2019 YAMAHA KODIAK 450 check engine

EBU17421
TABLE OF CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS .............................. 1-1
SAFETY INFORMATION ................................ 2-1
DESCRIPTION................................................ 3-1Left view ...................................................... 3-1
Right view.................................................... 3-1
Controls and instruments............................ 3-2
INSTRUMENT AND CONTROL
FUNCTIONS ................................................... 4-1 Main switch ................................................. 4-1
Indicator lights and warning lights .............. 4-1
Display unit ................................................ 4-4
Self-diagnosis device .................................. 4-5
Handlebar switches .................................... 4-6
Throttle lever ............................................... 4-8
Speed limiter ............................................... 4-8
Front brake lever ......................................... 4-9
Brake pedal and rear brake lever ................ 4-9
Drive select lever ....................................... 4-10
Fuel tank cap ............................................ 4-11
Fuel ........................................................... 4-12 Seat .......................................................... 4-13
Storage compartment............................... 4-14
Front carrier .............................................. 4-15
Rear carrier ............................................... 4-15
Front and rear shock absorbers .............. 4-15
Trailer hitch (for equipped models) ........... 4-17
Auxiliary DC jack....................................... 4-18
Winch pre-wiring ...................................... 4-18
PRE-OPERATION CHECKS .......................... 5-1 Fuel ............................................................. 5-3
Engine oil .................................................... 5-3
Final gear oil ............................................... 5-3
Differential gear oil ...................................... 5-3
Coolant ....................................................... 5-3
Front and rear brakes ................................. 5-3
Throttle lever ............................................... 5-4
Tires ............................................................ 5-4
Chassis fasteners ....................................... 5-7
Instruments, lights and switches ................ 5-7
OPERATION .................................................. 6-1 Starting the engine ..................................... 6-1UBB561E0.book Page 1 Monday, March 26, 2018 11:15 AM

Operating the drive select lever and driving in reverse ....................................... 6-2
Engine break-in ........................................... 6-4
Parking ........................................................ 6-4
Parking on a slope ...................................... 6-5
Accessories and loading ............................. 6-5
RIDING YOUR ATV ........................................ 7-1 GETTING TO KNOW YOUR ATV ................ 7-2
RIDE WITH CARE AND GOOD JUDGMENT .............................................. 7-2
BE CAREFUL WHERE YOU RIDE ............... 7-9
TURNING YOUR ATV................................ 7-12
CLIMBING UPHILL ................................... 7-13
RIDING DOWNHILL .................................. 7-16
CROSSING A SLOPE................................ 7-17
CROSSING THROUGH SHALLOW WATER .................................................... 7-18
RIDING OVER ROUGH TERRAIN ............. 7-20
SLIDING AND SKIDDING .......................... 7-21
WHAT TO DO IF... ..................................... 7-22
WHAT TO DO... ......................................... 7-22
PERIODIC MAINTENANCE AND
ADJUSTMENT................................................ 8-1 Owner’s Manual and tool kit ....................... 8-2 Periodic maintenance chart: Emission
control system .......................................... 8-3
Periodic maintenance chart: General maintenance and lubrication .................... 8-5
Removing and installing panels ................ 8-10
Checking the spark plug........................... 8-17
Engine oil and oil filter cartridge ............... 8-19
Final gear oil ............................................. 8-24
Changing the differential gear oil.............. 8-27
Coolant ..................................................... 8-28
Cleaning the air filter ................................. 8-32
Cleaning the spark arrester ...................... 8-35
V-belt cooling duct check hose ................ 8-36
V-belt case drain plug............................... 8-37
Adjusting the throttle lever free play ......... 8-38
Valve clearance......................................... 8-38
Brakes....................................................... 8-38
Checking the front brake pads and rear brake friction plates ................................ 8-39
Checking the brake fluid level .................. 8-39
Changing the brake fluid .......................... 8-41
Checking the front brake lever free play... 8-41
Adjusting the rear brake lever and brake pedal ....................................................... 8-41
Axle boots................................................. 8-46
Brake light switches ................................. 8-47
Checking and lubricating the cables ........ 8-48
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2-4
2
Never maintain an ATV without proper knowl-
edge. Contact an authorized ATV dealer to in-
form you on basic ATV maintenance. Certain
maintenance can only be carried out by certified
staff.
In the event of an accident 1. If serious injuries are incurred, you may be safer staying next to your vehicle; it may
shield you from oncoming riders. Depending
on your injuries and position in the trail; you
must make a judgment call as to whether you
should move to a position off the trail. If you
have sustained head, neck, or back injuries,
or cannot feel your limbs, you should not
move. Keep your helmet on and remain mo-
tionless. Lie down next to your vehicle and
wait for help.
2. If less serious injuries are incurred and you can walk, then move to a position off the trail.
Check yourself for injuries and apply first aid
as needed.
3. If your injuries are light, when safe to do so, move your vehicle off the trail to avoid colli-
sions with oncoming riders. Check for injuries
and apply first aid as necessary. If you can
physically operate your vehicle, inspect your vehicle. If the vehicle is in safe operating con-
dition and you can safely operate it, restart it
and ride gently back to camp or other known
location where you can receive medical at-
tention. If necessary, contact your riding party
or local authorities to let them know where
you are and what has happened.
In the event of a breakdown 1. If your vehicle will not restart or is not in safe operating condition, turn off the main switch
and engine stop switch. If the breakdown oc-
curs at twilight or night, leave the main switch
on so that your lights may warn other riders of
your stopped vehicle.
2. Get out of danger. Check for oncoming vehi- cles and when safe, push your vehicle to the
side of the trail or even off the main trail to
avoid any possible collisions with oncoming
riders. If you cannot move your vehicle by
yourself, when safe, walk to the nearest van-
tage point and signal an oncoming rider to
help you push your vehicle to a safe place off
the trail.
3. Inspect your vehicle for any immediate haz- ardous conditions. The most obvious hazard-
ous conditions are leaking fuel and
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3-1
3
EBU17681
DESCRIPTION
EBU17691Left view
EBU17701Right view
1. Radiator cap
2. Air filter
3. Battery
4. Fuses
5. Brake/tail light
6. Engine oil filler cap
7. Oil filter cartridge
8. Coolant reservoir
9. V-belt cooling duct check hose
1
2
3
4
5
9
7
8
6
1. Spark arrester
2. Storage compartment and tool kit
3. Fuel tank cap
4. Spark plug
5. Auxiliary DC jack
6. Front shock absorber
7. Rear brake light switch
8. Brake pedal
9. V-belt case drain plug
10.Rear shock absorber110
6
2
3
4
5
7
9
8
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4-2
4
EBU17861Neutral indicator light “ ”
This indicator light comes on when the transmis-
sion is in the neutral position.EBU17831Reverse indicator light “ ”
This indicator light comes on when the transmis-
sion is in the reverse position.EBU17971Park indicator light “ ”
This indicator light comes on when the transmis-
sion is in the park position.EBU34562Coolant temperature warning light “ ”
This warning light comes on when the engine
overheats. When this occurs during operation,
stop the engine as soon as it is safe to do so and
allow it to cool down for about 10 minutes.
The electrical circuit of the warning light can be
checked by turning the key to “ ” (on). The
warning light should come on for a few seconds,
and then go off.
If the warning light does not come on initially when
the key is turned to “ ” (on), or if the warning
light remains on, have a Yamaha dealer check the
electrical circuit.
TIPThe radiator fan turns on or off automatically ac-
cording to the coolant temperature. NOTICEECB02401The engine may overheat if the ATV is over-
loaded. Reduce the load to specification.
 The engine may overheat if mud or dirt has
accumulated on the radiator. Gently clean
the radiator. (See page 9-1.)
 Continuous use while the warning light is on
will damage the engine. EBU29943Engine trouble warning light “ ”
This warning light comes on or flashes when an
electrical circuit monitoring the engine is not work-
ing correctly. When this occurs, have a Yamaha
dealer check the self-diagnosis system.
The electrical circuit of the warning light can be
checked by turning the key to “ ” (on). The
warning light should come on for a few seconds,
and then go off.
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4-3
4
If the warning light does not come on initially when
the key is turned to “ ” (on), or if the warning
light remains on, have a Yamaha dealer check the
electrical circuit.
EBU30571Electric Power Steering warning light “EPS”
(for EPS model)
This warning light comes on when the key is
turned to “ ” (on), and then goes off once the
engine is started. If the warning light remains on or
comes on after the engine is started, the EPS sys-
tem may not be working correctly. When this oc-
curs, have a Yamaha dealer check the EPS
system.
The electrical circuit of the warning light can be
checked by turning the key to “ ” (on). If the
warning light does not come on, have a Yamaha
dealer check the electrical circuit.TIP
If the engine is stopped using the engine stop
switch and the key is in the “ ” (on) position,
the EPS warning light comes on to indicate that
the power assistance for the steering is not
functioning. 
If the steering load is too heavy (i.e., excessive
steering use when the ATV is traveling at a slow
speed), the power assist is reduced to protect
the EPS motor from overheating.
EBU17955Four-wheel drive indicator light “ ”
This indicator light comes on when the drivetrain
is set to “4WD” (four-wheel drive).TIPDue to the synchronizing mechanism in the differ-
ential gear case, the light may not come on until
the ATV starts moving.
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4-6
4If a problem is detected in any of those circuits,
the engine trouble warning light will come on or
flash. If this occurs, have a Yamaha dealer check
the vehicle.
NOTICEECB01181To prevent engine damage, be sure to consult
a Yamaha dealer as soon as possible if this oc-
curs. EBU18067Handlebar switches
EBU18081Engine stop switch “ / ”
Set this switch to “ ” before starting the engine.
The engine stop switch controls the ignition and
stops the engine when it is running. Use this
switch to stop the engine in an emergency situa-
tion. The engine will not start or run when this
switch is set to “ ”.EBU18102Start switch “ ”
Push this switch to crank the engine with the start-
er. See the starting instructions on page 6-1 prior
to starting the engine.
1. Light switch “ / /OFF”
2. Engine stop switch “ / ”
3. Start switch “ ”
4. Horn switch “ ”
3421
1. On-Command drive switch “2WD/4WD”
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4-8
4
EBU18285Throttle leverPush the throttle lever to increase engine speed.
Spring tension returns the lever to the rest position
when released. Always check that the throttle le-
ver returns normally before starting the engine.
EBU18325Speed limiterThe speed limiter keeps the throttle from fully
opening, even when the throttle lever is pushed to
the maximum.
Adjusting the speed limiter1. Loosen the locknut.
2. To increase the maximum engine poweravailable and the maximum speed of the ATV,
turn the adjusting screw in direction (a). To
decrease the maximum engine power avail-
able and the maximum speed of the ATV, turn
1. Throttle lever
1. Locknut
2. Adjusting screw
3. No more than 12 mm (0.47 in)
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