engine YAMAHA KODIAK 700 2021 Repair Manual

9-67
9Engine 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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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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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)UB5K63E0.book Page 2 Monday, October 12, 2020 4:59 PM

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Engine:Combustion cycle:4-stroke
Cooling system:
Liquid cooled
Valve train: SOHC
Number of cylinders: Single cylinder
Displacement:
686 cm³
Bore × stroke:
102.0 × 84.0 mm (4.02 × 3.31 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:2.00 L (2.11 US qt, 1.76 Imp.qt)
With oil filter removal: 2.10 L (2.22 US qt, 1.85 Imp.qt)
Final gear oil:Type:Yamaha Friction Modified Plus Shaft Drive Oil (Part No.:
ACC-SHAFT-PL-32)
Quantity: 0.52 L (0.55 US qt, 0.46 Imp.qt)Differential gear oil:Type:
Yamaha Friction Modified Plus Shaft Drive Oil (Part No.: ACC-SHAFT-PL-32) or SAE 80 API GL-4 Hypoid gear oil0 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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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 (YFM700FWBD)
Brake/tail light:
21.0 W/5.0 W
Meter lighting: LED (YFM700FWBD)
Neutral indicator light: LED
High beam indicator light:
LED (YFM700FWBD)
Fuel level warning light: LED (YFM700FWB)
Reverse indicator light: LED
Coolant temperature warning light:
LED
Park indicator light: LED
Four-wheel-drive indicator light: 1.7 W (YFM700FWB) Engine trouble warning light:
LED
High-range indicator light: LED (YFM700FWBD)
Low-range indicator light:
LED (YFM700FWBD)
Differential gear lock indicator light: LED (YFM700FWBD)
EPS warning light: LED (YFM700FWBD)
Battery voltage warning light:
LED (YFM700FWBD)
Fuses:Main fuse:40.0 A
Headlight fuse:
10.0 A (YFM700FWB)
15.0 A (YFM700FWBD)
Signaling system fuse:
10.0 A
Ignition fuse: 10.0 A
Auxiliary DC jack fuse: 10.0 A
Fuel injection system fuse:
15.0 A
Four-wheel-drive motor fuse: 10.0 A (YFM700FWBD)
Radiator fan motor fuse: 20.0 A
EPS fuse:
40.0 A (YFM700FWBD)
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11
EBU30403Noise and vibration levels statement (for Eu-
rope)
The figures quoted are emission levels and are not
necessarily safe working levels. Whilst there is a
correlation between the emission and exposure
levels, this cannot be used reliably to determine
whether or not further precautions are required.
Factors that influence the actual level of exposure
of work-force include the characteristics of the
work room, the other sources of noise, etc. i.e. the
number of machines and other adjacent process-
es, and the length of time for which an operator is
exposed to the noise. Also the permissible expo-
sure level can vary from country. This information,
however, will enable the user of the machine to
make a better evaluation of the hazard and risk.EBU38670CO2 emissions levels statement (for Europe)
This CO2 measurement results from testing over a
fixed test cycle under laboratory conditions a(n)
(parent) engine representative of the engine type(engine family) and shall not imply or express any
guarantee of the performance of a particular en-
gine.UB5K63E0.book Page 6 Monday, October 12, 2020 4:59 PM

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EBU26004
CONSUMER INFORMATION
EBU38690Emissions Certification label (for Eu-
rope)This engine conforms to the Non-Road Mobile
Machinery (NRMM) regulation(s) in effect at the
time of manufacture.
The NRMM regulation limits gaseous and particu-
late pollution emissions for internal combustion
engines of non-road mobile machinery.Your Yamaha engine was designed and tested to
give an optimal blend of performance without ex-
cessive emissions. Therefore, do not attempt to
alter the engine specifications or tamper with the
intake, engine, or exhaust systems.
NOTICEECB03790Tampering with the engine or emissions con-
trol system will void the European Union type-
approval of this engine.
1. Emissions Certification label
1
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INDEX
AAccessories and loading ................................................ 7-5
Accessories, DC jack ................................................... 5-30
Air filter element, cleaning ........................................... 9-36
Axle boots .................................................................... 9-47BBattery ......................................................................... 9-53
Battery voltage warning light ......................................... 5-3
Brake fluid, changing ................................................... 9-44
Brake fluid level, checking ........................................... 9-43
Brake lever free play, checking the front ..................... 9-44
Brake lever, front ......................................................... 5-19
Brake levers, checking and lubricating ........................ 9-49
Brake light switches ..................................................... 9-48
Brake pads and friction plates, checking .................... 9-42
Brake pedal and rear brake lever ................................. 5-20
Brake pedal, checking and lubricating ........................ 9-50
Brakes .......................................................................... 9-41
Brakes, front and rear .................................................... 6-3
Brake/tail light bulb, replacing ..................................... 9-63CCables, checking and lubricating ................................ 9-48
Carrier, front ................................................................. 5-26
Carrier, rear .................................................................. 5-26
Chassis fasteners .......................................................... 6-7
Cleaning ....................................................................... 10-1
Coolant .................................................................6-3, 9-28
Coolant temperature warning light ................................ 5-3
DDifferential gear lock, indicators (YFM700FWBD) ......... 5-5
Differential gear oil ................................................6-3, 9-26
Drive lever 2WD/4WD (YFM700FWB) .......................... 5-17
Drive select lever ......................................................... 5-21
Drive select lever and driving in reverse ........................ 7-2EEmissions Certification label (for Europe) .................... 12-1
Engine break-in .............................................................. 7-4
Engine oil ....................................................................... 6-3
Engine oil and oil filter cartridge .................................. 9-19
Engine stop switch ...................................................... 5-13
Engine trouble warning light .......................................... 5-4
EPS warning light (YFM700FWBD) ................................ 5-4FFinal gear oil ......................................................... 6-3, 9-24
Four-wheel drive icon (YFM700FWBD) ......................... 5-5
Four-wheel drive indicator light (YFM700FWB) ............. 5-5
Four-wheel drive switch (On-Command 4WD) (YFM700FWBD) ......................................................... 5-15
Fuel ....................................................................... 5-22, 6-3
Fuel level warning light (YFM700FWB) .......................... 5-4
Fuel tank cap ............................................................... 5-21
Fuses, replacing .......................................................... 9-56HHandlebar switches ..................................................... 5-12
Headlight beam, adjusting ........................................... 9-62
Headlight bulb, replacing ............................................. 9-59
High beam indicator light ............................................... 5-3
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High-range indicator light (YFM700FWBD) .................... 5-2
Horn switch .................................................................. 5-13IIdentification numbers ................................................... 1-1
Indicator lights and warning lights ................................. 5-1
Instruments, lights and switches ................................... 6-7LLabel locations ............................................................... 2-1
Light switch .................................................................. 5-13
Low-range indicator light (YFM700FWBD) .................... 5-2MMain switch .................................................................... 5-1
Maintenance chart, emission control system ................ 9-3
Maintenance chart, general maintenance and lubrication .................................................................... 9-5
Model label ..................................................................... 1-1
Multi-function display .....................................................5-6NNeutral indicator light .....................................................5-2OOn-Command drive switch “4WD/LOCK”
(YFM700FWBD) ......................................................... 5-15
Override switch (YFM700FWBD) ................................. 5-14
Owner’s Manuals and Tool Kit ....................................... 9-2PPanels, removing and installing ..................................... 9-9
Park indicator light ......................................................... 5-2
Parking ........................................................................... 7-4
Parking on a slope ......................................................... 7-5
Part locations ................................................................. 4-1
RRear brake, adjusting the lever, pedal free play .......... 9-44
Rear knuckle pivots, lubricating ................................... 9-51
Reverse indicator light ................................................... 5-2
Riding your ATV ............................................................. 8-1SSafety information .......................................................... 3-1
Seat .............................................................................. 5-24
Shock absorber assemblies, adjusting the front and
rear (YFM700FWBD) .................................................. 5-26
Spark arrester, cleaning ............................................... 9-39
Spark plug, checking ................................................... 9-17
Specifications .............................................................. 11-1
Speed limiter ................................................................ 5-19
Stabilizer bushes, checking ......................................... 9-51
Starting the engine ......................................................... 7-1
Start switch .................................................................. 5-13
Steering shaft, lubricating ............................................ 9-52
Storage ........................................................................ 10-2
Storage compartment .................................................. 5-25TThrottle lever ........................................................ 5-18, 6-4
Throttle lever free play, adjusting ................................. 9-41
Tires ............................................................................... 6-4
Trailer hitch .................................................................. 5-29
Troubleshooting ........................................................... 9-65
Troubleshooting charts ................................................ 9-66VValve clearance ............................................................ 9-41
V-belt case drain plug .................................................. 9-40
Vehicle identification number ......................................... 1-1
UB5K63E0.book Page 2 Monday, October 12, 2020 4:59 PM