maintenance YAMAHA KODIAK 450 2020 Owner's Manual

8-29
8
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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8
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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8
TIPStraighten the handlebars for an accurate reading. NOTICEECB01161Brake fluid may damage painted surfaces or
plastic parts. Always clean up spilled fluid im-
mediately.
As the brake pads wear, it is normal for the brake
fluid level to gradually go down. A low brake fluid
level may indicate worn brake pads or brake sys-
tem leakage. Therefore, be sure to check the
brake pads for wear and the brake system for
leakage. If the brake fluid level suddenly goes
down, have a Yamaha dealer check the brake sys-
tem before further riding.
WARNING
EWB02721Improper maintenance can result in loss of
braking ability. Observe these precautions:
Insufficient brake fluid may allow air to enter
the brake system, reducing braking perfor-
mance.
 Clean the filler cap before removing. Use
only DOT 4 brake fluid from a sealed contain-
er.
 Use only the specified brake fluid; otherwise,
the rubber seals may deteriorate, causing
leakage.
 Refill with the same type of brake fluid. Add-
ing a brake fluid other than DOT 4 may result
in a harmful chemical reaction.
1. Minimum level markSpecified brake fluid:
DOT 4
1
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8
Be careful that water does not enter the
brake fluid reservoir when refilling. Water will
significantly lower the boiling point of the flu-
id and may result in vapor lock.
EBU24283Changing the brake fluidHave a Yamaha dealer change the brake fluid at
the intervals specified in the periodic maintenance
and lubrication chart. In addition, have the oil seals
of the brake master cylinder and calipers as well
as the brake hoses replaced at the intervals listed
below or whenever they are damaged or leaking.
Oil seals: Replace every two years.
 Brake hoses: Replace every four years.
EBU24396Checking the front brake lever free
playThere should be no free play at the brake lever
end. If there is free play, have a Yamaha dealer in-
spect the brake system.EBU30348Adjusting the rear brake lever and
brake pedalThe rear brake lever free play, brake pedal free
play, and the brake pedal height must be checked
and adjusted at the intervals specified in the peri-
odic maintenance chart.1. No brake lever free play
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8
Adjusting the brake pedal free play
Measure the brake pedal free play and adjust if
necessary.
TIPThe brake lever free play and brake pedal height
must be adjusted before adjusting the brake pedal
free play. 1. Loosen the locknut.
2. To increase the brake pedal free play, turn the
brake pedal free play adjusting nut in direc-
tion (a). To decrease the brake pedal free
play, turn the adjusting nut in direction (b).
3. Tighten the locknut.
EBU24231Axle bootsThe axle boots must be checked for damage at
the intervals specified in the periodic maintenance
and lubrication chart. Check the axle boots for
tears or damage. If any damage is found, have
them replaced by a Yamaha dealer.
1. Brake pedal free playBrake pedal free play: 20.0 mm (0.79 in)
1
1. Brake pedal free play adjusting nut
2. Locknut
21
(a)
(b)
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8-50
8Front brake lever
Rear brake lever
EBU28872Checking and lubricating the brake
pedalThe operation of the brake pedal should be
checked before each ride, and the pedal pivot
should be lubricated if necessary.EBU24964Checking the wheel hub bearingsThe front and rear wheel hub bearings must be
checked at the intervals specified in the periodic
maintenance and lubrication chart. If there is playRecommended lubricant:
Lithium-soap-based grease
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8
in a wheel hub or if a wheel does not turn smooth-
ly, have a Yamaha dealer check the wheel hub
bearings.
EBU24974Lubricating the drive shaft universal
jointThe drive shaft universal joint must be lubricated
at the intervals specified in the periodic mainte-
nance chart.
TIPFor parts equipped with a grease nipple, use a
grease gun. EBU25023Checking the stabilizer bushesThe stabilizer bushes must be checked for cracks
or damage at the intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer replace the stabilizer bush-
es if necessary.
Recommended lubricant:
Lithium-soap-based grease1. Grease nipple
1
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8
EBU25054Lubricating the rear knuckle pivotsThe rear knuckle pivots must be lubricated at the
intervals specified in the periodic maintenance
and lubrication chart.
TIPFor parts equipped with a grease nipple, use a
grease gun. EBU25095Lubricating the steering shaftThe steering shaft must be lubricated by a
Yamaha dealer at the intervals specified in the pe- riodic maintenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease1. Grease nippleRecommended lubricant:Lithium-soap-based grease
1
1
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9
EBU27264StorageShort-term
Always store your ATV in a cool, dry place and, if
necessary, protect it against dust with a porous
cover. NOTICE: Storing the ATV in a poorly ven-
tilated room or covering it with a tarp while it is
still wet, will allow water and humidity to seep
in and cause rust. To prevent corrosion, avoid
damp cellars, stables (because of the presence
of ammonia) and areas where strong chemi-
cals are stored.
[ECB00722]
Long-term
Before storing your ATV for several months: 1. Make any necessary repairs and perform all outstanding maintenance.
2. Follow all the instructions in the Cleaning sec- tion of this chapter.
3. Fill up the fuel tank and add fuel stabilizer (Fu- el Med Rx if available), and then run the en-
gine for 5 minutes to distribute the treated
fuel. 4. Perform the following steps to protect the en-
gine from internal corrosion.a. Remove the spark plug cap and spark plug.
b. Pour a teaspoonful of engine oil into the spark plug bore.
c. Install the spark plug cap onto the spark plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times with the starter. (This will coat the cylinder wall
with oil.)
e. Remove the spark plug cap from the spark plug, and then install the spark plug and
the spark plug cap.
5. Lubricate all control cables and the pivoting points of all levers and pedals.
6. Put the frame on stands or blocks to raise all wheels off the ground. (Alternatively, turn the
wheels each month to prevent the tires from
degrading in one spot.)
7. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.
Specified amount:
7.5 ml per liter of fuel (1 oz per gallon)UBB562E0.book Page 2 Thursday, March 14, 2019 9:59 AM