differential YAMAHA KODIAK 450 2022 User Guide

5-10
5
EBU39181Winch switch “OUT/IN”
This switch is used when operating the winch
(page 5-22). Read this manual and the Winch
Owner’s Manual completely before operating the
winch switch.EBU18192Override switch “OVERRIDE” (differential gear
lock models)
Top speed is normally limited when operating in
differential gear lock. If conditions require more
engine power when riding forward, push and hold
this switch to override the differential gear lock
speed limiting function. (See page 5-11.) Releas-
ing the switch restores the speed limiting function.
While the override switch is pushed, the segments
of the speedometer digits will appear as shown in
the figure.
TIPIf the digits of the speedometer appear as shown
when the switch is NOT being pushed, this could
indicate a malfunction in the electrical system. In
this case, take the ATV to a Yamaha dealer at the
first opportunity.
WARNING
EWB00151Always ride at a slow speed when the ATV is in
four-wheel-drive differential gear lock, and al-
low extra time and distance for maneuvers.
All wheels turn at the same speed when the dif-
ferential is locked, so it takes more effort to
turn the ATV. The effort needed to turn increas-
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5-11
5
es with the riding speed. You may lose control
and have an accident if you cannot make a
sharp enough turn for the speed you are trav-
eling.
EBU2660AOn-Command drive switch “2WD/4WD”
Stop the ATV and push this switch to change from
two-wheel drive to four-wheel drive or vice versa.
Select the appropriate drive according to the ter-
rain and riding conditions.

“2WD” (two-wheel drive): power is supplied to
the rear wheels only, giving a smooth ride and
fuel economy.
 “4WD” (four-wheel drive): power is supplied to
the front and rear wheels, giving increased trac-
tion.
WARNING
EWB00164Always stop the ATV before changing from
two-wheel drive to four-wheel drive and vice
versa. The ATV handles differently in two-
wheel drive than in four-wheel drive in some
circumstances. Changing from two-wheel
drive to four-wheel drive or vice versa while
moving may cause the ATV to unexpectedly handle differently. This could distract the oper-
ator and increase the risk of losing control and
of causing an accident.
EBU38760On-Command drive switch “4WD/LOCK” (dif-
ferential gear lock models)
Stop the ATV and push this switch to change from
standard four-wheel drive to four-wheel drive with
the differential locked. Select the appropriate
switch position according to the terrain and the
conditions.

“4WD” (four-wheel drive): power is supplied to
the front and rear wheels, with the front differen-
tial unlocked.
 “LOCK” (four-wheel drive with the differential
gear locked): power is supplied to the front and
rear wheels and the differential gear is locked.
Unlike in four-wheel drive, all wheels turn at the
same speed, giving maximum traction.
WARNING
EWB00132Always stop the ATV before changing from
four-wheel drive to four-wheel-drive differen-
tial gear lock or vice versa.
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5-12
5The ATV handles differently in four-wheel drive
than in differential gear lock in some circum-
stances. Changing from four-wheel drive to
differential gear lock or vice versa while mov-
ing may cause the ATV to handle differently un-
expectedly. This could distract the operator
and increase the risk of losing control and
causing an accident.
To access the “4WD/LOCK” switch, set the
“2WD/4WD” switch to “4WD”, and then move the
drive switch lock lever to the right.
TIP
When the switch is set to “LOCK”, the differen-
tial gear lock indicator light will flash until the dif-
ferential gear is completely locked or unlocked.
 When the indicator light is flashing, turning the
handlebar back and forth will help the differen-
tial gear lock to engage or disengage.
 Riding before the differential gear is properly en-
gaged or disengaged (e.g., when the indicator
light is flashing) will cause the vehicle speed to
be limited until the differential gear is completely
engaged or disengaged.
 When the ATV is in four-wheel-drive differential
gear lock, the maximum traveling speed is limit-
ed to 35 km/h (22 mi/h). However, if conditions
require full engine power to be available, push
and hold the override switch to disable the dif-
ferential gear lock speed limiter. (See page
5-10.)
WARNING
EWB00141Always ride at a slow speed when the ATV is in
differential gear lock, and allow extra time and
distance for maneuvers.
1. On-Command drive switch “4WD/LOCK”
2. Drive switch lock lever
LOCK4WD
1
2
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6-1
6
EBU19203
PRE-OPERATION CHECKS
EBU19227Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWB00482Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equip-
ment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected
by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:
ITEMROUTINE PAGE
Fuel • Check fuel level in fuel tank,
and add recommended fuel if neces-
sary.
• Check fuel line for leakage. Correct if necessary. 5-17, 6-3
Engine oil • Check oil level in engine, and add recommended oil to specified
level if necessary.
• Check ATV for oil leakage. Correct if necessary. 6-3, 9-19
Final gear oil • Check ATV for oil leakage. Correct if necessary. 6-3, 9-24
Differential gear oil • Check ATV for oil leakage. Correct if necessary. 6-3, 9-27
Coolant • Check coolant level in reservoir, and add recommended coolant to
specified level if necessary.
• Check cooling system for leakage. Correct if necessary. 6-3, 9-29
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6-3
6
EBU38000FuelMake sure there is sufficient gasoline in the tank
before starting off. Refuel if necessary. (See page
5-17.)EBU19561Engine oilMake sure that the engine oil is at the specified
level. Add oil as necessary. (See page 9-19.)EBU19591Final gear oilMake sure that the final gear oil is at the specified
level. Add oil as necessary. (See page 9-24.)EBU19601Differential gear oilMake sure that the differential gear oil is at the
specified level. Add oil as necessary. (See page
9-27.)EBU19632CoolantMake sure that the coolant is at the specified level.
Add coolant as necessary. (See page 9-29.)
TIPThe coolant level must be checked on a cold en-
gine since the level varies with engine tempera-
ture. EBU28533Front and rear brakesBrake levers and brake pedal
Check that there is no free play in the front
brake lever. If there is free play, have a Yamaha
dealer check the brake system.
 Check for correct free play in the rear brake le-
ver and brake pedal. If the free play is incorrect,
adjust it. (See page 9-42.)
 Check operation of the levers and pedal. They
should move smoothly and there should be a
firm feeling when the brake is applied. If not,
have a Yamaha dealer check them.
Brake fluid level (front brake)
Check the brake fluid level. Add fluid if necessary.
(See page 9-40.)
Specified brake fluid:DOT 4
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9-8
9
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 15 80 160 160 320UBHT60E0.book Page 8 Wednesday, August 4, 2021 8:09 AM

9-27
9
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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9-28
91. 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 gas-
kets 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.
8. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause.
1. Differential gear oil drain bolt
2. GasketTightening torque:Differential gear oil drain bolt:10 N·m (1.0 kgf·m, 7.4 lb·ft)
12
Tightening torque:Differential gear oil filler bolt:23 N

9-38
9
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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9-39
9
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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