2004–2007 Yamaha Kodiak 450 4X4 YFM450FGW Owner's Manual (P/N LIT-11626-20–17, LIT-11626-18-35)

This 837-page Yamaha factory PDF set brings together the Grizzly YFM45FGW and Kodiak YFM450FAT owner’s manuals plus the three service publications for YFM450FAR, YFM450FAS, and YFM450FAT. The service information is built around the FAR base manual, with FAS and FAT supplements for model-specific changes. All five publications are first editions issued between March 2002 and April 2006.

• Files and page breakdown: 176-page YFM45FGW Grizzly Owner’s Manual, P/N LIT-11626-20-17; 194-page YFM450FAT Kodiak Owner’s Manual, P/N LIT-11626-18-35; and a 467-page service PDF containing the 70-page YFM450FAT supplement, LIT-11616-18-35, the 373-page YFM450FAR base service manual, LIT-11616-16-01, and the 24-page YFM450FAS supplement, LIT-11616-17-25.
• Liquid-cooled 4-stroke SOHC engine and V-belt transmission repair: Covers engine removal, cylinder-head service, camshaft/rocker-arm/valve work, cylinder and piston inspection, crankcase separation, crankshaft and oil-pump service, transmission repair, middle-gear setup, recoil starter and A.C. magneto work, primary and secondary sheaves, and centrifugal clutch service.
• Drivetrain and On-Command diagnosis: Details front constant-velocity joints, the front differential and gear motor, 2WD/4WD and differential-lock fault isolation, differential and final-drive gear-lash adjustment, shim selection, universal joints, drive shafts, and the model-specific rear-drive layouts.
• Brakes, steering, and suspension: Provides brake-pad replacement, master-cylinder and caliper disassembly and assembly, hydraulic brake bleeding, steering-stem and bearing-retainer work, tie-rod, ball-joint, and steering-knuckle service, front-arm repair, plus the FAR rear axle/swingarm arrangement and the FAT rear CV joints, knuckles, stabilizer, upper and lower arms, and rear shock absorbers.
• Electrical testing and wiring: Includes ignition, electric starting, charging, lighting, signal, cooling-fan, and 2WD/4WD selecting-system diagnosis, along with switch-continuity checks, component test specifications, circuit diagrams, and separate YFM450FAR, YFM450FAS, and YFM450FAT wiring diagrams.
• Owner operation and scheduled service: Explains the On-Command switches, differential-lock override, multifunction or speedometer displays, drive selection, loading and towing limits, terrain-specific riding technique, pre-operation checks, time/distance/hour-based maintenance, fluid and tire specifications, minor repair, troubleshooting, cleaning, and storage.

How the Service Publications Work Together

Yamaha identifies the YFM450FAR base manual with model codes 5ND1 and 5ND5. The YFM450FAS supplement covers 5ND6. The YFM450FAT supplement identifies 1D91/1D95 for the U.S., 1D92/1D96 for Canada, 1D93/1D97 for Europe, and 1D94 for Oceania. Yamaha directs the FAS supplement to be used with the FAR manual, while the FAT supplement requires both the FAR base manual and the FAS supplement. That relationship matters: the supplements add changed specifications, routing, assemblies, and repair procedures instead of repeating the entire base book.

The configuration changes are substantial enough to affect parts identification and workshop planning. FAR material covers the earlier rear axle, final-drive, and swingarm layout. FAT pages address rear constant-velocity joints, a revised final-drive assembly, rear knuckles, a stabilizer, separate upper and lower rear arms, and rear shock absorbers. FAS content adds the differential-lock override feature, revised rear brake master-cylinder and steering sections, switch checks, and a model-specific signal-system circuit.

Scope note: the YFM45FGW Grizzly publication in this set is an owner’s manual. The workshop repair publications are identified by Yamaha as YFM450FAR, YFM450FAS, and YFM450FAT.

Factory Repair Reference

The service chapters use exploded assembly views, numbered job charts, and added step-by-step detail where a repair needs more explanation. Reference sections supply general and component-specific torque data, approved lubricants and capacities, wear limits, clearances, carburetor settings, shim and gear-lash data, electrical test values, and cable-routing information. Particularly useful diagram coverage includes the coolant-flow diagrams, oil-flow diagrams, 2WD/4WD selecting-system circuit diagram, switch-continuity views, model-specific wiring diagrams, and exploded views for the engine, sheaves, differential, final drive, brakes, and steering.

The special-tool section gives both Yamaha regional tool numbers and the corresponding 90890-series numbers. Examples include the YU-01135-A/90890-01135 crankcase separating tool, YM-04134/90890-04134 sheave spring compressor, YM-01467/90890-01467 and YM-01475/90890-01475 gear-lash tools, YU-24460-01/90890-01325 radiator-cap tester, and 90890-06754 ignition checker.

The repair cautions are equally model-specific. Yamaha warns that the front differential is a factory-matched unit that should not be internally disassembled, and that losing the indexed position of its shift-fork sliding gear can leave the indicator out of agreement with the actual 2WD or differential-lock mode. The drivetrain chapters also flag left-hand-thread bearing retainers and destructive low gear lash, two details that can otherwise lead to damaged threads or gear teeth during repair.

The two owner’s manuals cover rider controls, safe engagement of 4WD and differential lock, cold-engine coolant inspection, carrier and trailer loading, braking and throttle technique on hills and side slopes, maintenance charts, basic adjustments, wheel service, and owner-level troubleshooting. Together, the publications separate routine operation and minor repair from the internal engine, drivetrain, chassis, and electrical work documented in the service set.