2003-2004 Yamaha Kodiak 400, YFM400 manual

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Models Covered in this Manual

Kodiak 400, YFM400 / Yamaha Motor Corp., Ltd

Production/model years: 2003, 2004.

Product Information

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

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