lock YAMAHA KODIAK 450 2021 Owner's Manual

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EBU38831Changing 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 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 quantityW 0.35 L (0.37 US qt, 0.31 Imp.qtF1. Differential gear oil filler bolt
2. GasketRecommended differential gear oil:Yamaha Friction Modified Shaft Drive Gear Oil or SAE 80 API GL-4 Hypoid gear oil
Oil quantityW 0.23 L (0.24 US qt, 0.20 Imp.qtF
2
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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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
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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.
EBU24062Valve 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 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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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.
EBU24284Changing the brake fluidHave a Yamaha dealer change the brake fluid at
the intervals specified in the periodic maintenance
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
1
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Adjusting the brake lever free play
Measure the brake lever free play and adjust if
necessary.
1. Loosen the locknut at the brake lever. 2. To increase the brake lever free play, turn the
brake lever free play adjusting bolt in direction
(a). To decrease the brake lever free play, turn
the adjusting bolt in direction (b). NOTICE:
Distance A must not measure more than
12.7 mm (0.50 in). If distance A exceeds
12.7 mm (0.50 in), the specified brake lever
free play cannot be obtained, therefore
proceed with the following steps.
[ECB01143]
1. Brake lever free playBrake lever free play: 10.0 mm (0.39 in)
1
1. Locknut
2. Distance A
3. Brake lever free play adjusting bolt
12
3
(a)
(b)
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TIPIf the specified brake lever free play could be ob-
tained as described above, skip steps 3-8. 3. Fully turn the adjusting bolt in direction (a) toloosen the brake cable.
4. Slide the rubber cover back.
5. Loosen the brake cable adjuster locknut.
6. To increase the brake lever free play, turn the brake lever free play adjusting nut in direction
(a). To decrease the brake lever free play, turn the adjusting nut in direction (b).
NOTICE:
Make sure that distance B measures 22
mm (0.87 in) or less. If distance B reaches
22 mm (0.87 in), adjust the brake lever free
play at the brake lever again. If distance A
exceeds 12.7 mm (0.50 in), have a Yamaha
dealer check the vehicle.
[ECB01153]
7. Tighten the brake cable adjuster locknut.
8. Slide the rubber cover to its original position.
9. Tighten the locknut at the brake lever.
Adjusting the brake pedal height
1. Brake cable adjuster locknut
2. Brake lever free play adjusting nut
3. Rubber cover
4. Distance B
(a)
(b)3
2
1
4
1. Brake pedal height
2. Brake pedal
3. Footboard bracket1
2
3
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Measure the brake pedal height and adjust if nec-
essary.
1. Remove the footboard by removing the quick fasteners, bolts, and nuts.
2. Loosen the locknut. 3. Turn the adjusting bolt in or out until the brake
pedal height is within the specified limits.
4. Tighten the locknut.
5. Install the footboard by installing the quick fasteners, bolts, and nuts, and then tighten
the bolts to the specified torques.
Brake pedal height:
80.0 mm (3.15 in)
1. Footboard
2. Quick fastener
3. Bolt and nut
4. Bolt
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3
312
1. Locknut
2. Adjusting boltTightening torque:Locknut:7 N

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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.
EBU24232Axle bootsThe axle boots must be checked for damage at
the intervals specified in the periodic maintenance
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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EBU34223Replacing a headlight bulbIf a headlight bulb burns out, replace it with the
specified bulb as follows.
Left and right headlight bulbs1. Remove the cover at the rear of the headlight by pulling it off.
2. Remove the bulb cover by pulling it off. 3. Remove the socket by pushing it in and turn-
ing it counterclockwise.1. Cover at the rear of the headlight
1
1. Bulb cover
1. Socket
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