maintenance YAMAHA KODIAK 450 2018 Owners Manual

EBU17171
INTRODUCTION
EBU17293Congratulations on your purchase of the Yamaha YFM45KDXJ / YFM45KPXJ / YFM45KDHJ /
YFM45KPAJ / YFM45KPHJ. This ATV represents the result of many years of Yamaha experience in the
production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha,
you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader
in these fields.
This manual will provide you with a good basic understanding of the features and operation of this ATV.
This manual includes important safety information. It provides information about special techni-
ques and skills necessary to ride the ATV. It also includes basic maintenance and inspection proce-
dures. If you have any questions regarding the operation or maintenance of your ATV, please consult a
Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
 Read this manual completely before operating your ATV. Make sure you understand all instructions.
 Pay close attention to the warning and notice labels on the ATV.
 This ATV should not be ridden by anyone under 16 years of age.UBB560E0.book Page 1 Friday, March 10, 2017 10:20 AM

Operating the drive select lever and driving in reverse ....................................... 6-2
Engine break-in ........................................... 6-4
Parking ........................................................ 6-4
Parking on a slope ...................................... 6-5
Accessories and loading ............................. 6-5
RIDING YOUR ATV ........................................ 7-1 GETTING TO KNOW YOUR ATV ................ 7-2
RIDE WITH CARE AND GOOD JUDGMENT .............................................. 7-2
BE CAREFUL WHERE YOU RIDE ............... 7-9
TURNING YOUR ATV................................ 7-12
CLIMBING UPHILL ................................... 7-13
RIDING DOWNHILL .................................. 7-16
CROSSING A SLOPE................................ 7-17
CROSSING THROUGH SHALLOW WATER .................................................... 7-18
RIDING OVER ROUGH TERRAIN ............. 7-20
SLIDING AND SKIDDING .......................... 7-21
WHAT TO DO IF... ..................................... 7-22
WHAT TO DO... ......................................... 7-22
PERIODIC MAINTENANCE AND
ADJUSTMENT................................................ 8-1 Owner’s manual and tool kit ....................... 8-2 Periodic maintenance chart: Emission
control system .......................................... 8-3
Periodic maintenance chart: General maintenance and lubrication .................... 8-4
Removing and installing panels .................. 8-8
Checking the spark plug........................... 8-15
Engine oil and oil filter cartridge ............... 8-17
Final gear oil ............................................. 8-22
Changing the differential gear oil.............. 8-24
Coolant ..................................................... 8-26
Cleaning the air filter ................................. 8-30
Cleaning the spark arrester ...................... 8-33
V-belt cooling duct check hose ................ 8-35
V-belt case drain plug............................... 8-35
Adjusting the throttle lever free play ......... 8-36
Valve clearance......................................... 8-36
Brakes....................................................... 8-37
Checking the front brake pads and rear brake friction plates ................................ 8-37
Checking the brake fluid level .................. 8-38
Changing the brake fluid .......................... 8-39
Checking the front brake lever free play... 8-39
Adjusting the rear brake lever and brake pedal ....................................................... 8-40
Axle boots................................................. 8-45
Brake light switches ................................. 8-46
Checking and lubricating the cables ........ 8-46
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2-2
2
Never operate at speeds too fast for your skills
or the riding conditions. Always go at a speed
that is proper for the terrain, visibility, operating
conditions, and your experience.
 Never attempt wheelies, jumps, or other stunts.
 Always inspect your ATV each time you use it to
make sure it is in safe operating condition. Al-
ways 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 when op-
erating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the
ATV.
 Never operate on excessively rough, slippery or
loose terrain until you have learned and prac-
ticed the skills necessary to control the ATV on
such terrain. Always be especially cautious on
these kinds of terrain.
 Always follow proper procedures for turning as
described in this manual. Practice turning at low
speeds before attempting to turn at faster
speeds and never turn at excessive speeds. 
Never operate the ATV on hills too steep for the
ATV or for your abilities. Practice on smaller hills
before attempting larger hills.
 Always follow proper procedures for climbing
hills as described in this manual. Check the ter-
rain carefully before you start up any hill. Never
climb hills with excessively slippery or loose
surfaces. Shift your weight forward. Never open
the throttle suddenly. Never go over the top of a
hill at high speed.
 Always follow proper procedures for going
down hills and for braking on hills as described
in this manual. Check the terrain carefully before
you start down any hill. Shift your weight back-
ward. Never go down a hill at high speed. Avoid
going down a hill at an angle that would cause
the vehicle to lean 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
on any hill until you have mastered the turning
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2-4
2
Never maintain an ATV without proper knowl-
edge. Contact an authorized ATV dealer to in-
form you on basic ATV maintenance. Certain
maintenance can only be carried out by certified
staff.
In the event of an accident 1. If serious injuries are incurred, you may be safer staying next to your vehicle; it may
shield you from oncoming riders. Depending
on your injuries and position in the trail; you
must make a judgment call as to whether you
should move to a position off the trail. If you
have sustained head, neck, or back injuries,
or cannot feel your limbs, you should not
move. Keep your helmet on and remain mo-
tionless. Lie down next to your vehicle and
wait for help.
2. If less serious injuries are incurred and you can walk, then move to a position off the trail.
Check yourself for injuries and apply first aid
as needed.
3. If your injuries are light, when safe to do so, move your vehicle off the trail to avoid colli-
sions with oncoming riders. Check for injuries
and apply first aid as necessary. If you can
physically operate your vehicle, inspect your vehicle. If the vehicle is in safe operating con-
dition and you can safely operate it, restart it
and ride gently back to camp or other known
location where you can receive medical at-
tention. If necessary, contact your riding party
or local authorities to let them know where
you are and what has happened.
In the event of a breakdown 1. If your vehicle will not restart or is not in safe operating condition, turn off the main switch
and engine stop switch. If the breakdown oc-
curs at twilight or night, leave the main switch
on so that your lights may warn other riders of
your stopped vehicle.
2. Get out of danger. Check for oncoming vehi- cles and when safe, push your vehicle to the
side of the trail or even off the main trail to
avoid any possible collisions with oncoming
riders. If you cannot move your vehicle by
yourself, when safe, walk to the nearest van-
tage point and signal an oncoming rider to
help you push your vehicle to a safe place off
the trail.
3. Inspect your vehicle for any immediate haz- ardous conditions. The most obvious hazard-
ous conditions are leaking fuel and
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4-6
4
TIPThe odometer will lock at 99999.
 The tripmeter will reset and continue counting
after 9999.9 is reached. Service tripmeter
The service tripmeter shows the distance traveled
since it was reset at the last maintenance.
To reset the service tripmeter, push the select but-
ton “SEL” for one second.TIPThe service tripmeter will reset and continue
counting after 9999.9 is reached. Hour meter
The hour meter shows the total time the engine
has been running.EBU30761Self-diagnosis deviceThis model is equipped with a self-diagnosis de-
vice for various electrical circuits. If a problem is detected in any of those circuits,
the engine trouble warning light will come on or
flash. If this occurs, have a Yamaha dealer check
the vehicle.
NOTICEECB01181To prevent engine damage, be sure to consult
a Yamaha dealer as soon as possible if this oc-
curs. EBU18066Handlebar switches1. Light switch “ / /OFF”
2. Engine stop switch “ / ”
3. Start switch “ ”
4. Horn switch “ ”
3421
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4-13
4
3. Wipe up any spilled fuel immediately.
NOTICE: Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since fuel may
deteriorate painted surfaces or plastic
parts.
[ECB00982]
4. Turn the fuel tank cap fully clockwise to make sure it is securely closed.
WARNING
EWB02532Gasoline is poisonous and can cause injury or
death. Handle gasoline with care. Never siphon
gasoline by mouth. If you should swallow some
gasoline or inhale a lot of gasoline vapor, or get
some gasoline in your eyes, see your doctor
immediately. If gasoline spills on your skin,
wash with soap and water. If gasoline spills on
your clothing, change your clothes. NOTICEECB00071Use only unleaded gasoline. The use of leaded
gasoline will cause severe damage to internal
engine parts, such as the valves and piston
rings, as well as to the exhaust system.
Your Yamaha engine has been designed to use
regular unleaded gasoline with a research octane
number of 91 or higher (95 or higher for Europe). If
knocking (or pinging) occurs, use a gasoline of a
different brand. Use of unleaded fuel will extend
spark plug life and reduce maintenance costs.EBU34141SeatTo remove the seat
Pull up the seat at the rear, and then pull the seat
rearward.1. Seat
1
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5
EBU19203
PRE-OPERATION CHECKS
EBU19226Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWB00482Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equip-
ment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected
by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:
ITEMROUTINE PAGE
Fuel • Check fuel level in fuel tank,
and add recommended fuel if neces-
sary.
• Check fuel line for leakage. Correct if necessary. 4-11, 5-3
Engine oil • Check oil level in engine, and add recommended oil to specified
level if necessary.
• Check ATV for oil leakage. Correct if necessary. 5-3, 8-17
Final gear oil • Check ATV for oil leakage. Correct if necessary. 5-3, 8-22
Differential gear oil • Check ATV for oil leakage. Correct if necessary. 5-3, 8-24
Coolant • Check coolant level in reservoir, and add recommended coolant to
specified level if necessary.
• Check cooling system for leakage. Correct if necessary. 5-3, 8-26
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8-1
8
EBU28788
PERIODIC MAINTENANCE AND ADJUSTMENT
EBU21676Periodic inspection, adjustment, and lubrication
will keep your vehicle in the safest and most effi-
cient condition possible. Safety is an obligation of
the vehicle owner and operator. The most impor-
tant points of vehicle inspection, adjustment, and
lubrication are explained on the following pages.
WARNING
EWB01842Failure to properly maintain the vehicle or per-
forming maintenance activities incorrectly may
increase your risk of injury or death during ser-
vice or while using the vehicle. If you are not fa-
miliar with vehicle service, have a Yamaha
dealer perform the service.
WARNING
EWB02563Turn off the engine when performing mainte-
nance unless otherwise specified.
A running engine has moving parts that can
catch on body parts or clothing and electri-
cal parts that can cause shocks or fires. 
Running the engine while servicing can lead
to eye injury, burns, fire, or carbon monoxide
poisoning - possibly leading to death. See
page 2-6 for more information about carbon
monoxide.

WARNING
EWB02691Brake discs, calipers, drums, and linings can
become very hot during use. To avoid possible
burns, let brake components cool before
touching them. The intervals given in the periodic maintenance
charts should be considered as a general guide
under normal riding conditions. However, DE-
PENDING ON THE WEATHER, TERRAIN, GEO-
GRAPHICAL LOCATION, AND INDIVIDUAL USE,
THE MAINTENANCE INTERVALS MAY NEED TO
BE SHORTENED.TIPFor ATVs not equipped with an odometer or an
hour meter, follow the month maintenance in-
tervals instead.
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8-2
8

For odometer or hour meter-equipped vehicles,
follow the month maintenance interval if the ATV
isn’t ridden for the stated mileage or engine op-
erating hours.
 Items marked with an asterisk should be per-
formed by a Yamaha dealer as they require spe-
cial tools, data and technical skills.
EBU21692Owner’s manual and tool kitBe sure to put this owner’s manual and the low-
pressure tire gauge in the plastic bag and always
carry them along with the owner’s tool kit under
the seat.
The service information included in this manual
and the tools provided in the owner’s tool kit are
intended to assist you in the performance of pre-
ventive maintenance and minor repairs. However,
additional tools such as a torque wrench may be
necessary to perform certain maintenance work
correctly.
TIPIf you do not have the tools or experience required
for a particular job, have a Yamaha dealer perform
it for you. 1. Owner’s tool kit
2. Owner’s manual
3. Low-pressure tire gauge
13
2
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EBU36871Periodic maintenance chart: Emission control systemNO.ITEM CHECK OR MAINTENANCE
JOB INITIAL
EVERY
Whichev-
er comes first month136612
km (mi) 240
(150) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320
1 *Fuel line • Check fuel hoses for cracks or other damage, and
replace if necessary. √√√
2 Spark plug • Check condition and clean, regap, or replace if
necessary. √√√√√
3 *Va l ve s • Check valve clearance and adjust if necessary. √ √√√
4 *Crankcase breath-
er system • Check breather hose for cracks or other damage,
and replace if necessary. √√√
5 *Exhaust system • Check for leakage and replace gasket(s) if neces-
sary.
• Check for looseness and tighten all screw clamps and joints if necessary. √√√
6 Spark arrester • Clean. √√√
7 *Air induction sys-
tem • Check the air cut-off valve, reed valve, and hose
for damage.
• Check condition and clean or replace if neces- sary. √√√
UBB560E0.book Page 3 Friday, March 10, 2017 10:20 AM