2005 YAMAHA KODIAK 450 boot

Tire wear limit......................................5-31
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............ 8-17
Engine oil and oil filter cartridge ......... 8-33
Final gear oil ....................................... 8-43
Differential gear oil.............................. 8-51
Cooling system ................................... 8-57
Changing the coolant.......................... 8-61
Axle boots ........................................... 8-67
Spark plug inspection ......................... 8-69
Air filter element cleaning ................... 8-75
V-belt cooling duct check hose ........... 8-83
V-belt case drain plug ......................... 8-83
Carburetor adjustment ........................ 8-85
Idle speed adjustment ........................ 8-87
Valve clearance adjustment ............... 8-89
Throttle lever adjustment .................... 8-91
Select lever safety system cable
adjustment ........................................ 8-93
Front brake pad check ........................ 8-93
Rear brake pad check ........................ 8-95
Inspecting the brake fluid level ........... 8-97
Brake fluid replacement .................... 8-101
Front brake lever free play................ 8-103
8
U1D960.book Page 2 Wednesday, June 23, 2004 3:59 PM

2-3

Never carry a passenger on an ATV.


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


Never operate an ATV on any paved street,
paved road or motorway.


Watch carefully for other vehicles when operat-
ing on unpaved public streets or roads. Make
sure you know your country’s laws and regula-
tions before you ride on unpaved public streets
or roads.


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, a 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, operating condi-
tions, and your experience.


Never attempt wheelies, jumps, or other stunts.
U1D960.book Page 3 Wednesday, June 23, 2004 3:59 PM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-93, 8-97–8-103
Rear brakeCheck operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-95–8-101,
8-105–8-107
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-33–8-43
Coolant reservoirCheck coolant level in reservoir.
Fill with coolant if necessary.5-19–5-21,
8-57–8-67
Final gear oil and
differential gear oilCheck for leakage.5-15–5-17,
8-43–8-55
ThrottleCheck for proper throttle cable operation and free play. 5-21, 8-91
Wheels and tiresCheck tire pressure, wear and damage.5-25–5-31,
8-115–8-117
Fittings and fastenersCheck all fittings and fasteners. 5-21
Lights and switchesCheck for proper operation.5-23, 8-109,
8-129–8-133
Axle bootsCheck for damage. 8-67
U1D960.book Page 1 Wednesday, June 23, 2004 3:59 PM

7-11 1. Protective clothing 2. Goggles
3. Gloves 4. Boots
5. Helmet
1. Vêtement de protection 2. Lunettes
3. Gants 4. Bottes
5. Casque
1. Vestimenta adecuada 2. Gafas
3. Guantes 4. Botas
5. Homologado
Apparel
Always wear an approved helmet that fits properly.
You should also wear:
eye protection
(goggles or face shield)
gloves
boots
long-sleeved shirt or jacket
long pants
WARNING
_ Never operate this ATV without wearing an ap-
proved motorcycle helmet, eye protection and
protective clothing. Operating without an ap-
proved motorcycle helmet increases your
chances of a severe head injury or death in the
event of an accident. Operating without eye
protection can result in an accident and in-
creases your chances of a severe injury in the
event of an accident. Operating without protec-
tive clothing increases your chances of severe
injury in the event of an accident. _
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8-9
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
When disassembling the master cylinders or caliper cylinders, replace the brake fluid. Normally
check the brake fluid level and add fluid as required.
On the inner parts of the master cylinders and caliper cylinders, replace the oil seals every two years.
Replace the brake hoses every four years, or if cracked or damaged.
Front and rear axle boots*Check operation.
Replace if damaged.Stabilizer bushes*
Check for cracks or damage.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.Lights and switches*Check operation.
Adjust headlight beams.
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 9 Wednesday, June 23, 2004 3:59 PM

8-67 1. Front axle boot (× 2 each side)
1. Soufflet d’axe avant (× 2 de chaque côté)
1. Guardapolvo de eje delantero (× 2 en cada lado)
NOTE:_ If any leakage is found, ask a Yamaha dealer to in-
spect the cooling system. _16. Install the panels and the front carrier.
EBU00862
Axle boots
Check the protective boots for holes or tears. If any
damage is found, have them replaced by a
Yamaha dealer.
U1D960.book Page 67 Wednesday, June 23, 2004 3:59 PM

8-69 1. Rear axle boot (× 2 each side)
1. Soufflet d’axe arrière (× 2 de chaque côté)
1. Guardapolvo de eje trasero (× 2 en cada lado)
1. Spark plug cap
1. Capuchon de bougie
1. Tapa de bujía
EBU00864
Spark plug inspection
Removal
1. Remove panel A. (See pages 8-19–8-21 for
panel removal and installation procedures.)
2. Remove the spark plug cap.
U1D960.book Page 69 Wednesday, June 23, 2004 3:59 PM