2002 Yamaha YFM400FWA(P) Kodiak 400 ATV Supplementary Service Manual OEM (P/N LIT-11616-16-02)

• Coverage and file set: Includes the complete YFM400FAR service manual for model codes 5TE1 and 5TE5, plus the 2002 YFM400FWA(P) supplementary manual for 5GHL (Canada), 5GHM (Europe), and 5GHN (Oceania). The 407-page PDF set consists of 366 pages for the YFM400FAR manual and 41 pages for the regional supplement.
• Engine and transmission repair: Covers engine removal and installation, cylinder-head and valve service, piston and cylinder inspection, crankcase separation, crankshaft and oil-pump work, transmission service, recoil starter and magneto repair, CVT primary and secondary sheaves, V-belt, and centrifugal clutch procedures.
• Shaft-drive and 4WD work: Details front CV joints, the selectable 2WD/4WD differential, middle drive and driven shafts, gear-shim selection, backlash measurement and adjustment, rear axle removal, and final-drive disassembly and setup.
• Chassis, brake, and cooling service: Includes front brake pad replacement, master-cylinder and caliper overhaul, hydraulic bleeding, rear drum-brake service, steering-stem and tie-rod work, ball-joint replacement, suspension inspection, radiator and thermostat checks, and water-pump rebuilding.
• Electrical diagnosis: Provides circuit diagrams and fault-isolation checks for ignition, electric starting, charging, lighting, signals, cooling-fan control, and the 2WD/4WD selecting system, with switch-continuity and component resistance tests.
• Regional supplement scope: Adds revised specifications, cable-routing views, cylinder-head installation data, CDI-magneto and transmission exploded sequences, electric-start troubleshooting, signal-system checks, and a dedicated YFM400FWA(P) wiring diagram.

Yamaha states that the YFM400FAR manual was produced primarily for Yamaha dealers and qualified mechanics and assumes a basic understanding of mechanical principles and repair procedures. Its depth also makes it suitable for an experienced owner who already has the correct measuring equipment, pullers, holding tools, and safe workshop setup; it is not written as a beginner’s maintenance guide.

Factory Repair Depth

The full YFM400FAR manual follows each major assembly from removal through inspection and reassembly. Engine coverage includes camshaft, rocker-arm, valve and valve-guide work; piston, ring, and cylinder measurement; starter clutch and recoil starter inspection; crankshaft and balancer installation; and crankcase assembly checks. The transmission sections go beyond external adjustment, covering shift forks, shift cam, gear dogs, shafts, chain, and operational checks before the crankcase halves are closed.

Driveline procedures include symptom-based diagnosis for rumble, whine, clunk, binding, and loss of drive. The manual then covers differential and final-drive inspection, pinion and ring-gear positioning, shim selection, gear-lash adjustment, and differential preload checks. Chassis chapters handle wheel hubs, disc and drum brakes, steering knuckles, front arms, shock absorbers, swingarm, and rear axle housing.

Carburetor service includes disassembly, passage and jet inspection, diaphragm and needle-valve checks, float-height setup, and fuel-level adjustment. Cooling-system repair covers the radiator, thermostat, impeller, bearing, oil seal, and mechanical water-pump seal. Tables provide component-specific torque values, fluid capacities and approved lubricants, wear limits, clearances, gear-lash data, and electrical test specifications.

Diagrams, Troubleshooting, and Special Tools

Named visual references include the coolant-flow diagrams, oil-flow diagrams, cable-routing views, ignition-system circuit diagram, 2WD/4WD selecting-system circuit diagram, and the full YFM400FAR and YFM400FWA(P) wiring diagrams. Exploded assembly views and job-order charts accompany removal and disassembly sections. Troubleshooting also covers hard starting, poor idle and high-speed performance, faulty shifting or clutch operation, overheating, poor braking, unstable handling, and lighting faults.

The tool list supplies Yamaha numbers for specialized work, including the rotor holding tool YU-01235 / 90890-01235, sheave spring compressor YM-04134 / 90890-04134, gear-lash tools YM-01467 and YM-01475, ball-joint remover/installer YM-01474, radiator-cap tester YU-24460-01 / 90890-01325, and pocket tester YU-03112-C / 90890-03112.

Scope and Assembly Cautions

The 41-page YFM400FWA(P) supplement, manual number 5GH3-AE2, is not a stand-alone repair manual. Yamaha directs the reader to use it with the 2000 YFM400FWA(M) base manual 5GH3-AE1, which is referenced but not included in this two-file set. The complete YFM400FAR manual carries LIT-11616-16-02 and cover number 5TE-F8197-10.

The manual warns that the factory-set differential gear assembly must not be dismantled; doing so can cause the unit to malfunction. It also identifies left-hand threads on middle-drive and final-drive bearing retainers, where turning in the conventional direction can damage the retainer or shaft threads.

ATV repair can involve 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.