engine YAMAHA KODIAK 450 2020 Workshop Manual

8-36
812. Install the air filter case cover by hooking the
holders onto the cover. NOTICE: Make sure
that the air filter element is properly seated
in the air filter case. Never operate the en-
gine with the air filter element removed.
Doing so would allow unfiltered air to enter
the engine, causing rapid engine wear and
possible engine damage. Additionally, the
fuel injection system would be affected re-
sulting in poor engine performance and
possible overheating.
[ECB00763]
13. Install the seat.EBU28905Cleaning the spark arresterBe sure the exhaust pipe and muffler are cool be-
fore cleaning the spark arrester.
WARNING
EWB02342Always let the exhaust system cool prior to
touching exhaust components.
Do not start the engine with the spark arrester
removed. Sparks or exhaust particulate can
cause eye injury, burns, or start a fire. 1. Remove the tailpipe bolts.
2. Remove the tailpipe by pulling it out of the muffler, and then remove the gasket.1. Gasket
2. Spark arrester
3. Tailpipe
4. Tailpipe bolt
3
2
4
1
4
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8
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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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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8-58
82. Remove the seat. (See page 4-18.)
3. Remove the blown fuse, and then install a
new fuse of the specified amperage.
WARNING! Always use a fuse of the spec-
ified rating, and never use a substitute ob-
ject in place of the proper fuse. An
improper fuse or a substitute object can
cause damage to the electrical system,
which could lead to a fire.
[EWB02173]
4. Turn on the main switch, start the engine, andthen turn on the circuit in question.
5. If the fuse immediately blows again, have a Yamaha dealer check the vehicle.
Specified fuses:
Main fuse:40.0 A
Headlight fuse: 15.0 A
Ignition fuse: 10.0 A
Four-wheel-drive motor fuse: 10.0 A (B5R1/B5R2/B5R3)
3.0 A (BJ5H/BB5R/BJ5D/BJ5E/BB5M)
Signaling system fuse: 10.0 A
Radiator fan motor fuse: 20.0 A
Auxiliary DC jack fuse: 10.0 A
Fuel injection system fuse: 10.0 A
EPS fuse: 40.0 A (YFM450FWBD, YFM45KPAL)
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8
EBU27696Troubleshooting chartsStarting problems or poor engine performance
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.There is no fuel.
Check the battery.
Supply fuel.
The engine does not start.
Check the battery.
Operate the electric starter.4. Compression
There is compression.
There is no compression.
The engine does not start.
Have a Yamaha dealer check the ATV.
Remove the spark plug
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug. Have a Yamaha dealer check the ATV.
The engine does not start.
Check the compression.
DryWet
Operate the electric starter.
Have a Yamaha dealer check the ATV.
The engine does not start.
Check the ignition.
Operate the electric starter.2. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and have a Yamaha dealer charge
the battery if necessary.
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8
Engine overheating
WARNING
EWB02291Wait 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. TIP
Tap water can be used in an emergency. Change to the recommended coolant as soon as possible.
 The engine will tend to overheat if the radiator is caked with mud, or if the ATV is overloaded. Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer check
and repair the cooling system.Add coolant. (See TIP.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
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9
EBU25861
CLEANING AND STORAGE
EBU25882CleaningFrequent, thorough cleaning of your ATV will not
only enhance its appearance but will improve its
general performance and extend the useful life of
many components.1. Before cleaning the ATV: a. Block off the end of the exhaust pipe toprevent water entry. A plastic bag and
strong rubber band may be used.
b. Make sure the spark plug and all filler caps are properly installed.
2. If the engine case is excessively greasy, apply degreaser with a paint brush. Do not apply
degreaser to the wheel axles.
3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the
job. WARNING! Wet brakes may have re-
duced stopping ability, increasing the
chance of an accident. Test the brakes af-
ter washing. Apply the brakes several
times at slow speeds to let friction dry out
the linings.
[EWB02312]
NOTICE: Excessive wa-
ter pressure may cause water seepage and deterioration of wheel bearings,
brakes, transmission seals and electrical
devices. Many expensive repair bills have
resulted from improper high-pressure de-
tergent applications such as those avail-
able in coin-operated car washers.
[ECB00712]
4. Once most of the dirt has been hosed off,
wash all surfaces with warm water and mild,
detergent-type soap. An old toothbrush or
bottle brush is handy for hard-to-reach plac-
es.
5. Rinse the ATV off immediately with clean wa- ter and dry all surfaces with a chamois, clean
towel or soft absorbing cloth.
6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.
7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid
combination cleaner-waxes. Many contain
abrasives which may mar the paint or protec-
tive finish. When finished cleaning, start the
engine and let it idle for several minutes.
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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

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Carbon dioxide (CO2) level:Carbon dioxide (CO2) emissions (2016/1628):1015.0 g/kWh (YFM450FWB, YFM450FWBD)Engine:Combustion cycle:4-stroke
Cooling system: Liquid cooled
Valve train:
SOHC
Number of cylinders: Single cylinder
Displacement: 421 cm³
Bore × stroke:
84.5 × 75.0 mm (3.33 × 2.95 in)
Compression ratio: 10.0 : 1
Starting system: Electric starter
Lubrication system:
Wet sumpEngine oil:Recommended brand:
SAE viscosity grades:5W-30, 10W-30, 10W-40, 15W-40, 20W-40, 20W-50 Recommended engine oil grade:
API service SG type or higher, JASO standard MA
Quantity: Oil change: 2.30 L (2.43 US qt, 2.02 Imp.qt)
With oil filter removal: 2.40 L (2.54 US qt, 2.11 Imp.qt)
Final gear oil:Type:Yamaha Friction Modified Shaft Drive Gear Oil
Quantity: 0.38 L (0.40 US qt, 0.33 Imp.qt)0 10 30 50 70 90 110 130 F
–20 –10 0 10 20 30 40 50 CSAE 5W-30
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-40SAE 20W-50
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10
Shock absorber:Gas-hydraulic damper
Wheel travel: 171 mm (6.8 in)Rear suspension:Type:Double wishbone
Spring: Coil spring
Shock absorber:
Gas-hydraulic damper
Wheel travel: 189 mm (7.4 in)Electrical system:System voltage:
12 V
Ignition system: TCI
Charging system: AC magnetoBattery:Model:YTX20L-BS
Voltage, capacity: 12 V, 18.0 AhLights:Headlight:T19L, 30.0 W/30.0 W
Handlebar-mounted light: T15H, 35.0 W/36.5 W (YFM450FWBD, YFM45KPAL) Brake/tail light:
21.0 W/5.0 W
Meter lighting: LED
Neutral indicator light:
LED
Reverse indicator light: LED
Coolant temperature warning light: LED
Park indicator light:
LED
Four-wheel-drive indicator light: LED
Engine trouble warning light: LED
Differential gear lock indicator light:
LED (B5R1/B5R2/B5R3)
EPS warning light: LED (YFM450FWBD, YFM45KPAL)
Fuses:Main fuse:
40.0 A
Headlight fuse: 15.0 A
Signaling system fuse: 10.0 A
Ignition fuse:
10.0 A
Auxiliary DC jack fuse: 10.0 A
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