Yamaha Kodiak 400 4x4 ATV 2000–2002 Service & Owner’s Manual Set (P/N LIT-11616-13-21)

Yamaha specifies using the supplement with the included base service manual. The owner’s publication adds operating instructions, riding guidance, and preventive maintenance for its own model designation.

Supplement coverage: The included supplement contains specifications, cable routing, maintenance schedules, and middle-gear procedures. It ends at printed page 18; the later chassis sections and YFM400AM/YFM400AMC wiring diagram listed in its contents are not included.

PDF Search, Bookmarks, and Diagram Detail

Search and diagram readability: The service PDF has searchable OCR text. The owner’s main text is searchable, but some label graphics, warranty material, and the safety card are not. Both PDFs have embedded bookmarks. Small service-manual circuit labels require zooming, and some remain difficult to read when enlarged.

The ZIP contains two printable English PDFs totaling 558 pages. The service PDF combines the base manual and supplement; its total includes 16 pages of base-manual front matter and six pages of supplement front matter, including their covers. The owner’s PDF includes its covers, preliminary material, and a two-page safety card.

Engine, Shaft Drive, Electrical Tests, and ATV Operation

These are selected contents, rather than a complete contents list. Other topics include panel removal and installation, cleaning, and storage preparation.

• Engine repair: Engine removal and installation, cylinder-head and valve-train work, cylinder and piston inspection, and crankshaft, balancer, and oil-pump service.

• Automatic transmission and clutch: Internal transmission repair, primary and secondary sheave disassembly, V-belt inspection, wet centrifugal clutch service, and one-way clutch checks.

• Shaft-drive repair: CV joints, front differential, rear axle, final drive, and drive shafts, with shim selection, gear-lash adjustment, and operational checks.

• Cooling and carburetion: Radiator, thermostat, water-pump, and carburetor service, plus compression testing, valve-clearance adjustment, and fuel-level checks.

• Brakes and chassis: Master-cylinder and caliper repair, pad replacement, hydraulic bleeding, steering and suspension inspection, toe-in adjustment, and select-cable setup.

• Electrical diagnosis: Circuit diagrams and fault isolation for ignition, starting, charging, lighting, indicators, cooling-fan control, switch continuity, and on-command 2WD/4WD selection.

• Owner operation and maintenance: Warning labels, controls, starting, break-in, reverse use, cargo and towing guidance, terrain-specific riding techniques, pre-operation checks, and scheduled servicing.

Yamaha wrote the service publications primarily for its dealers and qualified mechanics with basic repair knowledge; the owner’s manual addresses preventive maintenance and minor repairs by the owner.

Engine Disassembly, Timing, and Required Tools

Exploded assembly views and job charts accompany step-by-step procedures for removal, inspection, and reassembly. Cylinder-head work includes valve-guide replacement, valve-seat refacing and lapping, and camshaft timing alignment. Separate sections cover piston-ring measurements, recoil starter and CDI magneto service, crankcase separation, and transmission checks before reassembly.

The tool list identifies 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. Bearing-retainer and gear-lash tools are also specified, helping establish the equipment needed before internal engine or driveline work begins.

Driveline Diagnosis and Assembly Limits

The shaft-drive troubleshooting material distinguishes bearing rumble, gear whine, and other driveline symptoms from engine surging or transmission behavior. Repair sections explain final-drive pinion and ring-gear positioning, bearing replacement, thrust-washer selection, and backlash adjustment.

The differential gear unit itself is factory assembled and must not be internally disassembled. Its surrounding service material covers the CV joints, seals, bearings, drive engagement, and related setup checks.

The middle-driven-shaft bearing retainer has left-hand threads, and pressing directly on the shaft end can damage its threads. Direct blows to the rear axle can damage its threads and splines; overtightening the temporary ring-gear holding bolt during backlash checks can damage the ring gear.

Cooling, Fuel System, Brakes, and Steering

Cooling-system coverage includes radiator-cap pressure testing, thermostat opening checks, and water-pump mechanical-seal installation. Carburetor sections address float height, fuel level, diaphragm condition, and jet inspection, with separate California and non-California specifications.

Chassis material extends to steering-stem bearings and retainers, tie rods, steering knuckles, ball joints, front arms, shock absorbers, and swingarm inspection. Brake procedures include master-cylinder and caliper disassembly, seal replacement, hose routing, and final operating checks.

Use the complete applicable section and factory data before beginning repair work; hydraulic brakes, spring-loaded sheaves, engine internals, driveline assemblies, and electrical systems require qualified personnel and the specified tools.

Circuit Diagrams and Fault Isolation

Representative 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 troubleshooting pairs these drawings with continuity and resistance checks, relay and diode tests, and circuit-specific fault paths. The starting section explains the interaction of the rear-brake, neutral, and park switches with the starting circuit cut-off relay. Reference tables provide torque data, lubrication points, fluid capacities, clearances, wear limits, and electrical test values.

Controls, Riding, and Owner Maintenance

The owner’s publication describes the liquid-cooled SOHC single-cylinder engine, electric and recoil starting, V-belt automatic transmission, hydraulic disc brakes, and selectable drive system. It explains the main switch, indicator lamps, handlebar controls, speed limiter, drive-select positions, fuel controls, suspension preload, and auxiliary DC jack.

Operating guidance covers cold and warm starting, warm-up, reverse, break-in, parking, accessories, carrier loading, trailer towing, and the effect of cargo on braking and stability. Riding sections address turning, climbing, descending, side slopes, shallow water, rough terrain, sliding, and stalling.

Maintenance material covers engine, final-drive, and differential oils; coolant; axle boots; spark plugs; air filters; V-belt cooling ducts; and the spark arrester. Battery, fuse, lamp, wheel, and brake checks sit alongside starting and overheating troubleshooting charts.

Selected Valve and Final-Drive Setup Values

For YFM400FWAM/YFM400FWAMC, the service manual lists cold valve clearances of 0.06–0.10 mm for the intake and 0.16–0.20 mm for the exhaust. These are adjustment ranges, distinct from the component wear limits in the adjoining tables.

The final-drive section specifies ring-gear thrust clearance of 0.1–0.2 mm and ring-gear stopper clearance of 0.30–0.60 mm. Separate thrust-washer and stopper-shim selection information addresses these two setup checks.