Yamaha Kodiak 400 ATV Service Manual Set, 2002 (P/N LIT-11616-16-02)

The full service manual provides YFM400FAR maintenance and repair chapters. The regional supplement supplies selected updates for YFM400FWA(P), with its own specifications and electrical references.

Supplement requirement: Yamaha specifies using the YFM400FWA(P) supplement with the 2000 YFM400FWA(M) Service Manual, 5GH3-AE1, which is not included.

Searchable PDFs and Wiring Diagram Detail

Text search and diagram navigation: Both PDFs support text search. Main-manual bookmarks cover chapters and sections, but one index shortcut requires a separate file that is not included. Four supplement bookmarks open the contents page; its wiring bookmark opens the diagram. Small wiring and connector labels in both files are readable when enlarged.

ZIP download with two printable English PDFs, 407 pages total. This includes 16 preliminary pages and one rear publication page in the main manual, plus eight preliminary pages in the supplement, two of which are blank.

Engine, Shaft-Drive, and Electrical Service

These selected content highlights are not a complete contents list. Other topics include spark-arrester cleaning and headlight-beam adjustment.

• Engine repair: Step-by-step procedures for engine removal and installation, cylinder-head and valve service, piston and cylinder inspection, crankcase separation, crankshaft work, and oil-pump repair.

• CVT and starting components: Primary and secondary sheave disassembly, V-belt service, centrifugal clutch inspection, recoil starter rebuilding, and magneto removal and installation.

• Shaft drive and 4WD: Front CV-joint service, selectable-drive differential work, middle-shaft removal, gear-shim selection, backlash adjustment, rear axle removal, and final-drive setup.

• Brakes and chassis: Front pad replacement, master-cylinder and caliper overhaul, hydraulic bleeding, rear drum-brake service, steering-stem and tie-rod work, ball-joint replacement, and suspension inspection.

• Carburetion and cooling: Carburetor disassembly and fuel-level adjustment, radiator inspection, thermostat testing, and water-pump disassembly, inspection, and reassembly.

• Electrical diagnosis: Circuit diagrams and fault-isolation checks for ignition, electric starting, charging, lighting, signals, cooling-fan control, and the 2WD/4WD selecting system.

• Regional updates: Revised specifications and cable routing, cylinder-head installation procedures, CDI-magneto and transmission exploded views, starting-system troubleshooting, signal checks, and a dedicated wiring diagram.

Yamaha produced these manuals primarily for its dealers and qualified mechanics, assuming a basic understanding of mechanical principles and machine repair procedures.

Engine Internals and Transmission Inspection

Engine coverage extends to camshaft and rocker-arm inspection, valve guides and valve seats, piston-ring measurements, starter-clutch checks, crankshaft and balancer installation, and crankcase assembly checks.

The transmission sections address shift forks, shift cam, gear dogs, shafts, and chain inspection. They also describe operational checks before the crankcase halves are closed.

Component tables provide torque specifications, fluid capacities, approved lubricants, wear limits, clearances, gear-lash data, and electrical test values.

Shaft-Drive Diagnosis and Assembly Limits

Symptom charts connect rumble, whine, clunk, binding, and loss of drive with possible bearing, gear-lash, or gear-tooth faults. This gives mechanics a framework for organizing inspection before selecting repair work.

Driveline setup includes pinion and ring-gear positioning, shim selection, and differential preload checks. The chassis chapters also cover wheel hubs, steering knuckles, front arms, shock absorbers, swingarm, and rear axle housing.

The manual warns that dismantling the factory-set differential gear assembly causes malfunction. It also identifies left-hand threads on middle-driven-shaft and final-drive bearing retainers, where incorrect handling risks thread damage.

Carburetor and Cooling-System Repair

Carburetor inspection covers passages, jets, diaphragm, piston valve, and needle valve, with float-height and fuel-level setup. These sections distinguish component inspection from external adjustment.

Cooling-system procedures address radiator-cap testing, thermostat operation, and water-pump components, including the impeller, bearing, oil seal, and pump seal.

Circuit References and Workshop Tools

Named visual references include coolant-flow diagrams, oil-flow diagrams, cable-routing views, ignition-system and 2WD/4WD selecting-system circuit diagrams, and full model-specific wiring diagrams. Exploded assembly views and job-order charts accompany removal and disassembly sections.

Electrical checks include switch continuity, component resistance, starter-motor inspection, and gear-motor operation. Troubleshooting also addresses hard starting, poor idle and high-speed performance, shifting and clutch faults, overheating, poor braking, unstable handling, and lighting faults.

The special-tool references identify the rotor holding tool YU-01235 / 90890-01235, sheave spring compressor YM-04134 / 90890-04134, gear-lash tools YM-01467 and YM-01475, and ball-joint remover/installer YM-01474. Cooling and electrical test equipment includes radiator-cap tester YU-24460-01 / 90890-01325 and pocket tester YU-03112-C / 90890-03112.

ATV repair involves fuel, hot coolant, brake hydraulics, battery hazards, rotating parts, and a raised machine. Use proper support and protective equipment, and follow the Yamaha safety notes for the system being serviced.

Preview of Valve Clearances and Charging-Coil Test Data

For YFM400FAR valve inspection, the cold clearance specifications are 0.06–0.10 mm at the intake and 0.16–0.20 mm at the exhaust.

The charging-coil specifications differ between publications: YFM400FAR lists 0.46–0.62 Ω, while the YFM400FWA(P) supplement lists 0.70–0.86 Ω. Both readings apply between the white leads at 20 °C (68 °F), keeping the test data tied to the correct model.