check engine YAMAHA KODIAK 450 2006 User Guide

8-9
NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
When disassembling the master cylinders or caliper cylinders, replace the brake fluid. Normally
check the brake fluid level and add fluid as required.
On the inner parts of the master cylinders and caliper cylinders, replace the oil seals every two years.
Replace the brake hoses every four years, or if cracked or damaged.
Drive shaft universal
joint*Lubricate with lithium-soap-based grease.Engine mount*
Check for cracks or damage.Front and rear axle boots*Check operation.
Replace if damaged.Stabilizer bushes*
Check for cracks or damage.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.Lights and switches*Check operation.
Adjust headlight beams.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
EE.book Page 9 Wednesday, May 11, 2005 1:21 PM

8-33 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
EBU10992
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 lubrica-
tion chart.
To check the engine oil level
1. Remove panel F. (See page 8-31 for panel
removal and installation procedures.)
2. Place the ATV on a level surface.
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Wait a few minutes until the oil settles.
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. _
EE.book Page 33 Wednesday, May 11, 2005 1:21 PM

8-43
‘1. Final gear oil filler bolt
2. Correct oil level
3. Final gear oil
1. Boulon de l’orifice de remplissage du carter de transmission finale
2. Niveau d’huile correct
3. Huile de transmission finale
1. Perno del orificio de llenado de aceite de la transmisión final
2. Nivel de aceite correcto
3. Aceite de la transmisión final
12. Start the engine and warm it up for several
minutes. While warming up, check for oil
leakage. If oil leakage is found, turn the en-
gine off immediately and check for the cause.
13. Turn the engine off, and then check the oil
level and correct it if necessary.
14. Install panel F.
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. _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. _
EE.book Page 43 Wednesday, May 11, 2005 1:21 PM

8-49
7. Install the oil filler bolt, and then tighten it to
the specified torque.
8. Check for oil leakage. If oil leakage is found,
check for the cause.
9. Install the engine guard and the final gear
case guard by installing the bolts, and then
tightening them to the specified torques. Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf)
Tightening torques:
Engine guard bolt:
7.0 Nm (0.7 m·kgf)
Final gear case guard bolt:
7.0 Nm (0.7 m·kgf)
EE.book Page 49 Wednesday, May 11, 2005 1:21 PM

8-57 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
EBU13210
Cooling system
1. Place the ATV on a level surface.
2. Check the coolant level in the coolant reser-
voir when the engine is cold as the coolant
level will vary with engine temperature.NOTE:_ The coolant level should be between the minimum
and maximum level marks. _3. If the coolant is at or below the minimum level
mark, remove panel D. (See pages 8-19–
8-21 for panel removal and installation proce-
dures.)
4. Remove the reservoir cap, add coolant to the
maximum level mark, install the reservoir
cap, and then install the panel.
EE.book Page 57 Wednesday, May 11, 2005 1:21 PM

8-65
CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you cannot get
distilled water. _14. 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.
15. Check for coolant leakage.Recommended antifreeze:
High quality ethylene glycol antifreeze
containing corrosion inhibitors for
aluminum engines.
Antifreeze and water mixing ratio:
1:1
Total amount:
1.30 L
Coolant reservoir capacity
(up to the maximum level mark):
0.25 L
EE.book Page 65 Wednesday, May 11, 2005 1:21 PM

8-81
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. _
EE.book Page 81 Wednesday, May 11, 2005 1:21 PM

8-83 1. V-belt cooling duct check hose (left front side of ATV)
1. Flexible de contrôle du conduit de refroidissement de la courroie
trapézoïdale (côté avant gauche du VTT)
1. Manguera de comprobación del conducto de enfriamiento de
la correa trapezoidal (lado delantero izquierdo del ATV)
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
EBU06411
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.
EBU08741
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. _
EE.book Page 83 Wednesday, May 11, 2005 1:21 PM

8-141
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 the 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 battery lead connections,
and charge the battery if necessary.Check the
fuel flow.
Turn the fuel cock
lever to “ON”.
Remove the fuel hose
from the fuel cock.
EE.book Page 141 Wednesday, May 11, 2005 1:21 PM

8-142
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
coolant reservoir 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.
EE.book Page 142 Wednesday, May 11, 2005 1:21 PM