check engine YAMAHA KODIAK 450 2020 Owner's Manual

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8
TIPIf a torque wrench is not available when installing
the spark plug, a good estimate of the correct
torque is 1/4–1/2 turn past finger tight. However,
the spark plug should be tightened to the speci-
fied torque as soon as possible. 3. Install the spark plug cap.EBU30245Engine oil and oil filter cartridgeThe 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 chart.
To check the engine oil level1. Park the ATV on a level surface.
2. Remove panel E. (See page 8-10.)
3. Check the engine oil level on a cold engine.
TIPIf the engine was started before checking the oil
level, warm up the engine, and then wait at least
ten minutes until the oil settles for an accurate
reading. 4. Remove the engine oil filler cap, and then wipe the dipstick with a clean rag.
5. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to
check the oil level.
Tightening torque:
Spark plug:18 N·m (1.8 kgf·m, 13 lb·ft)1. Engine oil filler cap
1
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TIPThe engine oil should be between the tip of the
dipstick and the maximum level mark. 6. If the engine oil is not between the tip of thedipstick and the maximum level mark, add
sufficient oil of the recommended type to
raise it to the correct level. NOTICE: Be sure
the engine oil is at the correct level, other-
wise engine damage may result.
[ECB00852]
7. Check the filler cap O-ring for damage, and replace it if necessary.
8. Install the engine oil filler cap and the panel.
To change the engine oil (and replace the oil fil-
ter cartridge) 1. Park the ATV on a level surface.
2. Remove panel E. (See page 8-10.)
3. Start the engine, warm it up for several min- utes, and then turn it off.
4. Place an oil pan under the engine to collect the used oil.
5. Remove the engine oil filler cap, and then re- move the engine oil drain bolt and its gasket
to drain the oil from the crankcase.
1. Engine oil filler cap
2. O-ring
3. Engine oil dipstick
4. Maximum level mark
5. Tip of the engine oil dipstick
12345
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12. Refill with the specified amount of the recom-
mended engine oil.
TIPBe sure to wipe off spilled oil on any parts after the
engine and exhaust system have cooled down. NOTICEECB00301In order to prevent clutch slippage (since the
engine oil also lubricates the clutch), do not
mix any chemical additives. Do not use oils
with a diesel specification of “CD” or oils of
a higher quality than specified. In addition,
do not use oils labeled “ENERGY CONSERV-
ING II” or higher.
 Make sure that no foreign material enters the
crankcase.
13. Check the engine oil filler cap O-ring for dam-
age, and then install the filler cap.
14. Start the engine and let it idle for several min- utes while checking for oil leakage. If any oil
leakage is found, immediately turn the engine
off and check for the cause.
15. Turn the engine off, wait at least ten minutes, and then check the oil level and correct it if
necessary.
16. Install panel E.EBU38620Why YamalubeYAMALUBE oil is a Genuine YAMAHA Part born of the engineers’ passion and belief that engine oil is
an important liquid engine component. We form
teams of specialists in the fields of mechanical en-
gineering, chemistry, electronics and track test-
ing, and have them develop the engine together
with the oil it will use. Yamalube oils take full ad-
vantage of the base oil’s qualities and blend in the
ideal balance of additives to make sure the final oil
clears our performance standards. Thus,
Yamalube mineral, semisynthetic and synthetic oils have their own distinct characters and value.
Yamaha’s experience gained over many years of
Recommended oil:
See page 10-1.
Oil quantity: Without oil filter cartridge replacement:2.30 L (2.43 US qt, 2.02 Imp.qt)
With oil filter cartridge replacement: 2.40 L (2.54 US qt, 2.11 Imp.qt)
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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. 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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TIPThe coolant should be between the minimum and
maximum level marks. 3. If the coolant is at or below the minimum levelmark, remove panel C to access the coolant
reservoir. (See page 8-10.)
4. Remove the coolant reservoir cap. WARNING! Remove only the coolant res-
ervoir cap. Never attempt to remove the
radiator cap when the engine is hot.
[EWB02672]
5. Add coolant to the maximum level mark, in-stall the reservoir cap, and then install the
panel. NOTICE: If coolant is not available,
use distilled water or soft tap water in-
stead. Do not use hard water or salt water
since they are harmful to the engine. If wa-
ter has been used instead of coolant, re-
place it with coolant as soon as possible,
otherwise the cooling system will not be
protected against frost and corrosion. If
water has been added to the coolant, have
a Yamaha dealer check the antifreeze con-
1. Maximum level mark
2. Minimum level mark
1
2
1. Coolant reservoir cap
1
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12. Pour the recommended coolant into the radi-
ator until it is full, and then install the radiator
cap.
13. Start the engine, let it idle for several minutes, and then turn it off.
TIPWhile the engine is idling, check the cooling sys-
tem for leaks. 14. When the engine is cool, remove the radiatorcap to check the coolant level in the radiator.
If it is low, add sufficient coolant until it reach-
es the top of the radiator, and then install the
radiator cap.
15. Install the panels and the front carrier.EBU37113Cleaning the air filterThe main air filter element and sub air filter ele-
ment should be cleaned every 20–40 hours of en-
gine operation. When servicing the air filter
elements, check the air filter case inlet for obstruc-
tions. Check the air filter case rubber joint to the
throttle body and the rubber joint manifold fittings
for an air-tight seal. Tighten all fittings securely to
avoid the possibility of unfiltered air entering the
engine.
TIP Replace the air filter elements if damaged.
 Service the air filter more frequently if you often
ride in wet or dusty areas.
 There is a check hose at the bottom of the air fil-
ter case. If dust or water collects in this hose,
empty the hose and clean the air filter case and
air filter elements. 1. Park the ATV on a level surface.
2. Remove the seat. (See page 4-18.)
3. Remove the air filter case cover by unhooking
the air filter case cover holders.1. Air filter case check hose
1
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5. Pull off the lock plate from the main air filter
assembly, and then remove the air filter ele-
ment (sponge material) from the frame.
6. Wash the air filter elements gently but thor- oughly with YAMALUBE Air Filter Cleaner, or
a dedicated parts cleaning solvent.
WARNING! Always use parts cleaning sol- vent. Never use low-flash-point solvents
or gasoline because the engine could
catch fire or explode.
[EWB01943]
7. Squeeze out the excess moisture, and let dry. NOTICE: Do not twist the sponge material
when squeezing it.
[ECB00442]
8. Check the air filter elements (sponge material) for damage, replace if necessary.
9. Apply YAMALUBE Foam Air Filter Oil (or equivalent) to the air filter elements.TIPThe sponge material should be wet but not drip-
ping. 10. Install the sub air filter element.
11. Install the main air filter element onto its frame, then the lock plate, and then install the
main air filter assembly.
1. Frame
2. Air filter element (sponge material)
3. Lock plate
1
2
3
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3. Tap the tailpipe lightly, and then use a wire
brush to remove any carbon deposits from
the spark arrester portion of the tailpipe and
inside of the tailpipe housing.
4. Check the gasket for damage. Replace if nec- essary.
5. Install the gasket onto the tailpipe, then insert the tailpipe into the muffler and align the bolt
holes.
6. Install the bolts and tighten to the specified torque.
EBU23921V-belt cooling duct check hoseIf dust or water collects in the V-belt cooling duct
check hose, remove the hose and clean it.
EBU23932V-belt case drain plugAfter riding in water deep enough to allow it to en-
ter the V-belt case, remove the V-belt case drain
plug to drain the water from the case.TIPIf water drains from the V-belt case after removing
the plug, have a Yamaha dealer check the ATV as
the water may affect other engine parts.
Tightening torque:Tailpipe bolt:10 N·m (1.0 kgf·m, 7.4 lb·ft)
1. V-belt cooling duct check hose (left front side of ATV)
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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