2000 Yamaha YFM400FWA(M) Service Manual (P/N 5GH3-AE1)

• Exact publication set: A 412-page PDF combining the 371-page Yamaha Kodiak 400 YFM400FWA(M) 2000 Service Manual (Manual No. 5GH3-AE1) with the 41-page YFM400FWA(P) 2002 Supplementary Service Manual (cover code 5GH3-AE2). Yamaha directs users to use the 2002 supplement with the base manual.
• Engine repair coverage: Covers removal and installation of the liquid-cooled four-stroke SOHC single, cylinder-head and valve service, camshaft and rocker arms, cylinder and piston inspection, crankcase separation and reassembly, crankshaft and balancer work, oil-pump service, recoil starter, and CDI magneto procedures.
• V-belt and transmission work: Documents inspection and service of the V-belt automatic transmission, including primary and secondary sheave removal, disassembly, inspection, assembly, and installation; centrifugal-clutch service; internal transmission work; middle drive and driven shafts; shim selection; and gear-lash measurement.
• 4WD shaft-drive repair: Includes constant-velocity joints and differential service, rear-axle removal, final-drive disassembly, pinion and ring-gear positioning, final-drive roller-bearing removal and reassembly, drive-shaft inspection, and backlash measurement and adjustment.
• Cooling, fuel, and periodic service: Treats the radiator, thermostat, water pump, carburetor inspection and assembly, fuel-level adjustment, valve-clearance and ignition-timing checks, compression testing, engine-oil and coolant replacement, toe-in, battery inspection, and other scheduled maintenance.
• Brake, steering, and suspension procedures: Details brake-pad replacement, master-cylinder and caliper service, hydraulic-system bleeding, handlebar and steering-stem work, tie rods and steering knuckles, front arms, shock absorbers, and the rear swingarm.
• Factory diagrams and fault finding: Provides coolant-flow and oil-flow diagrams, model-specific full wiring diagrams, and circuit diagrams with troubleshooting for the ignition, electric-starting, and 2WD/4WD selecting systems.

Exact Model and Regional Coverage

Coverage is organized by suffix, model year, and regional model code rather than a serial-number range. The 2000 manual lists 5GH3 for Canada, 5GH4 for Great Britain, France, and Switzerland, and 5GH5 for Oceania. The 2002 supplement lists 5GHL for Canada, 5GHM for Europe, and 5GHN for Oceania. The set contains no 2001-specific publication, and its coverage tables do not list a U.S.-market model code; match the ATV's model label before ordering.

Yamaha states that the manual was produced primarily for dealers and qualified mechanics and assumes basic mechanical-repair knowledge. It is not written as a beginner tutorial.

What the 2002 Supplement Changes

The AE2 supplement is not a stand-alone reprint. It adds new general, engine, clutch, carburetor, shaft-drive, and electrical specification pages, plus revised cable-routing views and maintenance information. Its procedure pages cover rear brake-light switch adjustment and updated cylinder-head installation, along with supplemental exploded views for the recoil starter/CDI magneto and transmission. Electrical additions include starting-system fault isolation, signal-system checks, and the model-specific wiring diagram.

Shop Data, Special Tools, and Repair Cautions

Reference data includes component-specific torque specifications, fluid and lubricant capacities, inspection clearances and wear limits, carburetor settings, clutch test data, gear-backlash and shim values, chassis adjustments, and electrical test values. Exploded views and job charts introduce removal and disassembly sections, with detailed text and illustrations where the work requires more explanation.

The special-tool catalog distinguishes U.S./Canadian tool numbers from the 90890-series references used in other markets. Examples include the YU-01135-A/90890-01135 crankcase separating tool, YM-04134/90890-04134 sheave spring compressor, and YM-01231/90890-01231 gear-lash measurement tool.

Two manual-specific cautions matter during major repair: insufficient shaft-drive gear lash can rapidly destroy the gear teeth, and the factory-set differential gear unit is not intended to be disassembled because doing so causes malfunction.

ATV service can involve fuel, brake hydraulics, a loaded secondary-sheave spring, electrical jump testing, and heavy engine assemblies. Follow Yamaha's warnings and verify the model-specific procedure before beginning maintenance, diagnosis, or parts replacement.