2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 Owners Manual
2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 Manual
2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 manual content summary:
- 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 1
READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER'S MANUAL YFM400FAP WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-15-19 5GH-28199-12 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 2
EBU00776 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 3
of your ATV, please consult a Yamaha dealer. AN IMPORTANT SAFETY MESSAGE: G READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. G PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. G NEVER - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 4
INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 5
manufacture. Please check your local riding laws and regulations before operating this machine. EBU00711 AFFIX DEALER LABEL HERE YFM400FAP OWNER'S MANUAL © 2001 by Yamaha Motor Corporation, U.S.A. 1st Edition, April 2001 All rights reserved. Any reprinting or unauthorized use without the written - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 6
EBU00014 WARNING Indicates a potential hazard that could result in serious injury or death. 4 CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS...1-1 SAFETY INFORMATION...2-1 DESCRIPTION AND MACHINE IDENTIFICATION ...3-1 Identification number records...3-2 Key identification number - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 7
Rear shock absorber adjustment...4-20 Auxiliary DC jack...4-21 5 PRE-OPERATION CHECKS ...5-1 Front and rear brakes ...5-2 Fuel ...5-4 Engine oil ...5-6 Final gear oil...5-7 Differential gear oil ...5-7 Throttle lever ...5-7 Fittings and Fasteners ...5-8 Lights...5-8 Switches...5-8 Tires ...5-8 How - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 8
8 PERIODIC MAINTENANCE AND ADJUSTMENT...8-1 Owner's manual and tool kit...8-1 Periodic maintenance/ lubrication ...8-3 Panel removal and installation ...8-5 ...8-49 Headlight beam adjustment...8-51 Tail/brake light bulb replacement ...8-51 Troubleshooting ...8-53 Troubleshooting charts ...8-54 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 9
9 CLEANING AND STORAGE...9-1 A. Cleaning...9-1 B. Storage ...9-3 SPECIFICATIONS...10-1 NOISE REGULATION...11-1 MAINTENANCE RECORD ...12-1 ATV LIMITED WARRANTY...13-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ...14-1 10 11 12 13 14 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 10
EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1-1 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 11
Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 3 1 2 3 4 5 6 7 1 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 12
5 LOAD LIMIT 80 kg (176 lbs) 4SH-24877-A0 7 WARNING UNDER 6 MAXIMUM . LOADING LIMIT PULLING LOAD: TONGUE WEIGHT: 4900 1102 147 33 (500kgf) N lbf ( 15kgf) N lbf 5GH-2151K-00 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 13
9 1-4 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 14
riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: G Read this manual and all labels carefully and follow the operating procedures described. G Never operate an ATV without proper training or - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 15
time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 16
sharply to one side. Go straight down the hill where possible. Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 17
. Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 18
WARNING POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 19
WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation. 2-6 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 20
Right handlebar switch Throttle lever Front brake lever NOTE: The machine you have purchased may differ slightly from those shown in the figures of this manual. 3-1 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 21
EBU00600 EBU00035 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 22
EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 23
EBU00039 CONTROL FUNCTIONS 1 WARNING Indicates a potential hazard that could result in serious injury or death. EBU00041 2 3 4 5 6 1. Main switch Main switch Functions of the respective switch positions are as follows: ON: Engine can be started only at this position and the headlight and - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 24
EBU00043 EBU00602 Indicator lights Reverse indicator light "R" This indicator light comes on when the transmission is in reverse. EBU00603 Neutral indicator light "N" This indicator light comes on when the transmission is in neutral. 1. 2. 3. 4. 5. Park indicator light "P" Reverse indicator - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 25
EBU00713 EBU00605 Coolant temperature warning light " " When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 26
EBU00714 Coolant temperature warning light checking method ACB-09E Turn the main switch to "ON" and the engine stop switch to " ". Coolant temperature warning light does not come on. Push the start switch with the transmission in the neutral position. Coolant temperature warning light comes on. - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 27
EBU00052 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank. When the needle reaches the red line, refill the tank at the first opportunity. 1. Fuel gauge 2. Red line 5.5 L (1.21 Imp gal, 1.45 US gal) NOTE: If the machine runs out of fuel, move the fuel cock lever to the " - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 28
EBU00053 Handlebar switches CAUTION: Do not use the headlight with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. EBU00849 1. Light switch " - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 29
EBU00607 Start switch " " The starter motor cranks the engine when this switch is pushed. CAUTION: See starting instructions prior to starting the engine. (See page 6-1 for details.) 4-7 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 30
WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 2WD while the ATV is moving. WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD in some circumstances. Changing from 2WD to 4WD or from 4WD to 2WD while moving may cause the ATV to unexpectedly handle differently. This - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 31
HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can't find or solve the - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 32
EBU00066 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV. WARNING POTENTIAL HAZARD Improper adjustment of the - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 33
EBU00070 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 1. Rear brake pedal 1. Front brake lever EBU00073 Rear brake pedal and lever The brake pedal is located on the right side of the machine and the brake lever - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 34
EBU00608 EBU00666 Drive select lever The drive select lever is used to shift your machine into the low, high, neutral, reverse and park positions. (Refer to page 6-4 for the drive select lever operation.) Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt. Then - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 35
EBU00092 WARNING POTENTIAL HAZARD Starting the engine in gear or starting the engine without shifting into the park position. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident. HOW TO AVOID THE HAZARD Shift the transmission in neutral or set the shift lever to - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 36
EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 37
EBU00095 RES Position 1. Arrow mark Starter (choke) " " Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to "Starting a cold - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 38
EBU00566 Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. To install the seat, insert the projection on the front of the seat into the seat holder and push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted. 1. Seat 2. Seat - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 39
EBU00581 EBU00582 Storage box Maximum load limit: 2 kg (4.4 lb) Front carrier Maximum load limit: 40 kg (88 lb) CAUTION: To protect from damage, do not put metal products, like tools or sharply edged products directly in the storage box. If they must be stored, wrap them in appropriate cushion - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 40
EBU00635 Front shock absorber adjustment The spring preload can be adjusted to suit the rider's weight and riding conditions. Adjust the spring preload as follows: To increase the spring preload, turn the adjuster in direction a. To decrease the spring preload, turn the adjuster in direction b. - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 41
WARNING POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting. 4-19 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 42
EBU00634 Rear shock absorber adjustment The spring preload can be adjusted to suit the rider's weight and riding conditions. Adjust the spring preload as follows: To increase the spring preload, turn the adjuster in direction a. To decrease the spring preload, turn the adjuster in direction b. - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 43
EBU00748 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack can only be used when the main switch is in the "ON" position. 1. Turn the headlight switch to the "OFF" - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 44
1. Auxiliary DC jack EBU00112 WARNING 4-22 Indicates a potential hazard that could result in serious injury or death. - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 45
PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM Brakes Fuel Engine oil Coolant reservoir Final gear oil/ Differential gear oil Throttle Wheels and tires Fittings and Fasteners Lights Axle boots ROUTINE • Check operation, free play, fluid level and fluid leakage. • - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 46
use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. Front and rear brakes Brake levers and brake pedal Check for correct free play in the brake levers and brake pedal. If the free play - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 47
accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have the ATV inspected by a Yamaha dealer. 5-3 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 48
EBU00886 Fuel Make sure there is sufficient gasoline in the tank. Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: Total: 15 L (3.3 Imp gal, 3.9 US gal) Reserve: 4.5 L (0.99 Imp gal, 1.19 US gal) Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 49
does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 50
resulting in reduced component life and poor engine performance. _ -20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C Recommended engine oil classification: API Service SE, SF, SG type or higher Oil quantity: Periodic oil change: 2.3 L (2.0 Imp qt, 2.4 US qt) With oil filter replacement: 2.4 L (2.1 Imp qt - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 51
EBU00493 EBU00678 Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-15 ~ 8-17 for details.) Recommended oil: SAE 80 API GL-4 Hypoid gear oil If desired, an SAE 80W90 hypoid gear oil may be used for all conditions. NOTE: GL-4 is a quality and - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 52
Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. EBU00153 Tires WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 53
2. The tires should be set to the recommended pressure: G Recommended tire pressure Front 25 kPa (0.25 kgf/cm2, 3.6 psi) Rear 25 kPa (0.25 kgf/cm2, 3.6 psi) G Check and adjust tire pressures when the tires are cold. G Tire pressures must be equal on both sides. 3. Tire pressure below the minimum - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 54
EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressure - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 55
EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. 3 mm (0.12 in) 5-11 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 56
familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner's Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer. 6-1 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 57
NOTE: G When the drive select lever is in the neutral or park position, if either indicator light does not come on, ask a Yamaha dealer to inspect its electric circuit. G The engine can be started in any gear if the rear brake lever is applied. However, it is recommended to shift into neutral or - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 58
NOTE: G If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. G If the battery is - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 59
stop and return the throttle lever to the closed position. 2. Apply the brakes, then shift by moving the drive select lever along the shift guide. NOTE: Make sure that the drive select lever is completely shifted into position. _ 1. Drive select lever 3. Open the throttle lever gradually. 6-4 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 60
rear brake pedal. 3. Shift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide. 1. Drive select lever NOTE: G When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 61
5. Open the throttle lever gradually and continue to watch to the rear while backing. WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 62
EBU00210 Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 63
EBU00612 2. 10 ~ 20 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely but do not use full throttle at any time. 3. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally. Parking When parking, stop the engine and shift the drive select lever - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 64
EBU00615 Parking on a slope WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the machine - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 65
EBU00221 Accessories and loading EBU00222 G Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. G Choose only accessories designed for your ATV. Your Yamaha dealer has a - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 66
EBU00960 Loading Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: G Never exceed the weight limits shown. An overloaded ATV can be unstable. MAXIMUM LOADING - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 67
G G G G Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer. Allow more braking distance. A heavier vehicle takes - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 68
EBU00937 WARNING _ Indicates a potential hazard that could result in serious injury or death. 6-13 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 69
Riding Your ATV 7 7-1 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 70
7-2 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 71
. This section, Riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this section you begin to ride, be sure you have read this 7-3 Owner's Manual completely and understand the operation of the controls. Pay particular attention to - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 72
the course and the operating techniques described in this Owner's Manual. For more information about the training course, contact an authorized more difficult maneuvers. WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 73
Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 74
This ATV is designed to carry operator and cargo only - passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. HOW TO - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 75
Apparel WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 76
Do not operate after consuming alcohol or drugs. Operator's performance capability is reduced by the influence of alcohol or drugs. WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 77
. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner's Manual for this vehicle on pages 5-8 ~ 5-9. Always maintain proper tire pressure as described in the Owner's Manual on page 5-10. WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 78
WARNING _ Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 79
ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in your Owner's Manual for carrying cargo or pulling a trailer. 7-11 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 80
During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 81
Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don't - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 82
added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer. 7-14 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 83
Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. Do not touch the hot exhaust system. Do not park the ATV in a place where - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 84
BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 85
Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 86
Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 87
WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 88
When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 89
ATV is designed for off-road use only, and handling maneuvers are more difficult to perform on pavement. Set the parking brake and follow the instruction on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV. Remember that the engine and exhaust - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 90
that this skill be learned first at low speed. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner's Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 91
Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 92
CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 93
of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner's Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 94
AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner's Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. 7-26 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 95
When crossing the side of a hill: Always follow proper procedures as described in the Owner's Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. 7-27 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 96
If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 97
position. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner's Manual. 7-29 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 98
RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. For maximum engine compression braking effect, select low range - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 99
HAPPEN Could cause loss of control or cause the ATV to overturn. Always follow proper procedures for going down hills as described in this Owner's Manual. Note: a special technique is required when braking as you go down a hill. HOW TO AVOID THE HAZARD Always check the terrain carefully before you - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 100
AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner's Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 101
7-33 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 102
an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner's Manual. 7-34 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 103
Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. CAUTION: _ After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case and the check - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 104
1. V-belt cooling duct check hose (Left front side of ATV) 1. Drive select lever box check hose 1. V-belt cooling intake box check hose (Above V-belt cooling duct) 7-36 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 105
ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner's Manual. 7-37 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 106
SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 107
With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 108
WHAT TO DO IF ...This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. WHAT TO DO ...G If your ATV doesn't turn when you want it to: Bring - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 109
G G If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 110
Yamaha dealer perform service if you are not familiar with machine service. EBU00535 WARNING POTENTIAL HAZARD Servicing an engine while performing maintenance unless otherwise specified. Owner's manual and tool kit You are recommended to put this owner's manual in the vinyl bag and always carry it - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 111
The service information included in this manual is intended to provide you, the owner, with the necessary information designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized Yamaha ATV dealer. 1 2 3 4 5 6 7 8 9 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 112
EBU00261 PERIODIC MAINTENANCE/LUBRICATION INITIAL ITEM Valves* Cooling system • Check valve clearance. • Adjust if necessary. • Check coolant leakage. • Repair if necessary. • Replace coolant every 24 months. • Check condition. • Adjust gap and clean. • Replace if necessary. • Clean. • Replace if - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 113
fittings and fasteners. • Correct if necessary. 1 month EVERY 1 year 3 6 6 months months months * It is recommended that these items be serviced by a Yamaha dealer. NOTE: • Recommended brake fluid: DOT 4 • Brake fluid replacement: 1. When disassembling the master cylinder or caliper, replace - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 114
EBU00614 Panel removal and installation The panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a panel has to be removed or reinstalled. 1. Panel C 3. Panel E 2. Panel D 4. Panel F 1. Panel A 2. Panel B 8-5 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 115
EBU00700 Panel A, D To remove 1. Remove the seat. 2. Pull outward on the areas shown, and then pull upward. 8-6 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 116
To install 1. Place the panel in its original position. 2. Install the seat. 8-7 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 117
EBU00616 Panel B To remove Remove the bolts. To install Place the panel in the original position and install the bolts. 1. Panel B 2. Bolt (× 2) 8-8 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 118
EBU00617 Panel C To remove 1. Remove the front carrier bolts and the front carrier. 2. Remove the quick fasteners and pull upward. 1. Bolt (× 2) 1. Bolt (× 4) 1. Quick fastener (× 2) 8-9 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 119
EBU00616 To install 1. Place the panel in the original position and install the quick fasteners. 2. Install the front carrier and the bolts, then tighten to the specified torque. Tightening torque: Carrier bolts: 19 Nm (1.9 m·kgf, 13 ft·lb) Panel E To remove Remove the bolts. To install Place the - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 120
EBU00638 Panel F To remove Pull outward on the areas shown. To install Place the panel in its original position. 1. Panel F 8-11 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 121
EBU00847 Engine oil Oil level inspection 1. Remove panel F. (See page 8-11 for panel removal and installation procedures.) 2. Place the ATV on a level place and warm up the engine for several minutes. 3. Stop the engine. 4. Remove the dipstick and wipe it off with a clean rag. Insert the dipstick - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 122
Engine oil and oil filter cartridge replacement 1. Remove panels E and F. (See pages 8-10 and 8-11 for panel removal and installation procedures.) 2. Warm up the engine for several minutes. 3. Stop the engine. Place an oil pan under the engine and remove the dipstick. 4. Remove the drain bolt and - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 123
1. Oil filter wrench 1. Torque wrench NOTE: An oil filter wrench is available at a nearby Yamaha dealer. _ _ 7. Apply a light coat of engine oil to the O-ring of the new oil filter. NOTE: Make sure the O-ring is seated properly. _ _ 6. Install the drain bolt and tighten it to the specified - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 124
9. Fill the engine with sufficient oil to reach the specified level. Install the dipstick and tighten it. Recommended oil: See page 10-2. Oil quantity: Total amount: 2.6 L (2.3 Imp qt, 2.7 US qt) Periodic oil change: 2.3 L (2.0 Imp qt, 2.4 US qt) With oil filter replacement: 2.4 L (2.1 Imp qt, 2.5 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 125
Final gear oil replacement 1. Remove the final gear case cover. 1. Final gear oil 2. Final gear case filler bolt 3. Proper level CAUTION: _ 1. Final gear case cover 2. Bolt (× 2) Be sure no foreign material enters the final gear case. _ 3. Install the oil filler bolt and tighten it to the - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 126
Recommended oil: See page 10-3. Oil quantity: Periodic oil change: 0.19 L (0.17 Imp qt, 0.2 US qt) Total amount: 0.22 L (0.19 Imp qt, 0.23 US qt) CAUTION: _ 1. Final gear case drain bolt 5. Install the drain bolt and tighten it to the specified torque. Tightening torque: Drain bolt (final gear - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 127
EBU00706 Differential gear oil Differential gear oil measurement 1. Place the machine on a level place. 2. Remove the oil filler bolt and check the oil level. It should be up to the brim of the hole. If the level is low, add sufficient oil to raise it to the specified level. 3. Install the oil - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 128
4. Install the drain bolt and tighten it to the specified torque. Tightening torque: Drain bolt: 10 Nm (1.0 m·kgf, 7 ft·lb) 5. Fill the differential gear case with oil. Recommended oil: SAE 80 API "GL-4" Hypoid gear oil Oil quantity: Periodic oil change: 0.35 L (0.31 Imp qt, 0.37 US qt) Total amount - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 129
EBU00771 Cooling system 1. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature. The coolant level should be between the maximum and minimum marks. 3. Remove the coolant reservoir cap, and then add coolant or distilled - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 130
EBU00887 CAUTION: Hard water or salt water is harmful to the engine. You may use soft water if you can't get distilled water. NOTE: G If water is added, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible. G The radiator fan operation is completely automatic. It is - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 131
1. Place the ATV on a level surface. 2. Remove panels E and F. (See page 8-10 and 8-11 for panel removal and installation procedures.) 3. Place a container under the engine, and then remove the coolant drain bolt. (Use a trough or a similar object as shown to prevent coolant from spilling on the - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 132
1. Radiator cap 1. Coolant reservoir drain hose 5. Remove the radiator cap. 6. Remove the coolant reservoir cap. 7. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. 8. After draining the coolant, thoroughly flush the cooling system with - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 133
10. Install the coolant reservoir hose. 11. Pour the recommended coolant into the radiator until it is full. Recommended antifreeze: High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines. Antifreeze and water mixing ratio: 1:1 Total amount: 1.1 L (0.97 Imp qt, - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 134
EBU00862 EBU00680 Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a Yamaha dealer. Spark plug inspection Removal 1. Remove the spark plug cap. 1. Spark plug cap 1. Axle boot (× 2 each side) 2. Use the spark plug wrench in the tool kit to - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 135
white insulator around the center electrode is a medium-to-light tan color for a ATV that is being ridden normally. Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and de8-26 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 136
NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. 4. Install the spark plug cap. a. Spark plug gap 2. Clean the - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 137
hose and clean the air filter element and air filter case. 1. Clip (× 4) 2. Air filter cover 3. Remove the air filter element, and separate it from the guide. 1. Air filter case check hose 1. Remove the seat. 2. Remove the air filter case cover. 8-28 1. Air filter element - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 138
Use parts cleaning solvent to clean the air filter element. 5. Squeeze the excess solvent out of the filter and let it dry. 1. Air filter guide 4. Wash the element gently but thoroughly in solvent. CAUTION: Do not twist the filter element when squeezing it. 6. Inspect the element. If damaged - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 139
filter oil is not available, motor oil may be used. NOTE: The element should be wet but not dripping. 8. Reinstall the element to the element guide. 9. Reinstall the element assembly and parts removed for access. NOTE: The air filter element should be cleaned every 20 ~ 40 hours. It should be - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 140
EBU00641 V-belt cooling duct check hose If dust or water collects in this hose, remove the hose and clean it. 1. V-belt cooling intake box check hose (Above V-belt cooling duct) 1. V-belt cooling duct check hose (Left front side of ATV) 8-31 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 141
EBU00522 Spark arrester cleaning Select a well-ventilated area free of combustible materials and make sure the exhaust and muffler are cool. 1. Remove the bolt. 2. Remove the tailpipe by pulling it out of the muffler. 1. Spark arrester 1. Bolt 2. Tailpipe 3. Purging bolt 3. Tap the tailpipe - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 142
EBU00296 WARNING POTENTIAL HAZARD Improperly purging the exhaust system Hot exhaust system WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When purging the exhaust system: Always - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 143
fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician. - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 144
EBU00307 Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 3 ~ 5 mm (0.12 ~ 0.20 in). 3. Tighten the locknut. a. Free play: 3 ~ 5 mm (0.12 ~ 0.20 in) - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 145
EBU00312 Front brake pad inspection Inspect the brake pads for damage and wear. If the thickness is less than the specified value, have a Yamaha dealer replace the pads. a. Wear limit: 1 mm (0.04 in) NOTE: The wheels need to be removed to inspect the brake pads. See page 8-44 for removal - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 146
EBU00621 Rear brake pad inspection Inspect the brake pad for damage or wear. Wear indicator grooves are provided on the brake pad. These indicators allow checking of brake pad wear without disassembling the brake. Inspect the grooves. If they have almost disappeared, ask a Yamaha dealer to replace - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 147
FRONT Observe these precautions: 1. When checking the fluid level, make sure the top of the master cylinder reservoir is level by turning the handlebars. 2. Use only the designated quality brake fluid. Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 148
. If not, ask a Yamaha dealer to adjust it. Brake fluid replacement 1. Complete fluid replacement should be done only by trained Yamaha service personnel. 2. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. G Replace all rubber - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 149
adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: G Make sure the brakes operate smoothly and that the free play is correct. G Make sure the brakes do not drag. G Make sure the brakes are - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 150
EBU00686 Rear brake lever adjustment The rear brake lever free play should be 0.5 ~ 2 mm (0.02 ~ 0.08 in). 1. Loosen the locknut. Rear brake pedal height adjustment NOTE: Adjust the rear brake before inspecting the rear brake pads. The top of the brake pedal should be positioned 54 mm (2.13 in ) - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 151
adjusted brake. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: G Make sure the brakes operate smoothly and that the free play is correct. G Make sure the brakes do not drag. G All air must be bled - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 152
EBU00356 EBU00717 Cable inspection and lubrication WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 153
EBU00373 Wheel removal 1. Elevate the wheel by placing a suitable stand under the frame. 2. Remove the nuts from the wheel. 3. Remove the wheel assembly. 1. Tapered nut (× 4) 8-44 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 154
EBU00828 Wheel installation When installing a wheel, reverse the removal procedure. NOTE: The arrow mark on the tire must point toward the rotating direction of the wheel. _ _ 1. Tapered wheel nuts are used for both front and rear wheels. Install the nut with its tapered side towards the wheel. - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 155
EBU00380 Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a Yamaha dealer. CAUTION: Do not try to remove the sealing caps of the battery cells. - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 156
EBU00385 EBU00876* Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. CAUTION: A special battery charger (constant voltage/ampere or constant voltage) is required - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 157
1. Main fuse 2. Spare fuse 1. 2. 3. 4. 5. 6. Headlight fuse Ignition fuse Auxiliary DC jack fuse Four-wheel drive fuse Signaling system fuse Spare fuse (× 3) 1. Fuse box Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Four-wheel drive fuse: Signaling system - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 158
EBU00632 WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse. Replacing the - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 159
WARNING POTENTIAL HAZARD The headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it. 4. Put a new - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 160
EBU00409 EBU00964 Headlight beam adjustment CAUTION: It is advisable to have a Yamaha dealer make this adjustment. 1. Vertical adjustment: To raise the beam, turn the adjusting screw clockwise. To lower the beam, turn the screw counterclockwise. Tail/brake light bulb replacement 1. Remove the - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 161
1. Tail/brake light unit 2. Bulb holder 1. Bulb holder 2. Bulb 3. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 4. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. 5. Install the bulb holder (together - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 162
trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting , but they are often inferior. Consequently, they have a shorter service life and can lead to expensive repair bills. WARNING POTENTIAL HAZARD - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 163
EBU00806 Troubleshooting charts Starting problems or poor engine performance Turn the fuel cock lever to "ON". There is fuel. 1. Fuel Check if there is fuel in the fuel tank. Some - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 164
Engine overheating WARNING Engine overheating POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 165
EBU00419 CLEANING AND STORAGE A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 166
6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 167
EBU00530 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 168
7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the machine. 9-4 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 169
9-5 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 170
EBU00428 SPECIFICATIONS Model Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 171
3 4 YAMALUBE 4 (20W40) or SAE 20W40 5 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 6 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C -20˚ -10˚ 7 8 9 10 11 12 13 14 API Service SE, SF, SG type or higher CAUTION: Be sure to use motor oils that do not contain antifriction modifiers. Passenger car motor oils (often labeled - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 172
Model Final gear case oil: Type Quantity: Periodic oil change Total amount Differential gear case oil: Type Quantity: Periodic oil change Total amount Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount Carburetor: Type/quantity Manufacturer YFM400FAP SAE80 API "GL-4" Hypoid gear oil 0.19 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 173
Model Spark plug: Type/manufacturer Spark plug gap Clutch type Transmission: Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Reverse gear Sub transmission ratio Chassis: Frame type Caster angle Trail Tire: Type Size YFM400FAP DR8EA / NGK 0.6 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 174
Model Brake: Front brake Rear brake Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Headlight type: type operation type - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 175
Model Bulb voltage, wattage × quantity: Headlight Tail/brake light Neutral indicator light Reverse indicator light Coolant temperature warning light Park indicator light Four wheel drive indicator light 12 V, 30 W/30 W × 2 12 V, 5/21 W × 1 12 V, 1.7 W × 1 12 V, 1.7 W × 1 12 V, 1.7 W × 1 12 V, 1.7 W - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 176
EBU00430 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 177
1 2 3 4 MAINTENANCE INTERVAL 1 Month 3 Months 6 Months 12 Months 18 Months 24 Months 30 Months 36 Months 42 Months 48 Months 54 Months 60 Months DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 5 6 7 8 9 10 11 12 13 14 12-1 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 178
EBU00432 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 13-1 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 179
1 2 3 4 5 6 7 8 9 10 11 12 13 14 13-2 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 180
EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 181
1 2 3 4 5 6 7 8 9 10 11 12 13 EBU00436 14 WARNING _ Indicates a potential hazard that could result in serious injury or death. 14-2 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 182
EBU00437 - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 183
with a passenger-passengers affect balance and steering and increase risk of losing control. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 . 5 - 6.5 × 2 CR - 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 184
- 2002 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 185
5GH-28199-12
LIT-11626-15-19
READ THIS MANUAL CAREFULLY!
It contains important safety information.
This ATV should not be ridden by anyone under 16 years of age.
WARNING
YFM400FAP
OWNER’S MANUAL