load YAMAHA KODIAK 400 2003 Owners Manual

Tire wear limit......................................5-33
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
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
What to do if ........................................7-75
What to do...........................................7-75
67
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 ............................................ 8-29
Final gear oil ....................................... 8-39
Cooling system ................................... 8-45
Changing the coolant.......................... 8-49
Spark plug inspection ......................... 8-57
Air filter element cleaning ................... 8-63
V-belt cooling duct check hose ........... 8-71
Carburetor adjustment ........................ 8-73
Idle speed adjustment ........................ 8-75
Valve clearance adjustment ............... 8-77
Throttle lever adjustment .................... 8-79
Front brake pad check ........................ 8-81
Rear brake shoe inspection ................ 8-81
Brake fluid level check ........................ 8-83
Brake fluid replacement ...................... 8-87
Front brake lever free play.................. 8-89
Rear brake pedal and lever
adjustment ........................................ 8-91
8
U5VH60.book Page 2 Wednesday, August 7, 2002 12:00 PM

1-1
EBU00464
LOCATION OF THE WARNING
AND SPECIFICATION LABELSRead and understand all of the labels on your ma-
chine. They contain important information for safe
and proper operation of your ATV.
Never remove any labels from your ATV. If a label
becomes difficult to read or comes off, a replace-
ment label is available from your Yamaha dealer.
1
40 kg (88 lbs)
5ND-F4877-20
LOAD LIMIT
U5VH60.book Page 1 Wednesday, August 7, 2002 12:00 PM

1-8
For Oceania
Pour l’Océanie
Para Oceanía
WARNING
Passengers can cause
a loss of control,
resulting in SEVERE
INJURY or DEATH.
NEVER ride as a
passenger.
(4XE-F151H-00)
5
6
80 kg (176 lbs)
5ND-F4897-20
LOAD LIMIT
For Europe
Pour l’Europe
Para Europa
PULLING LOAD: 4900 N(
500kgf)
1102 l b f
TONGUE WEIGHT: 147 N(
15kgf)
33 lbf
5ND-F151K-00
MAXIMUM.
LOADING LIMIT MAXIMUM LOADING LIMIT
7
YAMAHA MOTOR MFG
. CORP
.
OF AMERICA
NEWNAN
, GEORGIA U
.S.A.MODEL YFM400A
POWER 19.4 KW
DRY WEIGHT 233 Kg
5VH
-F155A
-00
8
U5VH60.book Page 8 Wednesday, August 7, 2002 12:00 PM

2-13

Always be sure there are no obstacles or peo-
ple behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly.


Always use the size and type tires specified in
this manual.


Always maintain proper tire pressure as de-
scribed in this manual.


Never modify an ATV through improper instal-
lation or use of accessories.


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 brak-
ing.
U5VH60.book Page 13 Wednesday, August 7, 2002 12:00 PM

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear shock absorber
assembly spring preload
adjusting ring
2. Storage box and tool kit
3. Spark plug
4. Front shock absorber
assembly spring preload
adjusting ring
5. Brake pedal
6. V-belt case
7. Radiator cap
8. Fuel cock
9. Air filter case
10. Fuses
11. Tail/brake light
12. Front shock absorber
assembly spring preload
adjusting ring13. V-belt cooling duct check
hose
14. Coolant reservoir
15. Oil filter cartridge
16. Engine oil dipstick
17. Rear brake lever
18. Left handlebar switches
19. Starter (choke)
20. Horn switch
21. Drive select lever
22. Speedometer
23. Main switch
24. Fuel tank cap
25. Auxiliary DC jack
26. Throttle lever
27. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5VH60.book Page 1 Wednesday, August 7, 2002 12:00 PM

4-3 1. Coolant temperature warning light “”
2. Reverse indicator light “R”
3. Neutral indicator light “N”
1. Témoin d’avertissement de la température du liquide de
refroidissement “”
2. Témoin de marche arrière “R”
3. Témoin de point mort “N”
1. Luz de aviso de la temperatura del refrigerante “”
2. Luz de control de marcha atrás “R”
3. Luz de control de punto muerto “N”
EBU00802
Indicator and warning lights
EBU01223
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.
To check the coolant temperature warning light,
shift the drive select lever into neutral, turn the key
to “ON”, and then press the start switch. If the light
does not come on, have a Yamaha dealer inspect
the electrical circuit.CAUTION:_

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.
_
U5VH60.book Page 3 Wednesday, August 7, 2002 12:00 PM

4-15 1. Throttle lever
1. Levier d’accélération
1. Palanca de aceleración
EBU00063
Throttle lever
Once the engine is running, movement of the
throttle lever will increase the engine speed.
Regulate the speed of the machine by varying the
throttle position. Because the throttle is spring-
loaded, the machine will decelerate, and the en-
gine will return to an idle any time the hand is re-
moved from the throttle lever.
Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.
WARNING
Malfunction of the throttle could make it diffi-
cult to speed up or slow down when you need
to. This could cause an accident. Check the
operation of the throttle lever before you start
the engine. If the throttle does not work
smoothly, check for the cause. Correct the
problem before riding the ATV or consult a
Yamaha dealer.
U5VH60.book Page 15 Wednesday, August 7, 2002 12:00 PM

4-35 1. Storage box
1. Compartiment de rangement
1. Caja para objetos
EBU00581
Storage boxCAUTION:_ 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 ma-
terial. _
Maximum load limit: 2.0 kg
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4-37
EBU00582
Front carrier
EBU00583
Rear carrierMaximum load limit: 40 kg
Maximum load limit: 80 kg
U5VH60.book Page 37 Wednesday, August 7, 2002 12:00 PM

4-39 1. Spring preload adjusting ring
2. Position indicator
1. Anneau de réglage de la précontrainte de ressort
2. Indicateur de position
1. Anillo de ajuste de la precarga del resorte
2. Indicador de posición
1. Special wrench
1. Clé spéciale
1. Llave especial
EBU01163
Front shock absorber adjustment
The spring preload can be adjusted to suit the rid-
er’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 direction
b.NOTE:_ A special wrench can be obtained at a Yamaha
dealer to make this adjustment. _
WARNING
_ Always adjust the shock absorbers on the left
and right side to the same setting. Uneven ad-
justment can cause poor handling and loss of
stability, which could lead to an accident. _
Standard position: 2
1 - Minimum (soft)
5 - Maximum (hard)
U5VH60.book Page 39 Wednesday, August 7, 2002 12:00 PM