2016 YAMAHA KODIAK 700 Owners Manual

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8
4. Check the gasket for damage, and replace it
if necessary.
5. Make sure the gasket is properly positioned, then insert the tailpipe into the muffler and
align the bolt holes.
6. Install the bolts and tighten them to the spec- ified torque.
WARNING
EWB02341Do not start the engine when cleaning the
spark arrester, otherwise it could cause injury
to the eyes, burns, carbon monoxide poison-
ing, possibly leading to death, and start a fire.
Always let the exhaust system cool prior to
touching exhaust components. EBU23932V-belt case drain plugAfter riding in water deep enough to allow it to en-
ter the V-belt case, remove the V-belt case drain
plug to drain the water from the case.TIPIf water drains from the V-belt case after removing
the plug, have a Yamaha dealer check the ATV as
the water may affect other engine parts.
1. Gasket
2. Spark arrester
3. TailpipeTightening torque:Tailpipe bolt:10 Nm (1.0 m·kgf, 7.2 ft·lbf)
3
2
1
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EBU29703Adjusting the throttle lever free playThe throttle lever free play should be checked and,
if necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
The throttle lever free play should measure 3.0–5.0
mm (0.12–0.20 in) as shown. Periodically check
the throttle lever free play and, if necessary, adjust
it as follows.1. Slide the rubber cover back.
2. Loosen the locknut. 3. To increase the throttle lever free play, turn
the throttle lever free play adjusting bolt in di-
rection (a). To decrease the throttle lever free
play, turn the adjusting bolt in direction (b).
4. Tighten the locknut.
5. Slide the rubber cover to its original position.
EBU24061Valve clearanceThe valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
1. V-belt case drain plug
1
1. Rubber cover
2. Throttle lever free play adjusting bolt
3. Locknut
4. Throttle lever free play
2WD
4WD
3
2
1
4
(b)
(a)
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must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU24072Adjusting the drive select lever safety
system cableThe drive select lever safety system cable stretch-
es with use, which can result in improper function.
Therefore, the safety system cable should be
checked and adjusted by a Yamaha dealer at the
intervals specified in the periodic maintenance
and lubrication chart.EBU29602BrakesReplacement of brake components requires pro-
fessional knowledge. Brake service should be
performed by a Yamaha dealer.
WARNING
EWB02572Operating with improperly serviced or adjust-
ed brakes could lead to a loss in braking ability
and an accident.
EBU28414Checking the front brake pads and rear
brake friction platesThe front brake pads and the rear brake friction
plates must be checked for wear at the intervals
specified in the periodic maintenance and lubrica-
tion chart.TIPThis ATV is equipped with a wet, multiple-disc
type rear brake, which is located inside of the final
gear case. EBUM0191Front brake pads
Each brake pad is provided with a wear indicator
groove, which allows you to check the brake pad
wear without having to disassemble the brake. To
check the brake pad wear, check the wear indica-
tor groove. If a brake pad has worn to the point
that the wear indicator groove has almost disap-
peared, have a Yamaha dealer replace the brake
pads as a set.
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TIPThe wheels need to be removed to check the
brake pads. (See page 8-64.) EBU30321Rear brake friction plates
The rear brake friction plates must be checked
and, if necessary, replaced by a Yamaha dealer at
the intervals specified in the periodic maintenance
and lubrication chart.
EBU29843Checking the brake fluid levelBefore riding, check that the brake fluid is above
the minimum level mark. Check the brake fluid lev-
el with the top of the reservoir level. Replenish the
brake fluid if necessary.
WARNING
EWB02721Improper maintenance can result in loss of
braking ability. Observe these precautions:
1. Wear indicator groove
1. Minimum level markSpecified brake fluid:DOT 4
2WD
4WD
1
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
Insufficient brake fluid may allow air to enter
the brake system, reducing braking perfor-
mance.
 Clean the filler cap before removing. Use
only DOT 4 brake fluid from a sealed contain-
er.
 Use only the specified brake fluid; otherwise,
the rubber seals may deteriorate, causing
leakage.
 Refill with the same type of brake fluid. Add-
ing a brake fluid other than DOT 4 may result
in a harmful chemical reaction.
 Be careful that water does not enter the
brake fluid reservoir when refilling. Water will
significantly lower the boiling point of the flu-
id and may result in vapor lock.
NOTICEECB01161Brake fluid may damage painted surfaces or
plastic parts. Always clean up spilled fluid im-
mediately. As the brake pads wear, it is normal for the brake
fluid level to gradually go down. A low brake fluid
level may indicate worn brake pads and/or brake
system leakage; therefore, be sure to check the brake pads for wear and the brake system for
leakage. If the brake fluid level goes down sud-
denly, have a Yamaha dealer check the cause be-
fore further riding.
EBU24283Changing the brake fluidHave a Yamaha dealer change the brake fluid at
the intervals specified in the periodic maintenance
and lubrication chart. In addition, have the oil seals
of the brake master cylinder and calipers as well
as the brake hoses replaced at the intervals listed
below or whenever they are damaged or leaking.

Oil seals: Replace every two years.
 Brake hoses: Replace every four years.EBU24395Checking the front brake lever free
playThe brake lever free play must be checked at the
intervals specified in the periodic maintenance
and lubrication chart. The brake lever should have
no free play as shown. If there is free play, have a
Yamaha dealer check the brake system.
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EBU34242Adjusting the rear brake lever and
brake pedal free playThe rear brake lever and brake pedal free play
must be checked and, if necessary, adjusted at
the intervals specified in the periodic maintenance
and lubrication chart.
Adjusting the brake lever free play
The brake lever free play should measure 6.0–7.0
mm (0.24–0.28 in). If the free play is incorrect, ad-
just it as follows.1. Loosen the locknut at the brake lever.1. No brake lever free play
1. Brake lever free play
1. Locknut
2. Brake lever free play adjusting bolt
1
(a)
(b)
12
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2. To increase the brake lever free play, turn the
brake lever free play adjusting bolt in direction
(a). To decrease the brake lever free play, turn
the adjusting bolt in direction (b).
TIPIf the specified brake lever free play could be ob-
tained as described above, skip steps 3–8. 3. Fully turn the adjusting bolt in direction (a) toloosen the brake cable.
4. Slide the rubber cover back.
5. Loosen the brake cable adjuster locknut. 6. To increase the brake lever free play, turn the
brake lever free play adjusting nut in direction
(a). To decrease the brake lever free play, turn
the adjusting nut in direction (b).
7. Tighten the brake cable adjuster locknut.
8. Slide the rubber cover to its original position.
9. Tighten the locknut at the brake lever.
Adjusting the brake pedal free play
The brake pedal free play should measure 12.0–
17.0 mm (0.47–0.67 in). If the free play is incorrect,
adjust it as follows.
1. Remove panel G.
2. Loosen the locknut.1. Brake cable adjuster locknut
2. Brake lever free play adjusting nut
3. Rubber cover
2
3
1
(a)(b)
1. Brake pedal free play
1
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83. To increase the brake pedal free play, turn the
brake pedal free play adjusting nut in direc-
tion (a). To decrease the brake pedal free
play, turn the adjusting nut in direction (b).
4. Tighten the locknut.
5. Install the panel.
EBU24231Axle bootsThe axle boots must be checked for damage at
the intervals specified in the periodic maintenance
and lubrication chart. Check the axle boots for
tears or damage. If any damage is found, have
them replaced by a Yamaha dealer.
1. Brake pedal free play adjusting nut
2. Locknut
2
(a)
(b)
1
1. Front axle boot (each side)
1
1
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