2005 YAMAHA KODIAK 450 brake fluid

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

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear shock absorber
assembly spring preload
adjusting ring
2. Storage compartment
and tool kit
3. Spark plug
4. Rear brake fluid reservoir
5. Front shock absorber
assembly spring preload
adjusting ring
6. Brake pedal
7. V-belt case
8. Radiator cap
9. Fuel cock
10. Air filter case
11. Fuses
12. Tail/brake light
13. Engine oil dipstick
14. Oil filter cartridge15. Coolant reservoir
16. V-belt cooling duct check
hose
17. Rear brake lever
18. Left handlebar switches
19. Starter (choke)
20. Horn switch
21. Drive select lever
22. Speedometer unit
23. Main switch
24. Fuel tank cap
25. Auxiliary DC jack
26. Right handlebar switch
27. Throttle lever
28. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U1D960.book Page 1 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

5-5
EBU12761
Front and rear brakes
Brake levers and brake pedal

Check that there is no free play in the front
brake lever. If there is free play, have a
Yamaha dealer adjust it.


Check for correct free play in the rear brake le-
ver. If the free play is incorrect, adjust it. (See
pages 8-105–8-107.)


Check for correct brake pedal height. If the
pedal height is incorrect, have a Yamaha deal-
er adjust it.


Check the operation of the brake levers and
pedal. They should move smoothly and there
should be a firm feeling when the brakes are
applied. If not, have a Yamaha dealer inspect
the brake system.
Brake fluid level
Check the brake fluid level. Add fluid if necessary.
(See pages 8-97–8-101.)
Recommended brake fluid: DOT 4
U1D960.book Page 5 Wednesday, June 23, 2004 3:59 PM

5-7
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joints or brake fluid reservoirs. Apply the
brakes firmly for one minute. If the lever moves
slowly inward, there may be a leak in the brake
system. If there is any leakage, the brake system
should be inspected by a Yamaha dealer.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, in-
spect the brake pads for wear. (See pages 8-93–
8-95.)
WARNING
_ Always check the brakes at the start of every
ride. Do not ride the ATV if you find any prob-
lem with the brakes or you could lose braking
ability, which could lead to an accident. If a
problem cannot be corrected by the adjust-
ment procedures provided in this manual,
have a Yamaha dealer check for the cause. _
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

8-9
* 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

8-97 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
FRONT
Avant
Delantero1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimoREAR
Arrière
Trasero
EBU06221
Inspecting the brake fluid level
Insufficient brake fluid may let air enter the brake
system, possibly causing the brakes to become in-
effective.
Before riding, check that the brake fluid is above
the minimum level mark and replenish when nec-
essary. A low brake fluid level may indicate worn
brake pads and/or brake system leakage. If the
brake fluid level is low, be sure to check the brake
pads for wear and the brake system for leakage.
The rear brake fluid master cylinder reservoir is lo-
cated under panel C. (See pages 8-23–8-27 for
panel removal and installation procedures.)
Observe these precautions:

When checking the fluid level, make sure the
top of the master cylinder reservoirs are level.


Use only the designated quality brake fluid.
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake performance.
Recommended brake fluid: DOT 4
U1D960.book Page 97 Wednesday, June 23, 2004 3:59 PM