2022 YAMAHA KODIAK 450 Owners Manual

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9
For differential gear lock models
Periodically 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.
EBU24062Valve 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 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: 2.0–4.0 mm (0.08–0.16 in)
2WD
4WD
3
4
2
1
(b)
(a)
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EBU28415Checking 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 chart.TIPThis ATV is equipped with a wet, multiple-disc
type rear brake, which is located inside of the final
gear case. EBU24174Front brake padsCheck each front brake pad for damage and mea-
sure the lining thickness. If a brake pad is dam-
aged or if the lining thickness reaches the
specified limit, have a Yamaha dealer replace the
brake pads as a set.
TIPThe wheels need to be removed to check the
brake pads. (See page 9-63.) EBU30322Rear 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
chart.EBU29845Checking the brake fluid levelBefore riding, check that the brake fluid is above
the minimum level mark. Replenish the brake fluid
if necessary.
1. Lining thickness
Brake pad lining thickness limit:
1.0 mm (0.04 in)
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TIPStraighten the handlebars for an accurate reading. 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 or brake sys-
tem leakage. Therefore, be sure to check the
brake pads for wear and the brake system for
leakage. If the brake fluid level suddenly goes
down, have a Yamaha dealer check the brake sys-
tem before further riding.
WARNING
EWB02721Improper maintenance can result in loss of
braking ability. Observe these precautions:
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.
1. Minimum level markSpecified brake fluid:
DOT 4
1
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9
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.
EBU24284Changing the brake fluidHave a Yamaha dealer change the brake fluid at
the intervals specified in the periodic maintenance
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
1
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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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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. Footboard bracket1
2
3
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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

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TIPTighten the footboard bolts in the order shown. 1. Footboard bolt A
2. Footboard bolt B
3. Quick fastener
3
1
2
1
3
Tightening torquesWFootboard bolt AW4.0 N