Insert the dipstick in the oil filler hole (without
screwing it in), and then remove it again to
check the oil level.NOTE:_ The engine oil should be between the minimum
and maximum level marks. _
U1D960.book Page 33 Wednesday, June 23, 2004 3:59 PM

8-43
‘1. Final gear oil filler bolt
2. Correct level
3. Final gear oil
1. Boulon de l’orifice de remplissage du carter de transmission finale
2. Niveau correct
3. Huile de transmission finale
1. Perno del orificio de llenado de aceite de la transmisión final
2. Nivel adecuado
3. Aceite de la transmisión final
12. Start the engine and warm it up for several
minutes. While warming up, check for oil
leakage. If oil leakage is found, turn the en-
gine off immediately and check for the cause.
13. Turn the engine off, and then check the oil
level and correct it if necessary.
14. Install panel F.
EBU15380
Final gear oil
Checking the final gear oil level
1. Place the ATV on a level surface.
2. Remove the oil filler bolt, and then check the
oil level in the final gear case.NOTE:_ The oil level should be at the brim of the filler hole. _3. If the oil is below the brim of the filler hole,
add sufficient oil of the recommended type to
raise it to the correct level.CAUTION:_ Be sure no foreign material enters the final
gear case. _
U1D960.book Page 43 Wednesday, June 23, 2004 3:59 PM

8-49
7. Install the oil filler bolt, and then tighten it to
the specified torque.
8. Check for oil leakage. If oil leakage is found,
check for the cause.
9. Install the engine guard and the final gear
case guard by installing the bolts, and then
tightening them to the specified torques. Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf)
Tightening torques:
Engine guard bolt:
7.0 Nm (0.7 m·kgf)
Final gear case guard bolt:
7.0 Nm (0.7 m·kgf)
U1D960.book Page 49 Wednesday, June 23, 2004 3:59 PM

8-57 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
EBU13210
Cooling system
1. Place the ATV on a level surface.
2. Check the coolant level in the coolant reser-
voir when the engine is cold as the coolant
level will vary with engine temperature.NOTE:_ The coolant level should be between the minimum
and maximum level marks. _3. If the coolant is at or below the minimum level
mark, remove panel D. (See pages 8-19–
8-21 for panel removal and installation proce-
dures.)
4. Remove the reservoir cap, add coolant to the
maximum level mark, install the reservoir
cap, and then install the panel.
U1D960.book Page 57 Wednesday, June 23, 2004 3:59 PM

8-65
CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you cannot get
distilled water. _14. Start the engine and let it idle for several min-
utes. Stop the engine, and then check the
coolant level in the radiator. If it is low, add
more coolant until it reaches the top of the ra-
diator.
15. Check for coolant leakage.Recommended antifreeze:
High quality ethylene glycol antifreeze
containing corrosion inhibitors for
aluminum engines.
Antifreeze and water mixing ratio:
1:1
Total amount:
1.30 L
Coolant reservoir capacity
(up to the maximum level mark):
0.25 L
U1D960.book Page 65 Wednesday, June 23, 2004 3:59 PM

8-81
NOTE:_ The air filter element should be cleaned every 20–
40 hours. It should be cleaned and lubricated more
often if the machine is operated in extremely dusty
areas. Each time the air filter element mainte-
nance is performed, check the air inlet to the filter
case for obstructions. Check the air filter case rub-
ber joint to the carburetor and manifold fittings for
an airtight seal. Tighten all fittings securely to
avoid the possibility of unfiltered air entering the
engine. _CAUTION:_ Never operate the engine with the air filter ele-
ment removed. This will allow unfiltered air to
enter, causing rapid engine wear and possible
engine damage. Additionally, operation with-
out the air filter element will affect carburetor
jetting with subsequent poor performance and
possible engine overheating. _
U1D960.book Page 81 Wednesday, June 23, 2004 3:59 PM