Yamaha Kodiak 400/Bruin 350, YFM400FAR/YFM350AS Service Manual, 2003–2008 (P/N LIT-11616-16-02 / 5TE-F8197-10)

• Exact Yamaha manual-set coverage: A 483-page PDF containing one non-Yamaha introductory page, the 365-page YFM400FAR Service Manual (LIT-11616-16-02 / 5TE-F8197-10), and the 117-page YFM350AS Supplementary Service Manual (LIT-11616-17-33 / 5WH-F8197-10). Yamaha identifies model codes 5TE1 and 5TE5 in the base manual and 5WH1 in the supplement.
• Engine and powertrain repair: Covers engine removal and installation; cylinder head, camshaft, rocker-arm, valve, cylinder, and piston work; recoil starter and A.C. magneto service; primary and secondary sheaves; clutch; crankcase; crankshaft and oil pump; transmission; and middle-gear inspection, shimming, assembly, and backlash checks.
• YFM350AS-specific service changes: Adds revised specifications and procedures for the air-cooled engine, balancer gears and oil pump, oil cooler, CVT sheaves, clutch, crankcase, crankshaft, transmission, middle gear, front axle, rear brake, steering, front suspension, electric starter, signal system, and oil-temperature warning circuit.
• Drivetrain, brake, and chassis procedures: The base manual includes front CV-joint and differential service, rear axle/final-drive and driveshaft repair, gear-lash adjustment and operational checks, hydraulic front-brake bleeding and overhaul, rear drum-brake service, steering-stem and tie-rod work, front-arm service, and swingarm and shock-absorber inspection.
• Fuel, cooling, and scheduled service: Details Mikuni BSR33 carburetor disassembly, inspection, assembly, and fuel-level adjustment; radiator, thermostat, and water-pump service; plus valve-clearance adjustment, ignition-timing and compression checks, V-belt inspection, fluid service, toe-in adjustment, and battery and fuse checks.
• Electrical diagnosis and technical reference: Provides system-specific circuit diagrams and troubleshooting for ignition, starting, charging, lighting, signaling, coolant-temperature monitoring, and 2WD/4WD selection, together with full wiring diagrams, connector and cable-routing views, torque tables, capacities, wear limits, clearances, and electrical test specifications.

How the Two Manuals Work Together

Yamaha's YFM350AS foreword directs the technician to use its supplement together with the YFM400FAR base manual for complete service information. The supplement reprints changed material rather than duplicating every unchanged repair procedure. This matters because the base publication specifies a 401 cc liquid-cooled engine and selectable 2WD/4WD system, while the 5WH1 supplement identifies a 348 cc air-cooled engine with its own oil-cooling, internal-engine, chassis, and electrical changes. The included 350-specific material is for YFM350AS/5WH1; it is not a generic supplement for every 350-series model.

Yamaha states that these publications were produced primarily for dealers and qualified mechanics and assumes a basic understanding of mechanical systems and machine repair. The set is therefore suited to trained technicians and comparably experienced repairers with the shop equipment needed for precision measurement, pressing, puller work, electrical testing, and drivetrain setup.

Shop-Level Repair Detail

Removal and disassembly sections open with exploded assembly drawings, numbered job order, part names, torque callouts, lubrication symbols, replacement-part symbols, and follow-on procedures where additional detail is needed. The specification chapters supply component-specific fastener data, lubrication points, fluid capacities, service limits, gear-shim and backlash data, carburetor settings, and electrical test values.

The special-tool tables identify both US/Canadian and 90890-series numbers. Examples include the tappet-adjusting tool YU-08035 / 90890-01311, sheave-spring compressor YM-04134 / 90890-04134, gear-lash measurement tools YM-01467 / 90890-01467 and YM-01475 / 90890-01475, and final-drive bearing-retainer wrench YM-04050 / 90890-04050. The 350 supplement adds crankshaft-installer pot 90890-01274 and spacer 90890-01309 for its revised assembly.

Named visual references include the YFM400FAR coolant-flow diagrams, engine oil-flow diagrams, cable-routing drawings, ignition-system circuit diagram, 2WD/4WD selecting-system circuit diagram, and separate full-page YFM400FAR and YFM350AS wiring diagrams. Electrical chapters pair those drawings with continuity checks, component tests, and fault-isolation charts rather than providing schematics alone.

Repair Cautions and Safety

The manual warns that pressing directly on the middle driven-shaft end can damage its threads and that striking the rear axle end can damage both the axle threads and splines. It also identifies the front differential gear assembly as a factory-matched unit that should not be separated; disassembly can cause the unit to malfunction.

For YFM400FAR cooling-system repair, let the engine and pressurized coolant circuit cool before opening the radiator cap. Securely support the ATV before wheel, brake, steering, suspension, or drivetrain disassembly, and follow the manual's component-specific warnings throughout the job.