2019 YAMAHA KODIAK 450 lock

8-35
87. Squeeze out the excess moisture, and let dry.
NOTICE: Do not twist the sponge material
when squeezing it.
[ECB00442]
8. Check the air filter elements (sponge material) for damage, replace if necessary.
9. Apply YAMALUBE Foam Air Filter Oil (or equivalent) to the air filter elements.TIPThe sponge material should be wet but not drip-
ping. 10. Install the sub air filter element.
11. Install the main air filter element onto its frame, then the lock plate, and then install the
main air filter assembly. 12. Install the air filter case cover by hooking the
holders onto the cover. NOTICE: Make sure
that the air filter element is properly seated
in the air filter case. Never operate the en-
gine with the air filter element removed.
Doing so would allow unfiltered air to enter
the engine, causing rapid engine wear and
possible engine damage. Additionally, the
fuel injection system would be affected re-
sulting in poor engine performance and
possible overheating.
[ECB00763]
13. Install the seat.EBU28905Cleaning the spark arresterBe sure the exhaust pipe and muffler are cool be-
fore cleaning the spark arrester.
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8-38
8
EBU29704Adjusting the throttle lever free playPeriodically check the throttle lever free play and
adjust if necessary.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
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication 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.
1. Throttle lever free play
2. Rubber cover
3. Locknut
4. Throttle lever free play adjusting boltThrottle lever free play: 3.0–5.0 mm (0.12–0.20 in)2
4 3
1
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8-41
8
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.
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.
EBU24396Checking the front brake lever free
playThere should be no free play at the brake lever
end. If there is free play, have a Yamaha dealer in-
spect the brake system.EBU30348Adjusting the rear brake lever and
brake pedalThe rear brake lever free play, brake pedal free
play, and the brake pedal height must be checked
and adjusted at the intervals specified in the peri-
odic maintenance chart.1. No brake lever free play
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8-42
8
Adjusting the brake lever free play
Measure the brake lever free play and adjust if
necessary.
1. Loosen the locknut at the brake lever. 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). NOTICE:
Distance A must not measure more than
12.7 mm (0.50 in). If distance A exceeds
12.7 mm (0.50 in), the specified brake lever
free play cannot be obtained, therefore
proceed with the following steps.
[ECB01143]
1. Brake lever free playBrake lever free play: 10.0 mm (0.39 in)
1
1. Locknut
2. Distance A
3. Brake lever free play adjusting bolt
12
3
(a)
(b)
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8-43
8
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).
NOTICE:
Make sure that distance B measures 22
mm (0.87 in) or less. If distance B reaches
22 mm (0.87 in), adjust the brake lever free
play at the brake lever again. If distance A
exceeds 12.7 mm (0.50 in), have a Yamaha
dealer check the vehicle.
[ECB01153]
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 height
1. Brake cable adjuster locknut
2. Brake lever free play adjusting nut
3. Rubber cover
4. Distance B
(a)
(b)3
2
1
4
1. Brake pedal height
2. Brake pedal
3. Footboard1
23
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8-44
8
Measure the brake pedal height and adjust if nec-
essary.
1. Remove the footboard by removing the quick fasteners, bolts, and nuts.
2. Loosen the locknut. 3. Turn the adjusting bolt in or out until the brake
pedal height is within the specified limits.
4. Tighten the locknut.
5. Install the footboard by installing the quick fasteners, bolts, and nuts, and then tighten
the bolts to the specified torques.
Brake pedal height:
80.0 mm (3.15 in)
1. Footboard
2. Quick fastener
3. Bolt and nut
4. Bolt
42
3
312
1. Locknut
2. Adjusting boltTightening torque:Locknut:7 N·m (0.7 kgf·m, 5.2 lb·ft)
2
1
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8-46
8
Adjusting the brake pedal free play
Measure the brake pedal free play and adjust if
necessary.
TIPThe brake lever free play and brake pedal height
must be adjusted before adjusting the brake pedal
free play. 1. Loosen the locknut.
2. 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).
3. Tighten the locknut.
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 playBrake pedal free play: 20.0 mm (0.79 in)
1
1. Brake pedal free play adjusting nut
2. Locknut
21
(a)
(b)
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8-59
83. Remove the socket by pushing it in and turn-
ing it counterclockwise. 4. Remove the burnt-out bulb.
5. Place a new bulb into position.
NOTICE: Do
not touch the glass part of the bulb. Oil
from your fingers or other contamination
will adversely affect the transparency of
the glass, luminosity of the bulb, and bulb
life. Thoroughly clean off any dirt and fin-
gerprints using a cloth moistened with al-
cohol or thinner.
[ECB00653]
6. Install the socket by pushing it in and turning it clockwise.
1. Bulb cover
1. Socket
11
1. Do not touch the glass part of the bulb.
UBB561E0.book Page 59 Monday, March 26, 2018 11:15 AM