Gear YAMAHA KODIAK 450 2020 Owner's Manual

8-8
8
23 Differential gear oil• Change.
• Check ATV for oil leakage, and correct if neces-
sary. √√
24 Final gear oil • Change.
• Check ATV for oil leakage, and correct if neces-
sary. √ √√√
25 Cooling system • Check coolant level and ATV for coolant leakage,
and correct if necessary. √√√√√
• Replace coolant. Every 2 years
26 *Moving parts and
cables
• Lubricate.
√√√√
27 *Throttle lever • Check operation.
• Check throttle lever free play, and adjust if neces-
sary.
• Lubricate cable and lever housing. √√√√√
28 *Front and rear
brake switches • Check operation and correct if necessary.
√√√√√
29 *Lights and switches • Check operation and correct if necessary.
• Adjust headlight beams.
√√√√√
NO.
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 320UBB562E0.book Page 8 Thursday, March 14, 2019 9:59 AM

8-24
8research and development into oil since the
1960’s helps make Yamalube the best choice for
your Yamaha engine.
EBU28568Final gear oilThe final gear case must be checked for oil leak-
age before each ride. If any leakage is found, have
a Yamaha dealer check and repair the ATV. In ad-
dition, the final gear oil level must be checked and
the oil changed as follows at the intervals speci-
fied in the periodic maintenance and lubrication
chart.
To check the final gear oil level
1. Park the ATV on a level surface. 2. Remove the final gear oil filler bolt and its gas-
ket, and then check the oil level in the final
gear case. 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.
4. Check the oil filler bolt gasket for damage, and replace it if necessary.
5. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.
1. Final gear oil filler bolt
2. Gasket
3. Final gear oil
4. Correct oil level1
2
3
4
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8
To change the final gear oil
1. Park the ATV on a level surface.
2. Remove the final gear case guard by remov- ing the bolts.
3. Place an oil pan under the final gear case to collect the used oil.
4. Remove the final gear oil filler bolt, the final gear oil drain bolt and their gasket to drain the
oil from the final gear case. 5. Install the drain bolt and its new gasket, and
then tighten the bolt to the specified torque.
6. Refill with the recommended final gear oil to the brim of the filler hole as shown. NOTICE:
Be sure no foreign material enters the final
gear case.
[ECB00422]
Tightening torque: Final gear oil filler bolt:22 N·m (2.2 kgf·m, 16 lb·ft)1. Final gear case guard
2. Bolt
1
2
1. Final gear oil drain bolt
2. GasketTightening torque: Final gear oil drain bolt:22 N·m (2.2 kgf·m, 16 lb·ft)
12
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8
TIPIf the recommended oil is not available, SAE 80W-
90 API GL-5 Hypoid gear oil may be used instead.However, when using this oil, noise from the final
gear case may occur when applying the rear
brake.
7. Check the oil filler bolt gasket for damage,
and replace it if necessary.
8. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.
9. Check the final gear case for oil leakage. If oil is leaking, check for the cause.
10. Install the final gear case guard by installing the bolts, and then tightening them to the
specified torque.
1. Final gear oil filler bolt
2. Gasket
3. Final gear oil
4. Correct oil levelRecommended final gear oil:Yamaha Friction Modified Shaft Drive Gear Oil
Oil quantity: 0.38 L (0.40 US qt, 0.33 Imp.qt)1
2
3
4
Tightening torque: Final gear oil filler bolt:22 N·m (2.2 kgf·m, 16 lb·ft)
Tightening torque: Final gear case guard bolt:8 N·m (0.8 kgf·m, 5.9 lb·ft)
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EBU38830Changing the differential gear oilThe differential gear case must be checked for oil
leakage before each ride. If any leakage is found,
have a Yamaha dealer check and repair the ATV.
In addition, the differential gear oil must be
changed as follows at the intervals specified in the
periodic maintenance and lubrication chart.
For non-differential gear lock modelsFor differential gear lock models1. Differential gear oil filler bolt
2. Gasket
2
1
Recommended differential gear oil:
Yamaha Friction Modified Shaft Drive Gear Oil or SAE 80 API GL-4 Hypoid gear oil
Oil quantity: 0.35 L (0.37 US qt, 0.31 Imp.qt)1. Differential gear oil filler bolt
2. Gasket
2
1
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81. Park the ATV on a level surface.
2. Place an oil pan under the differential gear
case to collect the used oil.
3. Remove the differential gear oil filler bolt, the differential gear oil drain bolt and their gasket
to drain the oil from the differential gear case. 4. Install the drain bolt and its new gasket, and
then tighten the bolt to the specified torque.
5. Refill with the specified amount of the recom- mended differential gear oil. NOTICE: Be
sure no foreign material enters the differ-
ential gear case.
[ECB00412]
TIP Do not exceed the specified differential gear oil
quantity when filling. Overfilling will cause the oil
to seep out of the breather hose during and af-
ter riding.
 The differential gear case capacity is greater
than the recommended oil quantity, therefore
the oil level cannot be accurately checked from
the oil filler hole. 6. Check the oil filler bolt gasket for damage,
and replace it if necessary.
7. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.
Recommended differential gear oil:
Yamaha Friction Modified Plus Shaft Drive Oil (Part No.: ACC-SHAFT-PL-32) or SAE 80
API GL-4 Hypoid gear oil
Oil quantity: 0.23 L (0.24 US qt, 0.20 Imp.qt)
1. Differential gear oil drain bolt
2. Gasket
12
Tightening torque:Differential gear oil drain bolt:10 N·m (1.0 kgf·m, 7.4 lb·ft)
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8. Check the differential gear case for oil leak-
age. If oil is leaking, check for the cause.
EBU23472CoolantThe coolant level should be checked regularly. In
addition, the coolant must be changed at the in-
tervals specified in the periodic maintenance and
lubrication chart.
TIPIf genuine Yamaha coolant is not available, use an
ethylene glycol antifreeze containing corrosion in-
hibitors for aluminum engines and mix with dis-
tilled water at a 1:1 ratio. NOTICEECB02190Mix antifreeze with distilled water only. Howev-
er, if distilled water is not available, soft water
may be used for refilling. Do not use hard water
or salt water since they are harmful to the en-
gine. EBU2712ATo check the coolant level1. Park the ATV on a level surface.TIPThe coolant level must be checked on a cold en-
gine since the level varies with engine tempera-
ture. 2. Check the coolant level in the coolant reser- voir.
Tightening torque:
Differential gear oil filler bolt:23 N·m (2.3 kgf·m, 17 lb·ft)
Recommended coolant: YAMALUBE coolant
Coolant quantity: Coolant reservoir (up to full level):0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator (including all routes): 1.32 L (1.40 US qt, 1.16 Imp.qt)
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EBU29705Adjusting the throttle lever free playFor non-differential gear lock models
1. V-belt case drain plug
1
1. Throttle lever free play
2. Rubber cover
3. Locknut
4. Throttle lever free play adjusting bolt24 3
1
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For differential gear lock models
Periodically check the throttle lever free play and
adjust if necessary.
1. Slide the rubber cover back.
2. Loosen the locknut. 3. To increase the throttle lever free play, turn
the throttle lever free play adjusting bolt in di-
rection (a). To decrease the throttle lever free
play, turn the adjusting bolt in direction (b).
4. Tighten the locknut.
5. Slide the rubber cover to its original position.
EBU24061Valve clearanceThe valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.EBU29602BrakesReplacement of brake components requires pro-
fessional knowledge. Brake service should be
performed by a Yamaha dealer.
WARNING
EWB02572Operating with improperly serviced or adjust-
ed brakes could lead to a loss in braking ability
and an accident.
1. Throttle lever free play
2. Rubber cover
3. Locknut
4. Throttle lever free play adjusting boltThrottle lever free play: 2.0–4.0 mm (0.08–0.16 in)
2WD
4WD
3
4
2
1
(b)
(a)
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8
EBU28414Checking the front brake pads and rear
brake friction platesThe front brake pads and the rear brake friction
plates must be checked for wear at the intervals
specified in the periodic maintenance and lubrica-
tion chart.TIPThis ATV is equipped with a wet, multiple-disc
type rear brake, which is located inside of the final
gear case. EBU24174Front brake padsCheck each front brake pad for damage and mea-
sure the lining thickness. If a brake pad is dam-
aged or if the lining thickness reaches the
specified limit, have a Yamaha dealer replace the
brake pads as a set.
TIPThe wheels need to be removed to check the
brake pads. (See page 8-63.) EBU30321Rear brake friction plates
The rear brake friction plates must be checked
and, if necessary, replaced by a Yamaha dealer at
the intervals specified in the periodic maintenance
and lubrication chart.EBU29845Checking the brake fluid levelBefore riding, check that the brake fluid is above
the minimum level mark. Replenish the brake fluid
if necessary.
1. Lining thickness
Brake pad lining thickness limit:
1.0 mm (0.04 in)
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