2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 Owners Manual
2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 Manual
2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 manual content summary:
- 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 1
READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER'S MANUAL YFM400FAT WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-18-36 1P1-F8199-10 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 2
EBU00776 - 2005 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 - 2005 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 5
time of manufacture. Please check your local riding laws and regulations before operating this ATV. EBU01067 AFFIX DEALER LABEL HERE YFM400FAT OWNER'S MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st edition, May 2004 All rights reserved. Any reprinting or unauthorized use without the written - 2005 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 7
5 PRE-OPERATION CHECKS ...5-1 Front and rear brakes ...5-2 Fuel ...5-4 Engine oil ...5-6 Final gear oil...5-6 Differential gear oil ...5-7 Coolant...5-8 Throttle lever ...5-9 Fittings and fasteners...5-9 Lights...5-9 Switches...5-9 Tires ...5-10 How to measure tire pressure...5-12 Tire wear limit - 2005 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 ...8-6 Engine oil and oil filter cartridge ...8-12 Final gear oil ...8-18 Differential gear oil replacement ...8- - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 9
light bulb replacement ...8-59 Troubleshooting ...8-61 Troubleshooting charts ...8-62 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 10
EBU00464 1- LOCATION OF THE WARNING AND SPECIFICATION LABELS 1-1 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 13
7 8 1-4 - 2005 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 - 2005 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 - 2005 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 - 2005 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 - 2005 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 immediately after the engine has been running and is still very hot. Do not spill gasoline on the - 2005 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 - 2005 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 - 2005 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 - 2005 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | 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. EBU12490 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, - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 24
EBU08020 EBU12232 Indicator and warning lights 1. 2. 3. 4. 5. Neutral indicator light "N" Reverse indicator light "R" Coolant temperature warning light " Park indicator light "P" Four-wheel drive indicator light " " " EBU06090 Park indicator light "P" This indicator light comes on when the - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 25
CAUTION: _ G G The engine may overheat if the ATV is overloaded. If this happens, reduce the load to specification. Restart after making sure that the light is out. Continuous use while the light is on may cause damage to the engine. _ 4-3 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 26
EBU15390 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 or park position. Coolant temperature warning - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 27
EBU12500 EBU09720 Reverse indicator light "R" This indicator light comes on when the drive select lever is in the "R" position. EBU00605 Neutral indicator light "N" This indicator light comes on when the drive select lever is in the "N" position. Four-wheel-drive indicator light " " This - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 28
EBU00447 EBU00052 Speedometer The speedometer shows riding speed. This speedometer is equipped with a trip odometer. The trip odometer can be reset to "0" with the reset knob. Use the trip odometer to estimate how far you can ride on a tank of fuel before going to reserve. This information will - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 29
EBU00053 Handlebar switches _ CAUTION: Do not use the headlights 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. _ EBU12050 1. Light switch - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 30
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.) 1. Four-wheel drive switch "2WD/4WD" EBU00601 On-Command four-wheel drive switch "2WD/4WD" To - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 31
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 32
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 33
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 34
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 EBU00732 Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 35
EBU15200 EBU08550 Drive select lever The drive select lever is used to shift your machine into the forward, 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 36
EBU00092 WARNING POTENTIAL HAZARD Starting the engine without setting the drive select lever to the park position "P". WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident. HOW TO AVOID THE HAZARD Set the drive select lever to the park position before starting the - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 37
EBU00930 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 38
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 39
EBU05670 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. - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 40
EBU00582 EBU15230 Front carrier Maximum load limit: 40 kg (88 lb) Storage compartment Maximum load limit: 2.0 kg (4 lb) The storage compartment is located under the seat. (See page 4-17 for seat removal and installation procedures.) When storing any documents in the storage compartment, be sure - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 41
EBU15220 Front and 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 42
1. Spring preload adjusting ring 2. Position indicator 1. Special wrench NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. _ _ Standard position: 2 1- Minimum (soft) 5- Maximum (hard) 4-20 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 43
EBU10020 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. - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 44
Maximum rated capacity for the auxiliary DC jack: DC 12 V, 120 W (10 A) 4. When the auxiliary DC jack is not being used, cover it with the cap. CAUTION: _ G G G Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow. If - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 45
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 and differential gear oil Throttle Wheels and tires Fittings and fasteners Lights and switches Axle boots ROUTINE • Check operation, free - 2005 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 G Check that there is no free play in the front brake lever. If there is free - 2005 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 a Yamaha dealer check for the cause. 5-3 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 48
EBU01085 Fuel Make sure there is sufficient gasoline in the tank. Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: Total: 15.0 L (3.30 Imp gal, 3.96 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 - 2005 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 50
EBU10842 EBU00493 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-12- 8-17.) Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-18- 8-20 for details.) Recommended oil: SAE 80 API GL-4 Hypoid - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 51
EBU00678 Differential gear oil Make sure the differential gear oil is at the specified level. Add oil as necessary. (See pages 8-21-8-22 for details.) Recommended oil: SAE 80 API GL-4 Hypoid gear oil 5-7 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 52
EBU12530 Coolant Check the coolant level in the coolant reservoir when the engine is cold. (The coolant level will vary with engine temperature.) The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir. If the coolant level is at or below the - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 53
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. EBU10030 Lights Check the headlights and tail/brake light to make sure they are in working condition. Repair as - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 54
EBU00157 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 operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 55
4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst. 5-11 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 56
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 57
EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. Tire wear limit 5-13 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 58
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 59
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 the respective electric circuit. G The engine can be started in any gear if the rear brake lever or brake pedal is applied. However, it is recommended to - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 60
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 61
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 62
the 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 63
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 64
EBU02101 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 65
EBU06120 10-20 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely but do not use full throttle at any time. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally. Parking When parking, stop the engine and shift the drive select lever into the - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 66
EBU06151 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 67
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 68
EBU15240 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 69
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 70
EBU15250 WARNING _ Indicates a potential hazard that could result in serious injury or death. 6-13 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 71
Riding Your ATV 7 7-1 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 72
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 73
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 74
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 75
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 76
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 77
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 78
. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner's Manual for this vehicle on pages 5-10-5-11. Always maintain proper tire pressure as described in the Owner's Manual on page 5-12. WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 79
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 80
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 81
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 82
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 83
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 84
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 85
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 86
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 87
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 88
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, - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 89
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 90
is designed for off-road use only, and handling maneuvers are more difficult to perform on pavement. Shift to the parking position "P" 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 91
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 92
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 93
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 94
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 95
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 96
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 97
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 98
position "P". 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 99
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, change to 4WD - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 100
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 101
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 102
7-33 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 103
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 104
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, the V-belt - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 105
1. V-belt cooling duct check hose (left front side of ATV) 1. Storage compartment check hose 1. Drive select lever box check hose 1. V-belt case drain plug 7-36 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 106
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 107
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 108
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 109
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 110
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 111
dealer perform service if you are not familiar with machine service. EBU14510 WARNING POTENTIAL HAZARD Servicing an engine while performing maintenance unless otherwise specified. 8-1 Owner's manual and tool kit You are recommended to put this owner's manual in the vinyl bag and always carry it - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 112
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 113
EBU02611 PERIODIC MAINTENANCE/LUBRICATION NOTE: _ G For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. G For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. How- ever, keep in mind that if the ATV - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 114
ITEM ROUTINE Whichever month comes first km (mi) hours 1 320 (200) 20 INITIAL 3 1,200 (750) 75 6 2,400 (1,500) 150 EVERY 6 12 2,400 4,800 (1,500) (3,000) 150 300 Engine oil Engine oil filter cartridge Engine oil strainer* Final gear oil Differential gear oil Front brake* Rear brake* Select - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 115
. Check operation. Adjust headlight beams. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: G Recommended brake fluid: DOT 4 G Brake fluid replacement: • When disassembling the master cylinder or caliper, replace the brake fluid - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 116
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 8-6 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 117
EBU00700 Panel A, D To remove 1. Remove the seat. 2. Pull outward on the areas shown, and then pull upward. 8-7 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 118
To install 1. Place the panel in its original position. 2. Install the seat. 8-8 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 119
EBU01147 EBU15370 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. Panel C To remove 1. Remove the top carrier bolts. CAUTION: _ When installing the panel, be sure not to pinch the cables or wires. _ 1. - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 120
To install 1. Place the panel in the original position, and then install the quick fastener screws. 2. Place the carrier in the original position, and then install the carrier bolts under the fenders. 3. Install the top carrier bolts, and then tighten all bolts to the specified torques. 1. Bolt (× - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 121
EBU01013 EBU00638 Panel E To remove Remove the bolts, and then take the panel off. To install Place the panel in the original position, and then install the bolts. Panel F To remove Pull outward on the areas shown. 1. Panel F 1. Panel E 2. Bolt (× 3) 8-11 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 122
EBU10992 To install Place the panel in its original position. Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 123
5. Remove the engine oil filler cap and wipe off the dipstick with a clean rag. 6. Insert the dipstick in the oil filler hole (without screwing it in), and then remove it again to check the oil level. NOTE: The engine oil should be between the minimum and maximum level marks. _ _ 1. Engine oil - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 124
8. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap. 9. Install the panel. To change the engine oil (with or without oil filter cartridge replacement) 1. Remove panel F. (See pages 8-11-8-12 for panel removal and installation procedures.) 2. Start the engine, warm - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 125
NOTE: Skip steps 5-9 if the oil filter cartridge is not being replaced. _ _ 5. Remove panels D and E. (See pages 8-7-8-8, 8-11 for panel removal and installation procedures.) 6. Remove the oil filter cartridge with an oil filter wrench. 1. Oil filter wrench NOTE: An oil filter wrench is available - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 126
8. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. 1. O-ring 1. Torque wrench Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) 9. Install panels E and D. 8-16 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 127
10. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 23 Nm (2.3 m·kgf, 16 ft·lbf) 11. Add the specified amount of recommended engine oil, and then install the engine oil filler cap and tighten it. Recommended engine oil: See - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 128
EBU15380 Final gear oil Checking the final gear oil level 1. Place the ATV 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. _ _ CAUTION: _ Be sure no foreign material enters the - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 129
Changing the final gear oil 1. Remove the engine guard and the final gear case guard by removing the bolts. 1. Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. 1. Engine guard 3. Bolt (× 11) 2. Final gear case guard 2. Place the ATV on a level - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 130
6. Add the recommended final gear oil to the brim of the filler hole. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.23 L (0.20 Imp qt, 0.24 US qt) 9. Install the engine guard and the final gear case guard by installing the bolts, and then tightening them to the specified torques. - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 131
EBU12411 Differential gear oil replacement 1. Place the ATV on a level surface. 2. Place a container under the differential gear case to collect the used oil. 3. Remove the oil filler bolt and oil drain bolt to drain the oil. 1. Differential gear oil drain bolt 4. Install the oil drain bolt, and - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 132
5. Fill the differential gear case with the specified amount of the recommended oil. NOTE: G Do not exceed the specified differential gear oil quantity when filling. Overfilling will cause the oil to seep out of the breather hose during and after riding. G The differential gear oil level cannot be - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 133
EBU12560 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 134
EBU12572 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 135
1. Place the ATV on a level surface. 2. Remove panels E and F. (See pages 8-11-8-12 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 136
1. Radiator cap 1. Coolant reservoir hose 5. Remove the radiator cap. 6. Remove panel D. (See pages 8-7-8-8 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 137
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 panel D. 13. Pour the recommended coolant into the radiator until it is full, and then install the radiator cap. Recommended antifreeze: High - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 138
EBU00862 Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a Yamaha dealer. 1. Rear axle boot (× 2 each side) 1. Front axle boot (× 2 each side) 8-28 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 139
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. 8-29 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 140
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 141
EBU15140 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. _ _ Air filter element cleaning NOTE: There is a check - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 142
4. Pull off the lock plate, and then remove the air filter element from its frame. 1. Fastener (× 4) 2. Air filter case cover 3. Remove the air filter element assembly. 1. Air filter element frame 3. Lock plate 2. Air filter element 5. Wash the element gently but thoroughly in solvent. 1. Air - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 143
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. 6. Squeeze the excess solvent out - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 144
EBU06411 NOTE: The air filter element should be cleaned every 20-40 hours. It should be cleaned and lubricated more often if the machine is operated in extremely dusty areas. Each time the air filter element maintenance is performed, check the air inlet to the filter case for obstructions. Check - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 145
EBU08741 EBU01066 V-belt case drain plug After riding in water deep enough to allow it to enter the V-belt case, remove this plug to drain the water from the case. NOTE: If water drains from the V-belt case after removing the plug, have a Yamaha dealer inspect the ATV as the water may affect other - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 146
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: Always let - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 147
EBU00296 EBU12580 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idling speed may be performed by the owner as a - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 148
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. 1. Locknut a. Throttle lever free play 8-38 2. Adjusting bolt - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 149
EBU03050 EBU13090 Select lever safety system cable adjustment The select lever safety system cable stretches with use, resulting in improper function. To prevent this, the cable must be adjusted regularly. This adjustment, however, should be left to a Yamaha dealer. Front brake pad check Check - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 150
EBU06212 Rear brake pad check Check the brake pads for damage or wear. Wear indicator grooves are provided on the brake pads. These indicators allow checking of brake pad wear without disassembling the brake. Check the wear indicator grooves. If a brake pad has worn to the point that the wear - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 151
EBU06221 Inspecting the brake fluid level 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 when necessary. A low brake fluid level may indicate worn - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 152
Observe these precautions: G When checking the fluid level, make sure the top of the master cylinder reservoirs are level. G Use only the designated quality brake fluid. Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. Recommended brake fluid: DOT 4 G G G - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 153
EBU11860 EBU11870 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 seals every two years. G - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 154
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 155
If correct free play cannot be obtained, ask a Yamaha dealer to make that adjustment. NOTE: When adjusting the rear brake lever free play: G Be sure not to step on the brake pedal. G Make sure the brake pedal does not move. _ _ Adjusting the brake pedal The top of the brake pedal should be - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 156
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 All air must be bled - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 157
EBU12590 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. ( - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 158
EBU00356 EBU12600 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 159
EBU13110 Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun. 1. Upper knuckle 2. Lower knuckle Recommended lubricant: Lithium-soap-based grease 8-49 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 160
EBU01112 EBU11211 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. Wheel installation 1. Install the wheel and the nuts. NOTE: G The arrow mark on the tire must point toward the rotating - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 161
EBU00380 2. Lower the ATV so that the wheel is on the ground. 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. 1. Tapered nut - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 162
CAUTION: Do not try to remove the sealing caps of the battery cells. You may damage the battery. WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully. WHAT CAN HAPPEN You could be poisoned. You could be severely burned by the sulfuric acid in battery electrolyte. - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 163
EBU00385 EBU08762* 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 164
1. Main fuse 2. Fuse box 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. Main fuse 2. Spare main fuse Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Four-wheel drive fuse: - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 165
EBU14560 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 166
2. Remove the headlight bulb holder by turning it counterclockwise. 1. Headlight bulb holder tab (× 2) 1. Headlight bulb holder 3. Remove the defective bulb by unhooking the headlight bulb holder tabs. 8-56 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 167
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 168
EBU01089 5. Install the headlight bulb holder by turning it clockwise. 6. Install the headlight bulb holder cover at the rear of the headlight. Headlight beam adjustment CAUTION: _ It is advisable to have a Yamaha dealer make this adjustment. _ To raise the beam, turn the adjusting screw in - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 169
EBU09640 Tail/brake light bulb replacement 1. Remove the nuts together with the washers. 1. Tail/brake light unit 2. Tail/brake light bulb holder 1. Tail/brake light unit 2. Nut (× 2) 3. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 2. - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 170
1. Tail/brake light bulb holder 2. Bulb 4. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. 5. Install the bulb holder (together with the bulb) by turning it clockwise. 6. Install the washers, and then install the nuts. 8-60 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 171
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 172
EBU08061 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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 173
Engine overheating 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 and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always use a - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 174
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 175
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 176
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 177
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 178
EBU00428 1- SPECIFICATIONS 1 2 YFM400FA 3 1,993 mm (78.5 in) 1,093 mm (43.0 in) 1,120 mm (44.1 in) 830 mm (32.7 in) 1,233 mm (48.5 in) 245 mm (9.65 in) 3,000 mm (118.1 in) 279.0 kg (615 lb) Liquid-cooled 4-stroke, SOHC Forward-inclined single cylinder 401.0 cm3 84.5 × 71.5 mm (3.33 × 2.81 in) 10.50 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 179
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 180
Model Final gear case oil: Type Quantity: Periodic oil change Differential gear case oil: Type Quantity: Periodic oil change Radiator capacity (including all routes): Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount Carburetor: Type/quantity Manufacturer YFM400FA SAE80 API GL-4 Hypoid - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 181
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 Forward gear Chassis: Frame type Caster angle Trail Tire: Type Size YFM400FA DR8EA / NGK 0.6-0.7 mm - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 182
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 183
Model Bulb voltage, wattage × quantity: Headlight Tail/brake light Meter lighting Neutral indicator light Reverse indicator light Coolant temperature warning light Park position indicator light Four-wheel drive indicator light Fuses: Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 184
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 185
) 2,400 (1,500) 4,800 (3,000) 7,200 (4,500) 9,600 (6,000) 12,000 (7,500) 14,400 (9,000) hours 20 75 150 300 450 600 750 900 DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 6 7 8 9 10 11 12 13 14 16,800 (10,500) 1,050 19,200 (12,000) 1,200 21,600 (13,500 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 186
EBU00432 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 13-1 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 187
1 2 3 4 5 6 7 8 9 10 11 12 13 14 13-2 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 188
EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 189
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 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 190
EBU00437 - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 191
and 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 IN USA 2004.06-3.9×1 CR (E) - 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 192
- 2005 Yamaha Motorsports Kodiak 400 Auto. 4x4 | Owners Manual - Page 193
1P1-F8199-10
LIT-11626-18-36
READ THIS MANUAL CAREFULLY!
It contains important safety information.
This ATV should not be ridden by anyone under 16 years of age.
WARNING
YFM400FAT
OWNER’S MANUAL