Yamaha Kodiak 450 4WD Service Manual Set, 2003–2006 (P/N LIT-11616-16-01)

The FAS supplement relies on the FAR base manual for procedures it carries over. Yamaha directs technicians to use both publications alongside the FAT supplement for complete FAT service information.

Searchable Text, Bookmarks, and Wiring Diagrams

Search and diagram detail: The manual text is searchable, and embedded bookmarks jump to sections in all three publications. The separate “Return to Index” bookmark points to an external file. Small connector labels and wire color codes on the full wiring diagrams are clear when zoomed in.

The ZIP download contains one printable 467-page PDF in the order shown above. The total includes the front and back covers of all three publications and two numbered pages with only running headers and page numbers.

Engine Teardown, Drivetrain Setup, and Electrical Tests

This selection of workshop procedures is part of the set’s coverage. Other topics include spark arrester cleaning and service for the recoil starter and A.C. magneto.

• Engine repair: Engine removal and installation, cylinder-head and valve-train service, cylinder and piston inspection, crankcase separation, and crankshaft and oil-pump service.

• Transmission and clutch: V-belt inspection, primary and secondary sheave service, centrifugal clutch inspection, transmission disassembly, and middle gear shimming.

• Four-wheel drive and final drive: Front CV joint service, gear-motor checks, differential operation and gear-lash adjustment, FAR rear-axle service, and FAT rear CV joint and driveshaft work.

• Brakes, steering, and suspension: Hydraulic brake bleeding, master-cylinder and caliper repair, steering-stem bearing retainer service, tie-rod and steering-knuckle work, and front arm and shock absorber service.

• Cooling and carburetion: Radiator cap pressure testing, thermostat checks, water-pump service, and carburetor disassembly, inspection, and fuel-level adjustment.

• Electrical diagnosis: Switch continuity checks and fault tracing for ignition, electric starting, charging, lighting, signals, the cooling fan, and the 2WD/4WD selecting system.

Yamaha wrote these manuals primarily for its dealers and qualified mechanics and assumes familiarity with ATV maintenance and repair.

Rear Suspension and Model-Specific Updates

Match the code on the ATV’s model label to the coverage list before selecting a procedure. The FAR uses a swingarm (monocross) and rear axle. The FAT uses double wishbones with rear knuckles, a stabilizer, rear CV joints, and a revised final drive. Its supplement covers pinion and bearing replacement, shim selection, and reassembly.

The FAS supplement adds the differential-lock speed-limiter override switch and updates rear brake master-cylinder, steering-stem, tie-rod, steering-knuckle, switch continuity, and signal-system information.

Maintenance, Exploded Views, and Shop Tools

Periodic service covers valve-clearance adjustment, ignition timing and compression checks, coolant and gear oil service, shift-control adjustment, toe-in, shock preload, and battery and fuse checks. Numbered exploded views and job-order charts help identify the parts involved before teardown and locate the corresponding inspection and reassembly procedures.

The tool list distinguishes US and Canadian numbers from the corresponding 90890-series numbers for other markets. Examples include the crankcase separator YU-01135-A / 90890-01135, gear-lash tools YM-01467 / 90890-01467 and YM-01475 / 90890-01475, bearing retainer wrench YM-04050 / 90890-04050, and secondary sheave spring compressor YM-04134 / 90890-04134.

Circuit Diagrams and Repair Cautions

The set includes coolant and oil flow diagrams, cable-routing layouts, ignition and 2WD/4WD circuit diagrams, and a full wiring diagram for each model. Connection checks and symptom-based troubleshooting accompany the diagrams. Reference tables give torque specifications, lubricants and capacities, wear limits, clearances, carburetor settings, and electrical resistance and output values.

The final-drive and middle driven shaft bearing retainers use left-hand threads, which can be damaged if forced in the wrong direction. Moving the shift-fork sliding gear during gear-motor installation can make the indicator disagree with the actual differential position.

Follow Yamaha’s warnings when working on brake hydraulics, testing the cooling system, or supporting the ATV and heavy assemblies during engine or drivetrain removal.

Clutch Wear and Final-Drive Setup Preview

For the YFM450FAR centrifugal clutch, Yamaha lists a standard shoe thickness of 1.5 mm (0.06 in) and a wear limit of 1.0 mm (0.04 in).

For the YFM450FAT rear final drive, the specified gear lash is 0.1–0.2 mm (0.004–0.008 in). The supplement checks that range at four shaft positions and provides a shim chart for adjustment.