Yamaha Kodiak 450 ATV Service Manual – YFM450FAR, 2003–2006 (P/N LIT-11616-16-01)

This Yamaha factory service manual covers the Kodiak 450 ATV, model YFM450FAR (model codes 5ND1 and 5ND5). It is the first edition from March 2002, P/N LIT-11616-16-01, with 5ND-F8197-10 also printed on the cover.

Searchable PDF and Wiring Diagram

Search and zoom: The PDF has searchable text and bookmarks for the chapters and full wiring diagram. The Return to Index bookmark points to a separate file outside this download. Zoom in to read small connector labels and wire-color codes in the full diagram and individual circuit diagrams.

The ZIP download contains one printable PDF. Its 373 pages include 16 opening pages with the front cover and contents, the full wiring diagram, and the back cover.

Engine, 4WD, and Electrical Service

These are selected workshop topics. The maintenance chapter also explains how to service the air filter and clean the spark arrester.

• Engine repair: Step-by-step engine removal and installation, with service procedures for the cylinder head, valve train, cylinder and piston, crankcase, crankshaft, oil pump, recoil starter, and A.C. magneto.

• V-belt drive and transmission: Teardown and inspection of the primary and secondary sheaves, V-belt, wet centrifugal clutch, internal transmission, and park mechanism.

• 4WD and final drive: Front constant-velocity joint service, gear-motor and differential operation checks, gear lash measurement, and rear axle, final drive, and drive shaft repair.

• Cooling and carburetion: Radiator and cap testing, thermostat inspection, water pump mechanical-seal service, and Mikuni BSR33 carburetor disassembly and adjustment.

• Brakes, steering, and suspension: Front and rear master cylinder and caliper repair, hydraulic brake bleeding, and service of the steering stem, tie rods, steering knuckles, front arms, shock absorbers, and swingarm.

• Electrical troubleshooting: Separate circuit diagrams and component tests for D.C. CDI ignition, electric starting, charging, lighting, signal, cooling-fan, and 2WD/4WD selecting systems.

Yamaha wrote this manual primarily for its dealer mechanics and assumes a working knowledge of mechanical repair.

Maintenance, Torque Tables, and Assembly Drawings

The periodic maintenance chapter covers valve clearance, idle and throttle adjustments, ignition timing, and compression checks. It also explains engine oil and coolant service, V-belt inspection, select-lever cable and shift-rod adjustment, final and differential gear oil service, toe-in, battery and fuse checks, and headlight aiming.

Exploded views pair part names and quantities with service notes, lubricant symbols, replacement marks, and tightening references. This keeps component orientation and assembly notes together during teardown and reassembly. Factory tables provide torque specs, fluid capacities, lubricant grades, clearances, and wear limits. The Coolant Flow Diagrams, Oil Flow Diagrams, and cable-routing drawings show where fluids, hoses, and cables run.

Differential and Final-Drive Setup

The 2WD, 4WD, and Diff-Lock drawings show how the gear motor changes front differential engagement. The drive train chapter gives separate gear lash checks for the middle gear, front differential, and rear final drive, with shim selection and a differential preload check. Yamaha specifies that the internal front differential gear assembly stays together as a factory-assembled unit during service.

The middle driven-shaft and final-drive pinion bearing retainers have left-hand threads. Forcing either in the usual loosening direction can damage the threads. If the front differential gear motor and shift-fork sliding gear are misindexed during assembly, the indicator can disagree with the actual drive mode and prevent 2WD or Diff-Lock from engaging.

Brake and Electrical Checks

The chassis chapter shows how to inspect wheels, hubs, and brake discs. Brake assembly notes identify hose routing and specify fresh DOT 4 fluid for internal components. The manual also flags hazards from hot, pressurized coolant and live-circuit testing.

Switch-continuity tables, bulb and socket checks, and voltage, resistance, and current specs help isolate faults before parts are replaced. For a 4WD selection fault, the electrical chapter separates relay and switch checks from gear-motor and wiring tests. The YFM450FAR Wiring Diagram shows connector layouts and wire-color codes. A separate troubleshooting chapter groups likely causes for hard starting, poor idle or high-speed performance, driveline noise, shifting or clutch faults, overheating, braking problems, unstable handling, and lighting faults.

Special Tools for Teardown and Testing

Tool callouts identify the crankcase separating tool YU-01135-A / 90890-01135, sheave holder YU-01880 / 90890-01701, and sheave spring compressor YM-04134 / 90890-04134. The final-drive gear lash procedure lists YM-01475 / 90890-01475, and electrical tests reference the pocket tester YU-03112 / 90890-03112.

Carburetor and Charging Specs at a Glance

For the Mikuni BSR33, Yamaha specifies a 13 mm float height with the carburetor inverted, the bowl gasket removed, and the float arm resting lightly on the needle valve. The fuel-level check specifies 4.0–5.0 mm above the float chamber mating surface with the ATV level.

For charging diagnosis, the manual specifies 0.41–0.61 Ω at 68 °F (20 °C) for the A.C. magneto charging coil. The test chart uses that reading to separate a stator fault from wiring or regulator checks.