check engine YAMAHA KODIAK 400 2003 Manuale de Empleo (in Spanish)

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 element•Clean.
•Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*•Check and adjust idle speed/starter operation.
•Adjust if necessary.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.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.
•Adjust if necessary.U5TE60.book Page 7 Monday, June 10, 2002 8:47 AM

8-29 1. Engine oil filler cap
1. Bouchon de remplissage d’huile de moteur
1. Tapa de relleno de aceite de motor
1. Maximum level mark 2. Minimum level mark
1. Repère de niveau maximum 2. Repère de niveau minimum
1. Marca de nivel máximo 2. Marca de nivel mínimo
EBU01099
Engine oil
Engine oil level measurement
1. Remove panel F. (See page 8-27 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 clean rag.
5. Insert the dipstick in the filler hole without
screwing it in.NOTE:_ Wait a few minutes until the oil level settles before
checking. _6. The oil level should be between the maxi-
mum and minimum marks. If the level is low,
fill the engine with sufficient oil to reach the
specified level.
U5TE60.book Page 29 Monday, June 10, 2002 8:47 AM

8-39
‘1. Final gear oil
2. Final gear case filler bolt
3. Proper level
1. Huile de transmission finale
2. Boulon de remplissage du carter de transmission finale
3. Niveau correct
1. Aceite de la transmisión final
2. Perno de relleno de la caja de la transmisión final
3. Nivel adecuado
10. Start the engine and warm it up for several
minutes. While warming up, check for oil
leakage. If oil leakage is found, stop the en-
gine immediately and check for the cause.
11. Install the panels.
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 sufficient oil of the recommended type to
raise it to the correct level.CAUTION:_ Be sure no foreign material enters the final
gear case. _4. Install the oil filler bolt.
U5TE60.book Page 39 Monday, June 10, 2002 8:47 AM

8-51 1. Coolant reservoir 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 pag-
es 8-17–8-21 for panel removal and installa-
tion procedures.)
U5TE60.book Page 51 Monday, June 10, 2002 8:47 AM

8-61 1. Axle boot (× 2 each side)
1. Soufflet d’axe (× 2 de chaque côté)
1. Guardapolvo de eje (× 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.
U5TE60.book Page 61 Monday, June 10, 2002 8:47 AM

8-75
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 mainte-
nance is performed, check the air inlet to the filter
case for obstructions. Check the air filter case rub-
ber joint to the carburetor and manifold fittings for
an airtight seal. Tighten all fittings securely to
avoid the possibility of unfiltered air entering the
engine. _CAUTION:_ Never operate the engine with the air filter ele-
ment removed. This will allow unfiltered air to
enter, causing rapid engine wear and possible
engine damage. Additionally, operation with-
out the air filter element will affect carburetor
jetting with subsequent poor performance and
possible engine overheating. _
U5TE60.book Page 75 Monday, June 10, 2002 8:47 AM

8-77 1. V-belt cooling duct check hose
1. Flexible de contrôle du conduit de refroidissement de la courroie
trapézoïdale
1. Manguera de comprobación del conducto de enfriamiento de
la correa trapezoidal
1. V-belt case drain plug
1. Boulon de vidange du carter de courroie trapézoïdale
1. Tapón de drenaje de la caja de la correa trapezoidal
EBU00874
V-belt cooling duct check hose
If dust or water collects in the V-belt cooling duct
check hose, remove the hose and clean it.
V-belt case drain plug
After riding in water deep enough to allow it to en-
ter 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 engine parts. _
U5TE60.book Page 77 Monday, June 10, 2002 8:47 AM

8-131
EBU00724Troubleshooting chart
Starting problems or poor engine performance1. Fuel
Check if there is fuel
in the fuel tank.There is fuel.Turn the fuel cock
lever to “OFF”.No fuel.Fuel cock is
clogged.
Clean the
fuel cock. Some fuel.Turn the fuel cock
lever to “RES”.Restart the engine.
No fuel.Supply fuel.
2. Compression
Use the electric
starter to see if
there is compression.There is compression.
Compression normal.
No compression.Ask a Yamaha dealer to
inspect.
3. Ignition
Remove the
spark plug and
check electrodes.WetWipe clean with dry cloth.
DryAttach spark plug cap and
ground to chassis.Use the
electric starter.Spark is good.Ignition system is
normal.
Spark is weak.
Adjust the spark plug gap
or replace the spark plug. No spark.
Ask a Yamaha dealer to
inspect. 4. Battery
Use the electric starter.Engine turns over
quickly.Battery is good.
Engine turns over
slowly.Check the connections.Check the
fuel flow.
Turn the fuel cock
lever to “ON”.
Remove the fuel hose
from the fuel cock.
U5TE60.book Page 131 Monday, June 10, 2002 8:47 AM

8-132
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.
U5TE60.book Page 132 Monday, June 10, 2002 8:47 AM