2003 Yamaha Motorsports Kodiak 400 Automatic Owners Manual
2003 Yamaha Motorsports Kodiak 400 Automatic Manual
2003 Yamaha Motorsports Kodiak 400 Automatic manual content summary:
- 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 1
READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER'S MANUAL YFM400AR WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-16-35 5VH-F8199-10 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 2
EBU00776 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 5
of manufacture. Please check your local riding laws and regulations before operating this machine. EBU01067 AFFIX DEALER LABEL HERE YFM400AR OWNER'S MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st edition, May 2002 All rights reserved. Any reprinting or unauthorized use without the written - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 7
Rear shock absorber adjustment...4-18 Auxiliary DC jack...4-19 5 PRE-OPERATION CHECKS ...5-1 Front and rear brakes ...5-2 Fuel ...5-4 Engine oil ...5-6 Final gear oil...5-7 Coolant...5-7 Throttle lever ...5-8 Fittings and fasteners...5-8 Lights...5-8 Switches...5-9 Tires ...5-9 How to measure tire - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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...8-52 Tail/brake light bulb replacement ...8-52 Troubleshooting ...8-53 Troubleshooting charts ...8-54 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 10
EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1-1 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 11
performance and can lead to an accident. Never exceed the maximum front cargo limit of : 40kg (88 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's Manual. 5ND-F4877-00 1-2 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 12
performance and can lead to an accident. Never exceed the maximum rear cargo limit of : 80kg (176 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's Manual. 5ND-F4897-00 1-3 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 13
7 8 1-4 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 20
jack 26. Throttle lever 27. Front brake lever NOTE: The machine you have purchased may differ slightly from those shown in the figures of this manual. 3-1 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 23
EBU00039 1- CONTROL FUNCTIONS 1 2 3 4 WARNING Indicates a potential hazard that could result in serious injury or death. EBU01249 5 6 1. Main switch Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights, - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 24
EBU00802 EBU01223 Indicator and warning lights 1. Coolant temperature warning light " 2. Reverse indicator light "R" 3. Neutral indicator light "N" " Coolant temperature warning light " " When the coolant temperature reaches a specified level, this light comes on to warn that the coolant - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 25
EBU01250 EBU00447 Reverse indicator light "R" This indicator light comes on when the drive select lever is in the "R" position. EBU00972 Neutral indicator light "N" This indicator light comes on when the drive select lever is in the "N" position. Speedometer The speedometer shows riding speed. - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 26
EBU00052 EBU00053 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. Handlebar switches 1. Light switch " / /OFF" 2. Engine stop switch " / " 3. Start switch " " 1. Fuel gauge 2. Red line - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 27
, remove the battery and recharge it. _ 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.) EBU01205 Engine stop switch " / " Make sure that the engine stop switch is set - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 28
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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 29
EBU01159 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. WARNING POTENTIAL HAZARD Improper adjustment - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 30
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. 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 is - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 31
EBU00074 Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. WARNING POTENTIAL HAZARD - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 32
EBU01106 EBU01107 Drive select lever The drive select lever is used to shift your machine into the forward, neutral and reverse 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 pull - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 33
EBU00092 WARNING POTENTIAL HAZARD Starting the engine without shifting into the neutral position. WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident. HOW TO AVOID THE HAZARD Shift the drive select lever into the neutral position and apply the parking brake - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 34
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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 35
EBU00095 RES Position 1. Arrow mark pointing to "RES" 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 36
EBU00567 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 projections on the front of the seat into the seat holders and push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted. _ _ 1. Seat 2. - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 37
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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 38
EBU01104 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 adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 39
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. 4-17 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 40
EBU01103 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 adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 41
EBU01002 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 should only be used when the engine is running. 1. Set the light switch to "OFF". _ Maximum rated capacity - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 42
1. Auxiliary DC jack EBU00112 WARNING 4-20 Indicates a potential hazard that could result in serious injury or death. - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 43
1- PRE-OPERATION CHECKS 1 2 Before using this machine, check the following points: ITEM Front brake Rear brake Fuel Engine oil Coolant reservoir Final gear oil Throttle Wheels and tires Fittings and fasteners Lights and switches ROUTINE • Check operation, free play, fluid level and fluid leakage. - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 44
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 front brake lever. If the free play is incorrect - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 45
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 a Yamaha dealer check for the cause. 5-3 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 46
EBU01085 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, 4.0 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 47
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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 48
oils labeled "ENERGY CONSERVING II" or higher. Make sure that no foreign material enters the crankcase. _ 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 49
EBU00493 EBU01253 Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-16- 8-18 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 50
and fasteners 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. EBU01003 Lights Check the headlights and tail/brake light to make sure they are in working condition. Repair as - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 51
EBU01170 EBU00157 Switches Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation. Tires WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 52
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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 53
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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 54
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) 5-12 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 55
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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 56
NOTE: When the drive select lever is in the neutral position, if the indicator light does not come on, ask a Yamaha dealer to inspect its electric circuit. _ _ Position 3: Cold engine startambient temperature above 25 °C (80 °F) and warm engine start position. 5. Use the starter (choke) in - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 57
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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 58
throttle lever to the closed position. 2. Shift the gear from neutral to forward and vice versa 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 59
closed position. 2. Apply the parking brake. 3. Shift the gear from neutral to reverse and vice versa by moving the drive select lever along the shift guide. NOTE: When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the ATV - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 60
EBU00210 WARNING POTENTIAL HAZARD Improper operation 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 there are no obstacles or people behind you. When it is safe to proceed, go - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 61
Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r/min so the engine can rid itself of the temporary build up of heat. If any abnormality is noticed during this period, consult a Yamaha dealer. 1. 0-10 hours: Avoid - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 62
EBU00211 EBU00215 Parking When parking, stop the engine and shift into neutral. Turn the fuel cock to "OFF" and apply the parking brake. 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 63
1. Bring the machine to a stop by applying the brakes. 2. Stop the engine. 3. With the rear brake applied, apply the parking brake. 6-9 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 64
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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 65
EBU01246 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 66
G G G G Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Allow more braking distance. A heavier vehicle takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully. Added - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 67
6-13 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 68
EBU01255 WARNING _ Indicates a potential hazard that could result in serious injury or death. 6-14 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 69
Riding Your ATV 7 7-1 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 70
7-2 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 71
use. This section, Riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this section, 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 5-9-5-10. Always maintain proper tire pressure as described in the Owner's Manual on page 5-11. WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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, - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 97
brake. 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 98
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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 99
7-31 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 101
7-33 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 case drain plug 7-36 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 112
EBU00261 PERIODIC MAINTENANCE/LUBRICATION ITEM Valves* Cooling system ROUTINE 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 necessary. Check and - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 113
fasteners* • Correct if necessary. • Check operation. Lights and switches* • Adjust headlight beam. * It is recommended that these items be serviced by a Yamaha dealer. NOTE: G Recommended brake fluid: DOT 4 G Brake fluid replacement: • When disassembling the master cylinder or caliper, replace - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 116
To install 1. Place the panel in its original position. 2. Install the seat. 8-7 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 117
EBU01147 Panel B To remove Remove the bolt, and then take the panel off. To install Place the panel in the original position and install the bolt. CAUTION: _ When installing the panel, be sure not to pinch the cables or wires. _ 1. Panel B 2. Bolt 8-8 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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) (under fenders) 1. Bolt (× 4) 1. Quick fastener (× 2) 8-9 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 119
EBU01013 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·lbf) Panel E To remove Remove the bolts, and then take the - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 121
EBU01099 Engine oil Engine oil level measurement 1. Remove panel F. (See page 8-11 for panel removal and installation procedures.) 2. Place the ATV on a level surface and warm up the engine for several minutes. 3. Stop the engine. 4. Remove the engine oil filler cap and wipe off the dipstick with a - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 to collect the used oil, and then remove the engine oil - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 Oring of the new oil filter cartridge. NOTE: Make sure the O-ring is seated properly. _ _ 6. Install the drain bolt and tighten it to the - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 124
9. Fill the engine with sufficient oil to reach the specified level. Install the engine oil filler cap and tighten it. Recommended engine oil: See page 5-6. Oil quantity: Total amount: 2.6 L (2.3 Imp qt, 2.8 US qt) Periodic oil change: 2.3 L (2.0 Imp qt, 2.4 US qt) With oil filter cartridge - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 125
EBU01145 Final gear oil Final gear oil measurement 1. Place the machine on a level surface. 2. Remove the oil filler bolt, and then check the oil level in the final gear case. NOTE: The oil level should be at the brim of the filler hole. _ _ 3. If the oil is below the brim of the filler hole, add - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 126
Final gear oil replacement 1. Remove the final gear case cover by removing the bolts. 1. Final gear case drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. 1. Final gear case cover 2. Bolt (× 2) 2. Place the machine on a level surface. 3. Place a container under - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 127
Recommended oil: See page 5-7. Oil quantity: 0.19 L (0.17 Imp qt, 0.20 US qt) CAUTION: _ Be sure no foreign material enters the final gear case. _ 7. Install the oil filler bolt. 8. Check for oil leakage. If oil leakage is found, check for the cause. 9. Install the final gear case cover bolts, - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 128
EBU01256 Cooling system 1. Place the ATV on a level surface. 2. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature. NOTE: The coolant should be between the minimum and maximum level marks. _ _ 3. If the coolant is at or - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 129
EBU01257 CAUTION: _ Changing the coolant Hard water or salt water is harmful to the engine. You may use soft water if you cannot get distilled water. _ WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 130
1. Place the ATV on a level surface. 2. Remove panels E and F. (See pages 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 131
1. Radiator cap 1. Coolant reservoir drain hose 5. Remove the radiator cap. 6. Remove the panel D. (See page 8-6 for panel removal and installation procedures.) 7. Remove the coolant reservoir cap. 8. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 132
11. Install the coolant reservoir hose. 12. Pour the recommended coolant into the reservoir to the maximum level mark, and then install the reservoir cap and the panel. 13. Pour the recommended coolant into the radiator until it is full, and then install the radiator cap. Recommended antifreeze: - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 133
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. 8-24 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 134
Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 135
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. 5. Install the panel. 8-26 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 136
EBU01133 Air filter element cleaning NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. _ _ 1. Holder (× 4) 2. Air filter case cover 3. Remove the air filter element, and - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 137
WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element. 5. Squeeze the excess solvent out - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 138
7. Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter element. If foam air filter oil is not available, engine oil may be used. NOTE: The air filter element should be wet but not dripping. _ _ 8. Pull the air filter element over its frame. 9. Install the air - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 139
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 duct check hose (left front side of ATV) 8-30 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 140
EBU01066 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe by pulling it out of the muffler. 1. Spark arrester 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install and - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 141
EBU00296 WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. 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 cleaning the spark arrester: - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 142
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. - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 143
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. Throttle lever free play 1. Locknut 2. - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 144
EBU00312 EBU00313 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. Rear brake shoe inspection A wear indicator is provided on the rear brake. This indicator allows checking of brake - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 145
EBU01185 Brake fluid level check Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 146
have a Yamaha dealer check the brake system. EBU01186 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. G Replace the oil - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 147
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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 148
EBU01239 Rear brake pedal and lever adjustment Brake pedal free play adjustment 1. Fully loosen the adjusting nut on the brake lever cable at the rear wheel. 2. Turn the adjusting nut on the brake pedal cable until the free play is 20-30 mm (0.8-1.18 in). a. Brake pedal free play 1. Adjusting nut - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 149
Brake lever free play adjustment 1. Loosen the locknut and fully turn in the adjusting bolt at the brake lever. 2. Turn in the adjusting nut on brake cable to provide a gap of 0-1 mm (0-0.04 in) between the brake camshaft lever and the pin. 1. Locknut 2. Adjusting bolt 1. Adjusting nut (brake - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 150
or 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. Replacement of brake components requires - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 151
EBU01259 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and rear brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1. Remove panel B. ( - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 152
EBU00356 EBU01260 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 153
EBU01112 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. 1. Nut (× 4) 8-44 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 154
EBU01121 Wheel installation 1. Install the wheel and the nuts. NOTE: G Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel. G The arrow mark on the tire must point toward the rotating direction of the wheel. _ _ 2. Lower the ATV so that - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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. - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 156
EBU00385 EBU00829 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 157
1. Main fuse 2. Spare main fuse 1. 2. 3. 4. 5. Headlight fuse Ignition fuse Auxiliary DC jack fuse Signaling system fuse Spare fuse (× 2) Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Signaling system fuse: 30 A 15 A 10 A 10 A 10 A 8-48 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 158
EBU01261 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 a - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 159
WARNING POTENTIAL HAZARD A 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. Insert a new - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 160
5. Install the bulb holder by turning it clockwise. 6. Install the bulb holder cover at the rear of the headlight. 1. Do not touch the glass part of the bulb. CAUTION: _ Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 161
EBU01089 EBU01105 Headlight beam adjustment CAUTION: _ Tail/brake light bulb replacement If the tail/brake light bulb burns out, have a Yamaha dealer replace it. It is advisable to have a Yamaha dealer make this adjustment. _ To raise the beam, turn the adjusting screw in direction a. To lower - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 165
EBU00419 1- CLEANING AND STORAGE CAUTION: Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 169
EBU00428 1- SPECIFICATIONS 1 2 YFM400A 3 1,984 mm (78.1 in) 1,085 mm (42.7 in) 1,120 mm (44.1 in) 827 mm (32.6 in) 1,233 mm (48.5 in) 245 mm (9.65 in) 3,000 mm (118.1 in) 250 kg (551 lb) Liquid-cooled 4-stroke, SOHC Forward-inclined single cylinder 401 cm3 84.5 × 71.5 mm (3.33 × 2.81 in) 10.5 :1 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 170
YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 -20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C Recommended engine oil classification: API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 171
Model Final gear case oil: Type Quantity: Periodic oil change Total amount Radiator capacity (including all routes): Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount Carburetor: Type/quantity Manufacturer YFM400A SAE 80 API GL-4 Hypoid gear oil 0.19 L (0.17 Imp qt, 0.2 US qt) 0.2 L (0. - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 172
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 Chassis: Frame type Caster angle Trail Tire: Type Size YFM400A DR8EA / NGK 0.6-0.7 mm (0.02-0.03 in) - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 173
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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 174
Model Bulb voltage, wattage × quantity: Headlight Tail/brake light Neutral indicator light Reverse indicator light Coolant temperature warning light Meter lighting Fuse: Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Signaling system fuse 12 V, 30/30 W × 2 12 V, 5/21 W × 1 12 V, 1.7 W - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 175
10-7 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 SERVICING DEALER NAME AND ADDRESS REMARKS 5 6 7 8 9 10 11 12 13 14 12-1 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 178
EBU00432 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 13-1 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 179
1 2 3 4 5 6 7 8 9 10 11 12 13 14 13-2 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 180
EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1 - 2003 Yamaha Motorsports Kodiak 400 Automatic | 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 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 182
EBU00437 - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 183
control. 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) NEVER operate: YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN USA - 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 184
- 2003 Yamaha Motorsports Kodiak 400 Automatic | Owners Manual - Page 185
5VH-F8199-10
LIT-11626-16-35
READ THIS MANUAL CAREFULLY!
It contains important safety information.
This ATV should not be ridden by anyone under 16 years of age.
WARNING
YFM400AR
OWNER’S MANUAL