coolant level YAMAHA KODIAK 400 2002 Owners Manual

Tires ...................................................5-25
How to measure tire pressure ............5-29
Tire wear limit .....................................5-31
OPERATION ...........................................6-1
Starting a cold engine ..........................6-3
Starting a warm engine ........................6-9
Warming up ..........................................6-9
Drive select lever operation and
reverse driving ..................................6-11
Engine break-in ..................................6-17
Parking ...............................................6-19
Parking on a slope .............................6-21
Accessories and loading ....................6-23
Loading ..............................................6-27
RIDING YOUR ATV..................................7-1
Getting to know your ATV .....................7-3
Ride with care and good judgement .....7-5
Be careful where you ride ...................7-27
Turning your ATV ................................7-39
Climbing uphill.....................................7-45
Riding downhill ....................................7-55
Crossing a slope .................................7-59
Crossing through shallow water ..........7-63
Riding over rough terrain ....................7-69
Sliding and skidding ............................7-71
67
What to do if ... ................................... 7-75
What to do ... ...................................... 7-75
PERIODIC MAINTENANCE AND
ADJUSTMENT ........................................ 8-1
Owner’s manual and tool kit ................ 8-3
Periodic maintenance/lubrication ......... 8-7
Panel removal and installation ........... 8-15
Engine oil ............................................ 8-31
Final gear oil ....................................... 8-41
Differential gear oil ............................. 8-47
Cooling system .................................. 8-53
Changing the coolant.......................... 8-57
Axle boots ........................................... 8-63
Spark plug inspection ........................ 8-65
Air filter cleaning ................................ 8-71
V-belt cooling duct check hose .......... 8-77
Carburetor adjustment ....................... 8-81
Idle speed adjustment ....................... 8-83
Valve clearance adjustment .............. 8-85
Throttle lever adjustment ................... 8-87
Front brake pad inspection ................ 8-89
Rear brake pad inspection ................. 8-89
Inspecting the brake fluid level .......... 8-91
Brake fluid replacement ...................... 8-95
Front brake adjustment ...................... 8-97
Rear brake lever adjustment ............. 8-99
8
U5GH62.book Page 2 Monday, August 6, 2001 9:09 AM

4-3 1. Park indicator light “P”
2. Reverse indicator light “R”
3. Neutral indicator light “N”
4. Coolant temperature warning light “”
5. Four-wheel-drive indicator light “”
1Témoin de stationnement “P”
2. Témoin de marche arrière “R”
3. Témoin de point mort “N”
4. Témoin d’avertissement de la température du liquide de
refroidissement “”
5. Témoin 4x4 “”
1 Luz de indicatora de estacionamiento “P”
2. Luz de control de marcha atrás “R”
3. Luz de control de punto muerto “N”
4. Luz de aviso de la temperatura del refrigerante “”
5. Luz de control del modo de tracción de cuatro
ruedas “”
EBU00043
Indicator lights
EBU00609
Park indicator light “P”
This indicator light comes on when the drive select
lever is in the “P” (park) position.
EBU00602
Reverse indicator light “R”
This indicator light comes on when the transmis-
sion is in reverse.
EBU00603
Neutral indicator light “N”
This indicator light comes on when the transmis-
sion is in neutral.
EBU00713
Coolant temperature warning light “”
When the coolant temperature reaches a specified
level, this light comes on to warn that the coolant
temperature is too hot. If the light comes on during
operation, stop the engine as soon as it is safe to
do so and allow the engine to cool down for about
10 minutes.
U5GH62.book Page 3 Monday, August 6, 2001 9:09 AM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
BrakesCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-7 ~ 5-9,
8-89 ~ 8-95
FuelCheck fuel level.
Fill with fuel if necessary.5-11 ~ 5-13
Engine oilCheck oil level.
Fill with oil if necessary.5-15 ~ 5-17,
8-31 ~ 8-41
Coolant reservoirCheck coolant level.
Fill with coolant if necessary.8-53 ~ 8-63
Final gear oil/
Differential gear oilCheck for leakage. 5-19, 8-41 ~ 8-51
ThrottleCheck for proper throttle cable operation. 5-21, 8-87
Wheels and tiresCheck tire pressure, wear and damage.5-25 ~ 5-31,
8-109 ~ 8-111
Fittings and FastenersCheck all fittings and fasteners. 5-21
LightsCheck for proper operation. 5-23, 8-123 ~ 8-131
Axle bootsCheck for damage. 8-63
U5GH62.book Page 1 Monday, August 6, 2001 9:09 AM

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*•Check valve clearance.
•Adjust if necessary.
Cooling system•Check coolant leakage.
•Repair if necessary.
•Replace coolant every 24 months.Spark plug•Check condition.
•Adjust gap and clean.
•Replace if necessary.Air filter•Clean.
•Replace if necessary.Every 20~40 hours
(More often in wet or dusty areas.)
Crankcase breather
system*•Check breather hose for cracks or damage.
•Replace if necessary.Exhaust system*•Check for leakage.
•Retighten if necessary.
•Replace gasket(s) if necessary.Carburetor*•Check and adjust idle speed/starter operation.
•Adjust if necessary.Fuel line*•Check fuel hose for cracks or damage.
•Replace if necessary.Engine oil
•Replace (Warm engine before draining).Engine oil filter cartridge
•Replace.Engine oil strainer*
•Clean.Final gear oil
•Check oil level/oil leakage.
•Replace every 12 months.Differential gear oil
Front brake*•Check operation/fluid leakage/see NOTE page 8-8.
•Correct if necessary.Rear brake*•Check operation/fluid leakage/see NOTE page 8-8.
•Correct if necessary.U5GH62.book Page 7 Monday, August 6, 2001 9:09 AM

8-53 1. Coolant reservoir tank cap
2. Maximum level mark
3. Minimum level mark
1. Bouchon du vase d’expansion
2. Repère de niveau maximum
3. Repère de niveau minimum
1. Tapa del depósito de refrigerante
2. Marca de nivel máximo
3. Marca de nivel mínimo
EBU01000
Cooling system
1. Check the coolant level in the reservoir when
the engine is cold as the coolant level will
vary with engine temperature. The coolant
level should be between the maximum and
minimum marks.
2. If the level is low, remove panel D. (See page
8-17 ~ 8-19 for panel removal and installation
procedures.)
U5GH62.book Page 53 Monday, August 6, 2001 9:09 AM

8-55 1. Coolant reservoir drain hose
1. Flexible de vidange du vase d’expansion
1. Manguera de drenaje del depósito de refrigerante
3. Remove the reservoir cap, and then add
coolant or distilled water to raise it to the
specified level.
4. Install the panel.CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you can’t get
distilled water. _NOTE:_

If water is added, have a Yamaha dealer check
the antifreeze content of the coolant as soon as
possible.


The radiator fan operation is completely auto-
matic. It is switched on or off according to the
coolant temperature in the radiator.
_If your ATV overheats, see page 4-3 for details.Coolant reservoir capacity:
0.25 L
U5GH62.book Page 55 Monday, August 6, 2001 9:09 AM

8-57 1. Coolant drain bolt
1. Boulon de vidange du liquide de refroidissement
1. Perno de drenaje del refrigerante
1. Trough
1. Feuille de papier repliée en forme de conduit
1. Pasante
EBU00977
Changing the coolant
WARNING
_ Wait for the engine and radiator to cool before
removing the radiator cap. You could be
burned by hot fluid and steam blown out under
pressure. Always put a thick rag over the cap
when opening. Allow any remaining pressure
to escape before completely removing the cap. _1. Place the ATV on a level surface.
2. Remove panels E and F. (See pages 8-27 ~
8-29 for 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 cool-
ant from spilling on the footrest.)
4. Remove the front carrier and panel C. (See
pages 8-23 and 8-25 for removal and installa-
tion procedures.)
U5GH62.book Page 57 Monday, August 6, 2001 9:09 AM

8-61
10. Install the coolant reservoir hose.
11. Pour the recommended coolant into the radi-
ator until it is full.CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you can’t get
distilled water. _
Recommended antifreeze:
High quality ethylene glycol antifreeze
containing corrosion inhibitors for aluminum
engines.
Antifreeze and water mixing ratio:
1:1
Total amount:
1.1 L
Coolant reservoir capacity
(up to the maximum level mark):
0.25 L
U5GH62.book Page 61 Monday, August 6, 2001 9:09 AM

8-63 1. Front axle boot (× 2 each side)
1. Soufflet d’axe avant (× 2 de chaque côté)
1. Guardapolvo de eje delantero (× 2 en cada lado)
12. Install the radiator cap.
13. Start the engine and let it idle for several min-
utes. Stop the engine, and then check the
coolant level in the radiator. If it is low, add
more coolant until it reaches the top of the ra-
diator.
14. Fill the coolant reservoir with coolant up to
the maximum level.
15. Install the coolant reservoir cap and check for
coolant leakage.NOTE:_ If any leakage is found, ask a Yamaha dealer to in-
spect the cooling system. _16. Install the panels and the front carrier.
EBU00862
Axle boots
Check the protective boots for holes or tears. If any
damage is found, have them replaced by a
Yamaha dealer.
U5GH62.book Page 63 Monday, August 6, 2001 9:09 AM

8-136
Engine overheatingNOTE:If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is
changed to the recommended coolant as soon as possible.
WARNING
Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by
hot fluid and steam blown out under pressure. Always put a thick rag over the cap when opening.
Allow any remaining pressure to escape before completely removing the cap. Wait until the
engine has cooled.
Check the coolant level in the
reservoir tank and/or radiator.
Level is OK.Level is low, check the
cooling system for leakage.
No
leakage.Leakage.
Ask a Yamaha dealer to inspect
and repair the cooling system.Add coolant. (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and/or repair the cooling system.
U5GH62.book Page 136 Monday, August 6, 2001 9:09 AM