Kodiak 400, YFM400 / Yamaha Motor Corp., Ltd
Production/model years: 2003, 2004.
2003-2004 Yamaha Kodiak 400, YFM400 manual
Models covered in this manual:
File specifications
File type: ZIP
Language: English
366 pages
Printable: Yes
Estimated download time: 0.75 Minutes
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Product Information
Table of Contents
-
Machine Identification
- Vehicle Identification Number
- Model Label
- 1-1
-
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
-
Checking of Connections
- 1-4
-
Special Tools
- 1-5
Specifications
-
General Specifications
- 2-1
-
Maintenance Specifications
- Engine
- Chassis
- Electrical
- 2-4
-
General Torque Specifications
- 2-20
-
Lubrication Points and Lubricant Types
- Engine
- 2-21
-
Coolant Flow Diagrams
- 2-22
-
Oil Flow Diagrams
- 2-24
-
Cable Routing
- 2-27
Periodic Checks and Adjustments
-
Introduction
- Periodic Maintenance/Lubrication
- 3-1
-
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
-
Footrest Boards
- 3-9
-
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
-
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
-
Electrical
- Checking the Battery
- Checking the Fuses
- Adjusting the Headlight Beams
- Changing the Headlight Bulb
- 3-54
Engine
-
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
-
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
-
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
-
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
-
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
-
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
-
Clutch
- Removing the Clutch
- Checking the Clutch
- Installing the Clutch
- 4-51
-
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
-
Crankshaft and Oil Pump
- Oil Pump
- Removing the Crankshaft
- Checking the Oil Pump
- Checking the Crankshaft
- Installing the Crankshaft and Balancer
- 4-65
-
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
-
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
-
Radiator
- Checking the Radiator
- Installing the Radiator
- 5-1
-
Thermostat
- Checking the Thermostat
- Installing the Thermostat
- 5-5
-
Water Pump
- Disassembling the Water Pump
- Checking the Water Pump
- Assembling the Water Pump
- 5-7
Carburetion
- Carburetor
- Disassembling the Carburetor
- Checking the Carburetor
- Assembling the Carburetor
- Adjusting the Fuel Level
- 6-1
Drive Train
-
Troubleshooting
- 7-1
-
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
-
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
-
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
-
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
-
Rear Brake
- Removing the Rear Brake
- Checking the Rear Brake
- Installing the Rear Brake
- 8-19
-
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
-
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
-
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
-
Electrical Components
- 9-1
-
Checking the Switches
- Checking a Switch
- Checking a Switch Shown in the Manual
- Checking the Switch Continuity
- 9-2
-
Checking the Bulbs and Bulb Sockets
- Types of Bulbs
- Checking the Condition of the Bulbs
- Checking the Condition of the Bulb Sockets
- 9-6
-
Ignition System
- Circuit Diagram
- Troubleshooting
- 9-9
-
Electric Starting System
- Circuit Diagram
- Troubleshooting
- Starter Motor
- Checking the Starter Motor
- Assembling the Starter Motor
- 9-15
-
Charging System
- Circuit Diagram
- Troubleshooting
- 9-22
-
Lighting System
- Circuit Diagram
- Troubleshooting
- Checking the Lighting System
- 9-25
-
Signal System
- Circuit Diagram
- Troubleshooting
- Checking the Signal System
- 9-32
-
Cooling System
- Circuit Diagram
- Troubleshooting
- 9-43
-
2WD/4WD Selecting System
- Circuit Diagram
- Troubleshooting
- 9-48
Troubleshooting
-
Starting Failure/Hard Starting
- Fuel System
- Electrical System
- Compression System
- 10-1
-
Poor Idle Speed Performance
- 10-2
-
Poor Medium and High-Speed Performance
- 10-2
-
Faulty Drive Train
- 10-3
-
Faulty Gear Shifting
- Hard Shifting
- Shift Lever Does Not Move
- Jumps Out of Gear
- 10-4
-
Faulty Clutch Performance
- Engine Operates but Machine Will Not Move
- Clutch Slipping
- Poor Starting Performance
- Poor Speed Performance
- 10-4
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