Yamaha Kodiak & Grizzly 450 4x4 (2004–2007) Manual Set (P/N LIT-11616-16-01)

The FAR manual provides the base workshop procedures. Yamaha pairs the FAS supplement with the FAR manual and specifies both earlier service publications for FAT work.

The Grizzly YFM45FGW book covers operation and owner maintenance. The workshop procedures in this set are for the Kodiak YFM450FAR, YFM450FAS, and YFM450FAT.

Search, Bookmarks, and Wiring Diagrams

Text and diagram access: All three PDFs have searchable text and bookmarks. The safety-card pages at the end of both owner’s manuals are image-only. Zoom in on the service wiring diagrams to read the smallest connector labels and wire-color codes.

The ZIP contains three printable PDFs totaling 837 pages. Each owner’s manual is a separate file. The 467-page service PDF opens with the FAT supplement, followed by the FAR manual and the FAS supplement. The total includes the original covers and, in each owner’s PDF, a two-page safety card and three additional publisher pages.

Kodiak Workshop Procedures and ATV Owner Maintenance

These selected topics show what the publications cover. The service manual also explains how to measure engine compression and check carburetor fuel level.

• Engine service: Engine removal, cylinder-head service, camshaft, rocker arm and valve work, cylinder and piston inspection, crankcase separation, and crankshaft and oil-pump service.
• V-belt transmission: Primary and secondary sheave service, centrifugal clutch inspection, transmission disassembly, middle-gear setup, and service of the recoil starter and A.C. magneto.
• Shaft drive and On-Command 4WD: Front CV joints, front differential and gear motor, driveshafts and universal joints, and differential and final-drive gear lash and shim selection.
• Brakes, steering, and suspension: Pad replacement, caliper and master-cylinder service, hydraulic bleeding, and work on steering stems, bearing retainers, tie rods, ball joints, knuckles, and front arms.
• Electrical diagnosis: Ignition, starting, charging, lighting, signal, cooling-fan, and 2WD/4WD selector tests, with switch-continuity views, component test specifications, circuit diagrams, and separate FAR, FAS, and FAT wiring diagrams.
• Operation and upkeep: Drive selection, differential-lock override, displays, pre-ride checks, loading and towing, hill riding, scheduled maintenance, minor repairs, troubleshooting, cleaning, and storage.

The owner’s books guide riders through operation and routine upkeep. Yamaha wrote the service publications primarily for dealer mechanics and assumes a working knowledge of mechanical repair.

Rear Drive and Differential Service

Rear layouts: The FAR manual covers the rear axle, final drive, and swingarm. The FAT supplement covers rear CV joints, a revised final drive, rear knuckles, a stabilizer, upper and lower rear arms, and rear shocks. The FAS supplement adds differential-lock override coverage, revised rear master-cylinder and steering procedures, switch checks, and a model-specific signal circuit.

Fault finding: The 2WD/4WD test sequence gives technicians a way to trace a failed drive-mode change through the relays, selector switch, gear motor, and wiring. Yamaha calls for keeping the factory-matched front differential gear unit assembled. A shift-fork sliding gear that moves out of position during gear-motor installation can leave the indicator out of sync with the actual drive mode. The final-drive procedures identify left-hand-thread retainers and warn that insufficient gear lash can damage the teeth.

Workshop References and Owner Checks

Repair references: Exploded views and numbered job charts accompany the engine, sheave, differential, final-drive, brake, and steering procedures. The service publications provide coolant and oil flow diagrams, cable routing, torque tables, lubricant and capacity data, wear limits, clearances, carburetor settings, and electrical test values.

Special tools: The base manual lists the YU-01135-A/90890-01135 crankcase separator, 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.

Owner checks: The rider books explain throttle and braking technique for climbs, descents, and side slopes, as well as carrier loading and trailer-hitch limits. Maintenance charts use time, distance, or engine hours. The accompanying procedures cover cold-engine coolant checks, fluid and tire specifications, wheel service, and basic adjustments.

Valve Clearance and Final Gear Oil Examples

For the YFM450FAR, the cold valve-clearance check calls for 0.06–0.10 mm at the intake and 0.16–0.20 mm at the exhaust.

The final gear case takes 0.23 L (0.24 US qt) for a periodic oil change on the YFM450FAR. The YFM450FAT supplement lists 0.16 L (0.17 US qt) for the same service on its revised rear drive.