2000-2005 Yamaha Kodiak 400 YFM400FW ATV Service Manual

Documents Yamaha Kodiak 400 YFM400FW ATV service procedures for model years 2000-2005. This manual outlines essential maintenance and repair steps for optimal performance. Part number LIT-11616-KD-40.

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Document Details

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Document Number / Seller:
28589 / Laura Martin
File Size:
23.98 MB
File Type:
PDF
Language:
English
Pages:
417
Printable:
Yes
Category:
ATV
Last updated / verified
Jul 24, 2025

Models Covered & Key Technical Specifications

YAMAHA Kodiak 400 (YFM400FW) - 2000-2005 | Technical Reference Section.

  • Nominal Fluid Capacity: 10 L (2.20 Imp gal, 2.64 US gal) for the fuel tank capacity.
  • Principal System Fill: 2.4 L (2.1 Imp qt, 2.5 US qt) defines the periodic oil change volume for the engine.
  • Rated Assembly Gap: For optimal operation, 920 kPa (9.2 kg/cm², 131 psi) at 350 r/min establishes the compression ratio Standard.
  • Technical Container: 0.5 L (0.44 Imp qt, 0.50 US qt) signifies the total amount for differential gear oil.
  • Standard Locking Torques: For optimal operation, 20 Nm (2.0 m • kg, 14 ft • lb) establishes the final gear case drain plug tightening torque.
  • Defined Dimensions: Overall length measures 1,925 mm (75.8 in).

Professional Workshop Service Manual & Technical Specifications

Precision Quality Manual: Yamaha Kodiak 400, YFM400FW ATV - Comprehensive Service Manual & Maintenance Procedures 2000-2005 Specification-Set

Model-Specs: Yamaha YFM400FW (2000-2005) // Coverage-Scope: ATV / All-Terrain Vehicle Logic // Documentation-Type: Service Manual

Performance-Element Technical-Path Validation-Data
Overall Length 1,925 mm (75.8 in)
Overall Width 1,155 mm (45.5 in)
Overall Height 1,130 mm (44.5 in)
Wheelbase 1,210 mm (47.6 in)
Minimum ground clearance 180 mm (7.09 in)
Minimum turning radius 3,500 mm (137.8 in)

Systematizing the service groups into these chapters: INDEX, GENERAL INFORMATION, SPECIFICATIONS, PERIODIC INSPECTION AND ADJUSTMENT, ENGINE OVERHAUL, CARBURETION, DRIVE TRAIN, CHASSIS, ELECTRICAL, and TROUBLESHOOTING.

This manual meticulously documents the systems and procedures required for the proper maintenance and repair of the Yamaha Kodiak 400 YFM400FW ATV. It covers all aspects from general information and detailed specifications to engine overhaul, carburetion, drive train, chassis, and electrical systems. Troubleshooting guidance is also thoroughly provided to assist in diagnosing and resolving any issues that may arise.

Disassembly instructions are documented for various components, including the engine, carburetor, and drive train systems.

Wear limits are specified for critical engine parts such as the cylinder head, cylinder, and camshaft, ensuring components are replaced before they fail.

System operation descriptions cover the electrical system, including ignition, starting, charging, and lighting systems.

The documentation addresses the chassis components, detailing adjustments and inspections for the steering system, suspension, brakes, and wheels.

Assembly instructions are detailed for engine components, transmission, and various chassis parts. This includes specific torque values for fastener tightening to ensure structural integrity.

This document details torque specifications for critical engine and chassis fasteners to ensure proper assembly and prevent fastener fatigue prevention.

FAQ

Specify the **applicable** lubrication requirements for the engine. keyboard_arrow_down

2.4 L (2.1 Imp qt, 2.5 US qt) is the periodic oil change quantity for the engine oil, and 0.3 L (0.26 Imp qt, 0.32 US qt) is for the transfer gear oil.

What is the **exact** testing parameters for engine compression? keyboard_arrow_down

920 kPa (9.2 kg/cm², 131 psi) at 350 r/min is the standard compression pressure.

Calculate the **specific** diagnostic procedures for electrical system faults. keyboard_arrow_down

Chapter 8, "ELECTRICAL", details circuit diagrams and troubleshooting steps for the ignition system, starting system, charging system, lighting system, and signal system.

What values **designated** fluid capacity requirements for the differential gear oil? keyboard_arrow_down

0.5 L (0.44 Imp qt, 0.50 US qt) is the total amount for differential gear oil, with periodic oil changes requiring 0.47 L (0.41 Imp qt, 0.50 US qt).

Assess the **critical** component identification for the fuel system. keyboard_arrow_down

Page 5-10 details the "FUEL LEVEL ADJUSTMENT" for the carburetor, including visual checks and adjustments for proper fuel delivery.

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Reviews (2)

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I found this service manual incredibly helpful for maintaining my ATV. The troubleshooting section is particularly useful. Plus, the customer service was fantastic; they responded to my email within hours!
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This service manual is a must-have for anyone working on the Yamaha YFM400FW. It’s well-organized and easy to follow, making complex repairs manageable. The download process was a breeze, and I received the link almost instantly! Highly recommend!