2000–2002 Yamaha Kodiak 400 4x4 Owner's Manual (P/N LIT-11626-15–19, LIT-11616-13-21)

• Exact Yamaha coverage: YFM400FWAM/YFM400FWAMC base service manual, YFM400AM/YFM400AMC supplementary service data, and the YFM400FAP owner’s manual.
• Covers engine removal and installation, cylinder-head and valve-train repair, cylinder and piston inspection, crankshaft and oil-pump service, transmission work, primary and secondary sheave disassembly, and clutch inspection.
• Details middle-gear, constant-velocity joint, front differential, rear axle, final-drive, and drive-shaft repair, including shim selection, gear-lash measurement and adjustment, and drivetrain operation checks.
• Includes radiator, thermostat, water-pump, and carburetor service, plus valve-clearance adjustment, compression testing, hydraulic brake bleeding, toe-in adjustment, select-cable setup, and final/differential gear maintenance.
• Provides system-specific circuit diagrams and fault isolation for ignition, electric starting, charging, lighting, signals, cooling fan control, switch continuity, and the on-command 2WD/4WD selecting system.
• The owner’s publication documents warning-label placement, control operation, 2WD/4WD switching, drive-select and reverse use, cold starting, break-in, cargo and towing rules, terrain-specific riding techniques, pre-operation checks, and scheduled maintenance.

Document Set and Publication Identity

This is a 558-page PDF set across two files. The 185-page YFM400FAP Owner’s Manual is Yamaha P/N LIT-11626-15-19, First Edition, April 2001. The 373-page service PDF contains a 349-page YFM400FWAM/YFM400FWAMC Service Manual, P/N LIT-11616-13-21, First Edition, April 1999, followed by a 24-page YFM400AM/YFM400AMC Supplementary Service Manual, P/N LIT-11616-13-39, First Edition, September 1999. The supplement is a change-data publication rather than a stand-alone workshop manual; Yamaha directs it to be used with the base service manual included ahead of it.

The base service manual identifies model codes 5GH1 and 5GH6 for non-California machines and 5GH2 and 5GH7 for California machines. The supplement identifies 5HA1 for non-California and 5HA2 for California. Coverage is defined by these Yamaha model designations and model codes rather than by a printed VIN or serial-number range.

Factory Repair Coverage

The service material is laid out around exploded assembly views, removal and disassembly charts, inspection criteria, reassembly notes, and component-specific torque data. Engine coverage reaches well beyond routine maintenance: cylinder-head removal, camshaft and rocker-arm inspection, valve and valve-spring work, piston and ring inspection, recoil starter and CDI magneto service, crankcase separation, crankshaft and balancer installation, oil-pump inspection, transmission installation, and middle-drive gear setup are all included.

The V-belt automatic drive system receives its own repair sections for the primary and secondary sheaves, V-belt inspection, spring-loaded secondary-sheave disassembly, wet centrifugal clutch, and one-way clutch operation. Shaft-drive chapters cover CV joints, differential assembly, front-drive operation, rear axle removal, final-drive pinion and ring-gear positioning, bearing service, backlash adjustment, and shim selection. Chassis repair includes front and rear master cylinders, calipers and pads, hydraulic brake bleeding, steering stem and bearing retainers, tie rods, steering knuckles, ball joints, front arms, shock absorbers, and swingarm inspection.

Diagrams, Test Data, and Special Tools

Representative factory illustrations include coolant-flow diagrams, oil-flow diagrams, cable-routing views, the ignition circuit diagram, the electric-starting circuit diagram, and the 2WD/4WD selecting-system circuit diagram. Electrical chapters pair those diagrams with continuity checks and troubleshooting sequences rather than presenting wiring alone.

Reference sections provide general and component-specific torque tables, lubrication points, approved fluid and lubricant categories, capacities, wear limits, clearances, compression and fuel-level test data, gear-lash specifications, shim-selection information, and electrical test values. The special-tool list names items such as the crankcase separating tool YU-01135-A / 90890-01135, sheave spring compressor YM-04134 / 90890-04134, sheave fixed block YM-04135 / 90890-04135, and clutch holding tool YM-91042 / 90890-04086, along with bearing-retainer and gear-lash tools used during driveline repair.

Operation, Loading, and Owner Maintenance

The owner’s manual identifies the YFM400FAP as a 401 cc liquid-cooled SOHC single with electric and recoil starting, a V-belt automatic transmission, hydraulic disc brakes, and selectable 2WD/4WD. It explains the main switch, indicator lamps, handlebar controls, speed limiter, drive-select positions, fuel-system controls, suspension preload, and auxiliary DC jack. Separate sections cover pre-ride inspection, cold- and warm-engine starting, warming up, reverse operation, engine break-in, parking, accessory use, carrier loading, trailer towing, and the effect of cargo on braking and stability.

Riding instruction is specific to ATV use: turning, climbing, descending, crossing a side slope, shallow-water crossings, rough terrain, and recovery from sliding or stalling. Owner-maintenance coverage includes engine, final-drive, and differential oils; coolant; axle boots; spark plug; air filter; V-belt duct; spark arrester; carburetor and idle adjustment; valve clearance; brakes; wheel removal; battery; fuses; lamps; troubleshooting charts; cleaning; and storage.

Important Scope and Repair Cautions

The supplementary section in the included service PDF ends after numbered page 18 in its middle-gear chapter. Its contents page lists later chassis material and a YFM400AM/YFM400AMC wiring diagram, but those pages are not present in the file.

Several cautions show why the factory repair information matters. The middle-driven-shaft bearing retainer uses left-hand threads, and the manual warns that pressing directly on the shaft end damages its threads. It also warns against striking the rear axle directly or overtightening the temporary ring-gear holding bolt during backlash checks, because the axle threads and splines or the ring gear can be damaged.

These Yamaha publications assume basic mechanical knowledge. Use the complete applicable section and verified factory data before beginning repair work; hydraulic brakes, spring-loaded sheaves, engine internals, driveline assemblies, and electrical systems should be handled by qualified personnel with the correct tools.