2003-2008 Yamaha Kodiak 400/Bruin 350 Service Manual
Complete engine, transmission, chassis, electrical repair procedures and specifications for YFM400FAR and YFM350AS models with diagnostic sequences and torque data.
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Models Covered & Key Technical Specifications
Yamaha Kodiak 400 4x4, YFM400FAR — 2003 Manufacturer Handbook for Kodiak 400 Series Repository.
- Approved Processing Speed: 401 cm³ (24.5 cu in) is rated at the engine cylinder displacement Architecture.
- Calibrated Mass Specs: 265 kg (584 lb) establishes the basic machine weight with full fuel tank Protocol.
- Primary Precision Specs: 10.5:1 supports the compression ratio for optimal combustion Norms.
- General Locking Torques: 40 Nm (29 ft·lb) provides the cylinder head bolt fastening requirement Bounds.
- Essential Measurement Bounds: 1,400 kPa (203 psi) at 750 r/min governs the standard compression pressure Topology.
- Operational Cycle Rate: The V-belt automatic transmission achieves 2.55–0.75:1 sub-transmission ratio Parameters.
Professional Workshop Service Manual & Technical Specifications
Detailed Specification Shop Manual: Yamaha Bruin 350, YFM350AS ATV Standards-Vault
Machine-Range: YFM350AS, 2003 Bruin 350 models // Unit-Designations: 348cc air-cooled engine, manual and automatic transmission systems / single-cylinder 4-stroke architecture // Machine-Range: Comprehensive 492-page technical documentation with complete subsystem coverage and wiring schematics.
| Identifier | Rating | Calibration-Data |
|---|---|---|
| Engine Displacement | 348 cm³ | Complete engine specifications provided |
| Transmission Type | V-belt automatic with shaft drive | System overview documented in Chapter 7 |
| Compression Ratio | 9.2:1 | Reference specifications included |
| Fuel Tank Capacity | 13.5 L (3.57 US gal) | Capacity and reserve documented |
| Basic Curb Weight | 245 kg (540 lb) | General specifications table referenced |
Technical units are distributed across ten major chapter categories. Maintenance hierarchies are structured into periodic service intervals (initial, 1-month, 3-month, 6-month, and annual schedules), engine procedure documentation, cooling and carburetion data, drive train reference material, chassis subsystem guidance, and electrical system circuit diagrams. The document provides engine operation parameters, transmission function overview, and final drive assembly reference information.
Core Parameters
Safety procedures are documented for the mechanical disassembly of major components including engine removal sequence, cylinder head access protocols, and crankcase separation methodology. The manual contains detailed chapters addressing the general information structure, special tools identification, machine identification procedures via VIN marking and model label location, and critical connector verification protocols. Explosion diagrams accompany all major removal and disassembly sections with numbered sequences and lubrication point indicators.
Integrated Nexus
Fluid capacities are listed for engine oil (2.2 L periodic, 3.1 L total capacity), final gear oil (0.25 L), and cooling system elements. Reference data for oil grades includes API service ratings, hypoid gear oil specifications, and lithium-soap-based grease application points. The manual documents the cooling system's water pump assembly construction, thermostat opening temperature ranges, and radiator capacity parameters. Carburetor specifications reference float height measurement at 13.0 mm, fuel level targeting 4.0–5.0 mm above the mating surface, and pilot jet sizing documentation.
Modular Benchmarks
Tool requirements are listed for specialized service tasks including the crankshaft installer set (YU-90050), valve guide removal/installation equipment, compression gauge adapter kits, and various bearing retainer wrenches. Installation guidelines are provided for the primary and secondary sheave assemblies, including V-belt orientation marking reference, sheave spring compression methodology, and secondary sheave assembly procedures with specific nut torque documentation.
Core Nexus
Maintenance guidelines are included for periodic checks addressing valve clearance adjustment (0.06–0.10 mm intake, 0.16–0.20 mm exhaust when cold), spark plug gap specification (0.6–0.7 mm), engine oil level verification using dipstick measurement, air filter element cleaning in petroleum-based solvent, and coolant level confirmation at the reservoir minimum/maximum markings. The document provides inspection intervals for brake fluid levels, tire pressure validation (22–28 kPa cold), and constant velocity joint dust boot condition assessment.
Precise Logic-Path
Wiring connections are organized by functional circuit including the ignition system circuit diagram (A.C. magneto, CDI unit, spark plug lead routing), electric starting system layout (starter relay, motor connections, main switch integration), charging system configuration (rectifier/regulator, battery charging coil resistance data), and lighting system distribution (headlight, tail/brake light, indicator light circuits). The document includes signal system circuit details for brake switches, neutral/reverse indicator functionality, and oil temperature warning light operation. The 2WD/4WD selecting system circuit diagram documents the gear motor activation, on-command switch logic, and differential case engagement procedures.
The manual documents torque specifications for the engine bracket assembly (33–56 Nm depending on location), cylinder head fastening sequence (40 Nm for M10 bolts, 10 Nm for M6 fasteners in crisscross pattern), and crankcase bearing retainer installation (25 Nm for M8 fasteners). Final drive and transmission component torque values are documented to ensure proper vibration dampening during operational service.
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