2003-2004 Yamaha Kodiak 400, YFM400 manual

Table of Contents

1. Machine Identification

   • Vehicle Identification Number
   • Model Label
   • 1-1

2. Important Information

   • Preparation for Removal Procedures
   • Replacement Parts
   • Gaskets, Oil Seals, and O-Rings
   • Lock Washers/Plates and Cotter Pins
   • Bearings and Oil Seals
   • Circlips
   • 1-2

3. Checking of Connections

   • 1-4

4. Special Tools

   • 1-5

Specifications

1. General Specifications

   • 2-1

2. Maintenance Specifications

   • Engine
   • Chassis
   • Electrical
   • 2-4

3. General Torque Specifications

   • 2-20

4. Lubrication Points and Lubricant Types

   • Engine
   • 2-21

5. Coolant Flow Diagrams

   • 2-22

6. Oil Flow Diagrams

   • 2-24

7. Cable Routing

   • 2-27

Periodic Checks and Adjustments

1. Introduction

   • Periodic Maintenance/Lubrication
   • 3-1

2. Seat, Carriers, Fenders, and Fuel Tank

   • Seat and Side Panels
   • Front Carrier, Front Bumper, and Front Fender
   • Rear Carrier and Rear Fender
   • Fuel Tank
   • 3-3

3. Footrest Boards

   • 3-9

4. Engine

   • Adjusting the Valve Clearance
   • Adjusting the Idling Speed
   • Adjusting the Throttle Lever Free Play
   • Adjusting the Speed Limiter
   • Adjusting the Starter Cable
   • Checking the Spark Plug
   • Checking the Ignition Timing
   • Measuring the Compression Pressure
   • Checking the Engine Oil Level
   • Changing the Engine Oil
   • Cleaning the Air Filter
   • Checking the Coolant Level
   • Changing the Coolant
   • Checking the Coolant Temperature Warning Light
   • Checking the V-Belt
   • Cleaning the Spark Arrester
   • 3-10

5. Chassis

   • Adjusting the Rear Brake
   • Checking the Front Brake Fluid Level
   • Checking the Front Brake Pads
   • Checking the Rear Brake Shoes
   • Checking the Brake Hoses
   • Bleeding the Hydraulic Brake System
   • Adjusting the Select Lever Control Cable and Shift Rod
   • Adjusting the Rear Brake Light Switch
   • Checking the Final Gear Oil Level
   • Changing the Final Gear Oil
   • Changing the Differential Gear Oil
   • Checking the Constant Velocity Joint Dust Boots
   • Checking the Steering System
   • Adjusting the Toe-In
   • Adjusting the Front Shock Absorbers
   • Adjusting the Rear Shock Absorber
   • Checking the Tires
   • Checking the Wheels
   • Checking and Lubricating the Cables
   • Lubricating the Levers, Pedal, etc.
   • 3-36

6. Electrical

   • Checking the Battery
   • Checking the Fuses
   • Adjusting the Headlight Beams
   • Changing the Headlight Bulb
   • 3-54

Engine

1. Engine Removal

   • Air Ducts, Muffler, and Exhaust Pipe
   • Select Lever Unit and Coolant Reservoir
   • Hoses and Leads
   • Engine Mounting Bolts
   • Installing the Engine
   • 4-1

2. Cylinder Head

   • Removing the Cylinder Head
   • Checking the Tappet Covers
   • Checking the Timing Chain Tensioner
   • Checking the Camshaft Sprocket
   • Checking the Cylinder Head
   • Installing the Cylinder Head
   • 4-8

3. Camshaft, Rocker Arms, and Valves

   • Removing the Camshaft and Rocker Arms
   • Removing the Valves and Valve Springs
   • Checking the Camshaft
   • Checking the Rocker Arms and Camshaft
   • Checking the Valves and Valve Springs
   • Installing the Valves and Valve Springs
   • Installing the Camshaft and Rocker Arms
   • 4-16

4. Cylinder and Piston

   • Removing the Piston
   • Checking the Timing Chain Guide
   • Checking the Cylinder and Piston
   • Checking the Piston Rings
   • Checking the Piston Pin
   • Installing the Piston
   • Installing the Cylinder
   • 4-27

5. Recoil Starter and A.C. Magneto

   • Removing the A.C. Magneto
   • Disassembling the Recoil Starter
   • Checking the A.C. Magneto
   • Checking the Starter Clutch
   • Checking the Starter Pulley
   • Checking the Recoil Starter
   • Assembling the Recoil Starter
   • Installing the A.C. Magneto
   • 4-34

6. Primary and Secondary Sheaves

   • Primary Sliding Sheave
   • Secondary Sheave
   • Removing the Primary and Secondary Sheaves
   • Disassembling the Secondary Sheave
   • Checking the Primary Sheave
   • Checking the Secondary Sheave
   • Assembling the Primary Sheave
   • Assembling the Secondary Sheave
   • Installing the Primary and Secondary Sheaves
   • 4-42

7. Clutch

   • Removing the Clutch
   • Checking the Clutch
   • Installing the Clutch
   • 4-51

8. Crankcase

   • Starter Motor, Timing Chain, and Oil Filter
   • Crankcase
   • Crankcase Bearings
   • Removing the Oil Pump Drive Gear
   • Separating the Crankcase
   • Checking the Timing Chain and Guide
   • Checking the Oil Strainer and Oil Delivery Pipe
   • Checking the Crankcase
   • Checking the Bearings
   • Assembling the Crankcase
   • Installing the Shift Lever
   • Installing the Oil Pump Drive Gear
   • 4-56

9. Crankshaft and Oil Pump

   • Oil Pump
   • Removing the Crankshaft
   • Checking the Oil Pump
   • Checking the Crankshaft
   • Installing the Crankshaft and Balancer
   • 4-65

10. Transmission

    • Checking the Shift Forks
    • Checking the Shift Cam
    • Checking the Transmission
    • Checking the Secondary Shaft and Driven Sprocket
    • Checking the Chain
    • Installing the Transmission
    • 4-70

11. Middle Gear

    • Middle Drive Shaft
    • Middle Driven Shaft
    • Removing the Middle Drive Shaft
    • Removing the Middle Driven Shaft
    • Checking the Pinion Gears
    • Selecting the Middle Drive and Driven Gear Shims
    • Installing the Middle Driven Shaft
    • Installing the Middle Drive Shaft
    • Measuring the Middle Gear Backlash
    • 4-75

Cooling System

1. Radiator

   • Checking the Radiator
   • Installing the Radiator
   • 5-1

2. Thermostat

   • Checking the Thermostat
   • Installing the Thermostat
   • 5-5

3. Water Pump

   • Disassembling the Water Pump
   • Checking the Water Pump
   • Assembling the Water Pump
   • 5-7

Carburetion

1. Carburetor
   • Disassembling the Carburetor
   • Checking the Carburetor
   • Assembling the Carburetor
   • Adjusting the Fuel Level
   • 6-1

Drive Train

1. Troubleshooting

   • 7-1

2. Front Constant Velocity Joints and Differential Gear

   • Removing the Differential Gear Assembly
   • Checking the Constant Velocity Joints
   • Checking the Differential Gear
   • Assembling the Front Constant Velocity Joints
   • Assembling the Differential Gear
   • Measuring and Adjusting the Differential Gear Lash
   • Checking the Differential Gear Operation
   • 7-4

3. Rear Axle/Final Drive Gear and Drive Shaft

   • Removing the Rear Axle
   • Disassembling the Final Drive Gear
   • Replacing the Final Drive Roller Bearings
   • Positioning the Final Drive Pinion Gear and Ring Gear
   • Checking the Rear Axle
   • Checking the Drive Shaft
   • Checking the Final Drive Gear
   • Measurement and Adjusting the Final Gear Lash
   • Assembling the Final Drive Gear
   • Installing the Final Drive Gear
   • 7-15

Chassis

1. Front and Rear Wheels

   • Front Wheels
   • Rear Wheels
   • Checking the Wheels
   • Checking the Wheel Hubs
   • Checking the Brake Discs
   • Installing the Wheel Hubs
   • Installing the Wheels
   • 8-1

2. Front Brake

   • Front Brake Pads
   • Replacing the Front Brake Pads
   • Front Brake Master Cylinder
   • Checking the Master Cylinder
   • Assembling the Front Brake Master Cylinder
   • Installing the Front Brake Master Cylinder
   • Front Brake Caliper
   • Disassembling the Front Brake Calipers
   • Checking the Front Brake Calipers
   • Assembling the Front Brake Calipers
   • Installing the Front Brake Calipers
   • 8-6

3. Rear Brake

   • Removing the Rear Brake
   • Checking the Rear Brake
   • Installing the Rear Brake
   • 8-19

4. Steering System

   • Handlebar
   • Removing the Rear Brake Switch
   • Checking the Handlebar
   • Installing the Handlebar
   • Installing the Rear Brake Lever
   • Installing the Master Cylinder Assembly
   • Steering Stem
   • Removing the Bearing Retainer
   • Checking the Steering Stem
   • Installing the Bearing Retainer
   • Installing the Cable Guide
   • Tie Rods and Steering Knuckles
   • Removing the Steering Knuckles
   • Checking the Tie Rods
   • Checking the Steering Knuckles
   • Installing the Tie Rods
   • 8-28

5. Front Arms and Front Shock Absorbers

   • Removing the Front Arms
   • Checking the Front Arms
   • Checking the Front Shock Absorber
   • Installing the Front Arms and Front Shock Absorber
   • 8-40

6. Rear Shock Absorber and Swingarm

   • Removing the Swingarm
   • Checking the Rear Shock Absorber
   • Checking the Swingarm
   • Checking the Rubber Boot
   • Installing the Rubber Boot
   • Installing the Rear Axle Housing
   • 8-46

Electrical

1. Electrical Components

   • 9-1

2. Checking the Switches

   • Checking a Switch
   • Checking a Switch Shown in the Manual
   • Checking the Switch Continuity
   • 9-2

3. Checking the Bulbs and Bulb Sockets

   • Types of Bulbs
   • Checking the Condition of the Bulbs
   • Checking the Condition of the Bulb Sockets
   • 9-6

4. Ignition System

   • Circuit Diagram
   • Troubleshooting
   • 9-9

5. Electric Starting System

   • Circuit Diagram
   • Troubleshooting
   • Starter Motor
   • Checking the Starter Motor
   • Assembling the Starter Motor
   • 9-15

6. Charging System

   • Circuit Diagram
   • Troubleshooting
   • 9-22

7. Lighting System

   • Circuit Diagram
   • Troubleshooting
   • Checking the Lighting System
   • 9-25

8. Signal System

   • Circuit Diagram
   • Troubleshooting
   • Checking the Signal System
   • 9-32

9. Cooling System

   • Circuit Diagram
   • Troubleshooting
   • 9-43

10. 2WD/4WD Selecting System

    • Circuit Diagram
    • Troubleshooting
    • 9-48

Troubleshooting

1. Starting Failure/Hard Starting

   • Fuel System
   • Electrical System
   • Compression System
   • 10-1

2. Poor Idle Speed Performance

   • 10-2

3. Poor Medium and High-Speed Performance

   • 10-2

4. Faulty Drive Train

   • 10-3

5. Faulty Gear Shifting

   • Hard Shifting
   • Shift Lever Does Not Move
   • Jumps Out of Gear
   • 10-4

6. Faulty Clutch Performance

   • Engine Operates but Machine Will Not Move
   • Clutch Slipping
   • Poor Starting Performance
   • Poor Speed Performance
   • 10-4