warning YAMAHA KODIAK 700 2016 Workshop Manual

8-39
8
6. Wash the sponge material gently but thor-
oughly in solvent. WARNING! Always use
parts cleaning solvent to clean the sponge
material. Never use low-flash-point sol-
vents or gasoline to clean the sponge ma-
terial because the engine could catch fire
or explode.
[EWB01942]
7. Squeeze the excess solvent out of the sponge material and let it dry. NOTICE: Do
not twist the sponge material when
squeezing it.
[ECB00442]
8. Check the sponge material and replace it if damaged.
9. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material.TIPThe sponge material should be wet but not drip-
ping. 10. Pull the sponge material over the air filter ele- ment frame, and then install the lock plate.
11. Insert the air filter element into the air filter case, and then install the air filter case cover
by hooking the holders onto the air filter case.
NOTICE: Make sure that the air filter ele-
ment is properly seated in the air filter
1. Air filter element frame
2. Sponge material
3. Air filter element lock plate
3
2
1
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8-41
8
4. Check the gasket for damage, and replace it
if necessary.
5. Make sure the gasket is properly positioned, then insert the tailpipe into the muffler and
align the bolt holes.
6. Install the bolts and tighten them to the spec- ified torque.
WARNING
EWB02341Do not start the engine when cleaning the
spark arrester, otherwise it could cause injury
to the eyes, burns, carbon monoxide poison-
ing, possibly leading to death, and start a fire.
Always let the exhaust system cool prior to
touching exhaust components. 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.
1. Gasket
2. Spark arrester
3. TailpipeTightening torque:Tailpipe bolt:10 Nm (1.0 m·kgf, 7.2 ft·lbf)
3
2
1
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8-43
8
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU24072Adjusting the drive select lever safety
system cableThe drive select lever safety system cable stretch-
es with use, which can result in improper function.
Therefore, the safety system cable should be
checked and adjusted by a Yamaha dealer at the
intervals specified in the periodic maintenance
and lubrication 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.
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. EBUM0191Front brake pads
Each brake pad is provided with a wear indicator
groove, which allows you to check the brake pad
wear without having to disassemble the brake. To
check the brake pad wear, check the wear indica-
tor groove. If a brake pad has worn to the point
that the wear indicator groove has almost disap-
peared, have a Yamaha dealer replace the brake
pads as a set.
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8
TIPThe wheels need to be removed to check the
brake pads. (See page 8-64.) 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.
EBU29843Checking the brake fluid levelBefore riding, check that the brake fluid is above
the minimum level mark. Check the brake fluid lev-
el with the top of the reservoir level. Replenish the
brake fluid if necessary.
WARNING
EWB02721Improper maintenance can result in loss of
braking ability. Observe these precautions:
1. Wear indicator groove
1. Minimum level markSpecified brake fluid:DOT 4
2WD
4WD
1
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8
WARNING
EWB02582Inspect cables frequently and replace if
damaged. Corrosion can result when the ca-
ble sheaths become damaged, and cables
can also become frayed or kinked, which
could restrict the operation of controls and
lead to an accident or injury.
 Always make sure all control cables work
smoothly before you begin riding in cold
weather. If the control cables are frozen or
do not work smoothly, you could be unable
to control the ATV, which could lead to an
accident or collision. EBU28712Checking and lubricating the front and
rear brake leversThe operation of the front and rear brake levers
should be checked before each ride, and the lever
pivots should be lubricated if necessary. Front brake lever
Recommended lubricants:
Front brake lever:Silicone grease
Rear brake lever: Lithium-soap-based greaseUB1660E0.book Page 50 Thursday, February 26, 2015 4:01 PM

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8
EBU2904DBatteryThe battery is located under panel A. (See page
8-10.)
This model is equipped with a VRLA (Valve Regu-
lated Lead Acid) battery. There is no need to
check the electrolyte or to add distilled water.
However, the battery lead connections need to be
checked and, if necessary, tightened.
WARNING
EWB02161Battery electrolyte is poisonous and danger-
ous, as it contains sulfuric acid, which can
cause severe burns. Avoid contact with skin,
eyes or clothing. Always shield your eyes when
working near batteries.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg
or vegetable oil. Call a physician immediately.
EYES: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes or other sources of
ignition away. Ventilate when charging or using
in an enclosed space.KEEP OUT OF REACH OF CHILDREN.
NOTICEECB00621Never attempt to remove the battery cell seals,
as this would permanently damage the battery. To remove the battery
1. Remove panel A. (See page 8-10.)
2. Remove the front carrier by removing the bolts.1. Front carrier
2. Carrier bolt (upper)
1
2
2
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8-58
8The main fuse, the fuel injection system fuse, the
EPS fuse, and the fuse box are located under pan-
el A. (See page 8-10.)
If a fuse is blown, replace it as follows.1. Turn the key to “ ” (off) and turn off all elec- trical circuits.
NOTICEECB00641To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse. 2. Remove the blown fuse, and then install anew 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]
1. Headlight fuse
2. Signaling system fuse
3. Radiator fan motor fuse
4. Ignition fuse
5. Four-wheel-drive motor fuse (YFM70KPSG)
6. Auxiliary DC jack fuse
7. Spare fuse
8. Spare fuse (YFM70KPXG / YFM70KPHG / YFM70KPSG)
123456
87
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8
EBU25741TroubleshootingAlthough Yamaha ATVs receive a thorough in-
spection before shipment from the factory, trouble
may occur during operation. Any problem in the
fuel, compression, or ignition systems, for exam-
ple, can cause poor starting and loss of power.
The following troubleshooting charts represent
quick and easy procedures for checking these vi-
tal systems yourself. However, should your ATV
require any repair, take it to a Yamaha dealer,
whose skilled technicians have the necessary
tools, experience, and know-how to service the
ATV properly.
Use only genuine Yamaha replacement parts. Im-
itation parts may look like Yamaha parts, but they
are often inferior, have a shorter service life and
can lead to expensive repair bills.
WARNING
EWB02281Do not smoke when checking the fuel system.
Fuel can ignite or explode, causing severe inju-
ry or property damage. Make sure there are no
open flames or sparks in the area, including pi-
lot lights from water heaters or furnaces. UB1660E0.book Page 66 Thursday, February 26, 2015 4:01 PM

8-68
8Engine 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. TIPIf coolant is not available, tap water can be temporarily used instead, provided that it is changed to the
recommended coolant as soon as possible. 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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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.
UB1660E0.book Page 1 Thursday, February 26, 2015 4:01 PM