2005–2006 Yamaha Kodiak 400 (YFM4FAV) Owner's Manual (P/N LIT-11626-19–58)

• Yamaha Kodiak 400 4WD YFM4FAV Owner's Manual — first edition dated June 2005, Yamaha P/N LIT-11626-19-58, with 193 PDF pages devoted to operation, safety, scheduled care, specifications, warranty, and maintenance records.
• 496-page service PDF compilation of Yamaha publications — YFM400FAT Supplementary Service Manual LIT-11616-18-36 (103 pages), YFM400FAR Service Manual LIT-11616-16-02 (364 pages), and YFM4FGX 2008 Supplementary Service Manual LIT-11616-21-45 (29 pages); 689 pages total.
• Operator coverage includes warning-label locations, On-Command 2WD/4WD controls, drive-select and reverse use, cargo and towing limits, pre-operation checks, cold- and warm-engine starting, break-in, parking, hill climbing and descent, slope crossing, shallow-water crossings, and recovery from sliding or stalling.
• Engine repair sections cover removal and installation, cylinder-head and valve service, cylinder and piston inspection, recoil starter and AC magneto work, primary and secondary sheaves, clutch, crankcase, crankshaft, oil pump, transmission, and middle-gear setup.
• Drivetrain procedures address 2WD/4WD fault tracing, front CV joints and differential repair, rear CV joints and final-drive service, pinion positioning, shim selection, differential and final gear-lash adjustment, drive-shaft checks, and operational testing.
• Chassis and system work covers hydraulic brake bleeding, master-cylinder and caliper repair, steering and suspension inspection, radiator/thermostat/water-pump service, carburetor disassembly and fuel-level adjustment, and ignition, starting, charging, lighting, signal, cooling-fan, and switch diagnosis.
• Factory reference material includes exploded views with job charts, coolant- and oil-flow diagrams, cable-routing layouts, circuit diagrams, full wiring diagrams, troubleshooting charts, special-tool references, torque tables, capacities, wear limits, clearances, gear-backlash data, and electrical test specifications.

Owner Operation, Safety, and Scheduled Care

The YFM4FAV book identifies the actual control layout rather than treating the machine as a generic utility ATV. It explains the main switch, indicators, speedometer, fuel gauge, handlebar switches, throttle and speed limiter, brake controls, drive-select lever, recoil starter, fuel cock, and starter. Carrier use, storage, shock adjustment, and auxiliary DC jack operation are covered in their own sections.

The safety material is equally machine-specific. It covers off-road-only operation, rider training and protective equipment, passenger and age restrictions, pre-ride inspection, cargo placement, towing, slopes, rough ground, water, skidding, and the actions to take if the ATV stalls or begins to roll backward. Separate emission-control and general maintenance/lubrication charts lead into panel access, engine and gear oils, cooling-system care, axle boots, air filter, V-belt ducting, and spark-arrester service. The same section covers valve and throttle adjustment, brakes, cables, pivots, battery, fuses, lights, cleaning, storage, and basic troubleshooting.

How the Factory Service Material Is Organized

The service PDF is a layered compilation of factory publications, not one standalone YFM4FAV-labeled repair manual. Yamaha directs the YFM400FAT supplement to be used with the YFM400FAR base manual. That distinction matters: where the base book shows the earlier rear drum-brake and swingarm arrangement, the YFM400FAT supplement supplies the hydraulic rear disc-brake, rear CV-joint/final-drive, rear-knuckle and stabilizer, and double-wishbone rear-suspension procedures for the revised configuration.

Removal and disassembly sections open with exploded diagrams and job instruction charts, followed by inspection, repair, reassembly, adjustment, and final-check information. The base manual carries the full engine, cooling, carburetion, front drivetrain, steering, and electrical chapters; the YFM400FAT supplement adds the changed model data and assemblies. The final 29 pages belong to the separate YFM4FGX 2008 model and add model-specific specifications, maintenance charts, steering changes, and a headlight-relay lighting circuit with its own wiring diagram. Those pages apply only to that model code.

Diagnostic Depth and Repair Cautions

Electrical diagnosis is supported by dedicated ignition, electric-start, charging, lighting, signal, cooling, and 2WD/4WD circuit diagrams rather than a wiring sheet alone. Representative factory tools include the crankcase separating tool YU-01135-A / 90890-01135, gear-lash measurement tool YM-01475 / 90890-01475, final-drive bearing-retainer wrench YM-04050 / 90890-04050, and clutch holding tool YM-91042 / 90890-04086.

Two manual-specific cautions show why the service material matters during repair. Insufficient differential or final-drive gear lash can quickly destroy the gear teeth, while the final-drive pinion bearing retainer uses left-hand threads; treating it like a conventional threaded retainer can damage the retainer or gearcase. Yamaha states that the service manuals were written for dealers and qualified mechanics and warns that repair work attempted without the expected mechanical knowledge can leave the ATV unsafe.