Yamaha KODIAK User Manual
READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFM4FAV
WARNING
This ATV should not be ridden by anyone under 16 years of age.
1P1-F8199-12LIT-11626-19-58
EBU00776
EBU00941
1-
INTRODUCTION
Congratulations on your purchase of the Yamaha YFM4FAV. It represents the result of many
years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing
machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
This manual will provide you with a good basic understanding of the features and operation of this
ATV.
This manual includes important safety information. It provides information about
special techniques and skills necessary to ride your ATV.
It also includes basic maintenance
and inspection procedures. If you have any questions regarding the operation or maintenance of
your ATV, please consult a Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
●
READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND
COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL
INSTRUCTIONS.
●
PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
●
NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE
TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887
FOR MORE INFORMATION.
●
THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE
UNDER 16 YEARS OF AGE.
EBU00801
WARNING
CAUTION:
NOTE:
IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe
injury or death to the machine operator, a bystander or a person
inspecting or repairing the machine.
A CAUTION indicates special precautions that must be taken to
avoid damage to the machine.
A NOTE provides key information to make procedures easier or clearer.
EBU15000
1-
IMPORTANT NOTICE
This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway.
This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.
Please check your local riding laws and regulations before operating this ATV.
EBU01067
YFM4FAV
OWNER’S MANUAL
AFFIX DEALER
LABEL HERE
©2005 by Yamaha Motor Corporation,
U.S.A.
1st edition, June 2005
All rights reserved. Any reprinting or
unauthorized use without the written
permission of
Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11626-19-58
EBU00014
WARNING
Indicates a potential hazard that could
result in serious injury or death.
CONTENTS
LOCATION OF THE WARNING
1
AND SPECIFICATION LABELS....... 1-1
SAFETY INFORMATION.................. 2-1
2
DESCRIPTION AND MACHINE
3
IDENTIFICATION ............................. 3-1
Identification number records.......... 3-2
Key identification number................ 3-2
Vehicle identification number .......... 3-3
Model label ...................................... 3-3
CONTROL FUNCTIONS...................4-1
4
Main switch ......................................4-1
Indicator and warning lights.............4-2
Speedometer ...................................4-6
Fuel gauge .......................................4-6
Handlebar switches .........................4-7
Throttle lever ..................................4-10
Speed limiter ..................................4-11
Front brake lever............................4-12
Brake pedal and rear brake
lever .............................................4-12
Drive select lever ...........................4-13
Recoil starter..................................4-13
Fuel tank cap .................................4-14
Fuel cock........................................4-15
Starter (choke) ...............................4-16
Seat................................................4-17
Front carrier ...................................4-18
Rear carrier ....................................4-18
Storage compartment ....................4-18
Front and rear shock absorber
adjustment ...................................4-19
Auxiliary DC jack............................4-21
PRE-OPERATION CHECKS ........... 5-1
5
Front and rear brakes ..................... 5-2
Fuel ................................................. 5-4
Engine oil ........................................ 5-6
Final gear oil.................................... 5-6
Differential gear oil .......................... 5-7
Coolant............................................ 5-8
Throttle lever ................................... 5-9
Fittings and fasteners...................... 5-9
Lights............................................... 5-9
Switches.......................................... 5-9
Tires .............................................. 5-10
How to measure tire pressure....... 5-12
Tire wear limit................................ 5-13
OPERATION..................................... 6-1
6
Starting a cold engine ..................... 6-1
Starting a warm engine................... 6-3
Warming up..................................... 6-3
Drive select lever operation and
reverse driving............................... 6-4
Engine break-in............................... 6-7
Parking ............................................ 6-8
Parking on a slope........................... 6-9
Accessories and loading ...............6-10
RIDING YOUR ATV ..........................7-1
7
Getting to know your ATV ...............7-3
Ride with care and good
judgement...................................... 7-4
Be careful where you ride.............. 7-16
Turning your ATV ..........................7-22
Climbing uphill ............................... 7-24
Riding downhill ..............................7-30
Crossing a slope............................ 7-32
Crossing through shallow water ....7-34
Riding over rough terrain............... 7-37
Sliding and skidding.......................7-38
What to do if ..................................7-40
What to do .................................... 7-40
PERIODIC MAINTENANCE AND
8
ADJUSTMENT.................................. 8-1
Owner’s manual and tool kit............ 8-1
Periodic maintenance chart for
the emission control system.......... 8-3
General maintenance and
lubrication chart ............................. 8-4
Panel removal and installation ........ 8-6
Engine oil and oil filter cartridge .... 8-12
Final gear oil .................................. 8-18
Differential gear oil replacement ...8-21
Cooling system.............................. 8-23
Changing the coolant ....................8-24
Axle boots...................................... 8-28
Spark plug inspection.................... 8-29
Air filter element cleaning.............. 8-31
V-belt cooling duct check hose .....8-34
V-belt case drain plug.................... 8-35
Spark arrester cleaning ................. 8-35
Carburetor adjustment................... 8-37
Idle speed adjustment ................... 8-37
Valve clearance adjustment.......... 8-38
Throttle lever adjustment............... 8-38
Select lever safety system cable
adjustment ...................................8-39
Front brake pad check...................8-39
Rear brake pad check....................8-40
Inspecting the brake fluid level ......8-41
Brake fluid replacement .................8-43
Front brake lever free play.............8-43
Adjusting the rear brake lever and
brake pedal ..................................8-44
Adjusting the rear brake light
switch ...........................................8-47
Cable inspection and
lubrication.....................................8-48
Lubricating the brake levers and
brake pedal ..................................8-48
Rear knuckle upper and lower
pivot lubrication ............................8-49
Wheel removal...............................8-50
Wheel installation...........................8-50
Battery............................................8-51
Battery maintenance......................8-53
Fuse replacement ..........................8-53
Replacing a headlight bulb ............8-55
Headlight beam adjustment.......... 8-58
Tail/brake light bulb
replacement ................................ 8-59
Troubleshooting ............................ 8-61
Troubleshooting charts ................. 8-62
CLEANING AND STORAGE............ 9-1
9
A. Cleaning...................................... 9-1
B. Storage ....................................... 9-3
SPECIFICATIONS.......................... 10-1
10
NOISE REGULATION.................... 11-1
11
MAINTENANCE RECORD ............ 12-1
12
ATV LIMITED WARRANTY............ 13-1
13
YAMAHA EXTENDED SERVICE
14
(Y.E.S.) ........................................... 14-1
EBU00464
1-
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1-1
Read and understand all of the labels on your
machine. They contain important information
for safe and proper operation of your ATV.
1
2
Never remove any labels from your ATV. If a
label becomes difficult to read or comes off, a
replacement label is available from your
3
4
5
Yamaha dealer.
6
12
WARNING
Overloading this ATV or carrying cargo improperly can change
handling, stability and braking performance and can lead to an
accident. Never exceed the maximum front cargo limit of
: 40kg (88 lbs)
NEVER sit on the carrier. Refer to instructions in the Owner's
Manual.
5ND-F4877-00
1-2
7
8
9
10
11
12
13
14
3
4
WARNING
Overloading this ATV or carrying cargo improperly can change
handling, stability and braking performance and can lead to an
accident. Never exceed the maximum rear cargo limit of
: 80kg (176 lbs)
NEVER sit on the carrier. Refer to instructions in the Owner's
Manual.
5ND-F4897-00
5
MAXIMUM.LOADING LIMITMAXIMUM LOADING LIMIT
PULLING LOAD: 4900 N(500kgf
TONGUE WEIGHT: 147 N
6
1102 l b f
33 lbf
(
15kgf
5ND-F151K-00
)
)
1-3
78
1-4
EBU13401
SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
An ATV handles differently
from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even
during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take
proper precautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
●
Read this manual and all labels carefully and follow the operating procedures described.
●
Never operate an ATV without proper training or instruction.
Take a Training Course.
Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call
1-800-887-2887 to find out about the training courses nearest you.
●
Always follow the age recommendation:
- A child under 16 years old should never operate an ATV with engine size greater than 90cc.
●
Never allow a child under age 16 to operate an ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she does not have the abilities to operate it safely.
●
Never carry a passenger on an ATV.
●
Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.
●
Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
2-1
●
Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or
a jacket, and long pants.
●
Never consume alcohol or drugs before or while operating this ATV.
●
Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is
proper for the terrain, visibility, operating conditions, and your experience.
●
Never attempt wheelies, jumps, or other stunts.
●
Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.
●
Always keep both hands on the handlebars and both feet on the footboards of the ATV during
operation.
●
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.
●
Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on
these kinds of terrain.
●
Always follow proper procedures for turning as described in this manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
●
Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller
hills before attempting larger hills.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
2-2
●
Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose
surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of
a hill at high speed.
●
Always follow proper procedures for going down hills and for braking on hills as described in
this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause
the vehicle to lean sharply to one side. Go straight down the hill where possible.
●
Always follow proper procedures for crossing the side of a hill as described in this manual.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the
ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning
technique described in this manual on level ground. Avoid crossing the side of a steep hill if
possible.
●
Always use proper procedures if you stall or roll backwards when climbing a hill. Maintain a
steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for
braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual.
●
Always check for obstacles before operating in a new area. Never attempt to operate over
large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.
2-3
●
Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice,
go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
●
Never operate an ATV in fast flowing water or in water deeper than that recommended in this
manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several times to let friction dry out the linings.
●
Always be sure there are no obstacles or people behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly.
●
Always use the size and type of tires specified in this manual.
●
Always maintain proper tire pressure as described in this manual.
●
Never modify an ATV through improper installation or use of accessories.
●
Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY,
call the Consumer Products Safety Com-
mission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.
2-4
WARNI NG
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could
be burned.
HOW TO AVOID THE HAZARD
Always turn off the engine when refueling.
Do not refuel immediately after the engine has been running and is still very
hot.
Do not spill gasoline on the engine or
exhaust pipe/muffler when refueling.
Never refuel while smoking, or in the vicinity of sparks, open flames, or other
sources of ignition such as the pilot
lights of water heaters and clothes dryers.
When transporting the ATV in another
vehicle, be sure it is kept upright and
that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the
carburetor or fuel tank.
WHAT CAN HAPPEN
Gasoline is poisonous and can cause
injuries.
HOW TO AVOID THE HAZARD
If you should swallow some gasoline or
inhale a lot of gasoline vapor, or get
some gasoline in your eyes, see your
doctor immediately. If gasoline spills on
your skin, wash with soap and water. If
gasoline spills on your clothing, change
your clothes.
2-5
WARNI NG
POTENTIAL HAZARD
Starting or running the engine in a
closed area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your ATV in an area with
adequate ventilation.
2-6
EBU00032
1-
DESCRIPTION AND MACHINE IDENTIFICATION
1. Rear shock absorber assembly
spring preload adjusting ring
2. Spark arrester
3. Storage compartment and tool
kit
4. Spark plug
5. Rear brake fluid reservoir
6. Front shock absorber assembly
spring preload adjusting ring
7. Brake pedal
8. V-belt case
9. Radiator cap
10. Fuel cock
11. Air filter case
12. Fuses
13. Tail/brake light
14. Engine oil dipstick
15. Oil filter cartridge
16. Coolant reservoir
17. V-belt cooling duct check hose
18. Rear brake lever
19. Left handlebar switches
20. Starter (choke)
21. Drive select lever
22. Speedometer
23. Main switch
24. Fuel tank cap
25. Auxiliary DC jack
26. On-Command four-wheel drive
switch
27. Throttle lever
28. Front brake lever
NOTE:
The machine you have purchased may differ slightly
from those shown in the figures of this manual.
3-1
EBU00600
Identification number records
Record the key identification number, vehicle
identification number and model label information in the spaces provided for assistance
when ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is
stolen.
1. KEY IDENTIFICATION NUMBER:
2. VEHICLE IDENTIFICATION NUMBER:
EBU00035
Key identification number
The key identification number is stamped on
the key as shown in the following illustration.
This number can be used for ordering a new
key.
1
2
3
4
5
6
7
8
9
10
3. MODEL LABEL INFORMATION:
1. Key identification number
3-2
11
12
13
14
EBU00036
Vehicle identification number
The vehicle identification number is stamped
into the frame.
1. Vehicle identification number (front left side)
NOTE:
The vehicle identification number is used to
identify your machine.
EBU00787
Model label
The model label is affixed to the location in the
illustration. Record the information on this label in the space provided. This information will
be needed to order spare parts from your
Yamaha dealer.
1. Model label
3-3
EBU00039
1-
CONTROL FUNCTIONS
WARNING
Indicates a potential hazard that could
result in serious injury or death.
EBU12490
Main switch
Functions of the respective switch positions
are as follows:
ON:
The engine can be started only at this position
and the headlights, taillight and meter lighting
come on when the light switch is on.
OFF:
All electrical circuits are switched off. The key
can be removed in this position.
1. Main switch
1
2
3
4
5
6
7
8
9
10
11
12
13
14
4-1
EBU08020
Indicator and warning lights
1. Neutral indicator light “N”
2. Reverse indicator light “R”
3. Coolant temperature warning light “”
4. Park indicator light “P”
5. Four-wheel drive indicator light “”
EBU06090
Park indicator light “P”
This indicator light comes on when the drive
select lever is in the “P” (park) position.
EBU12232
Coolant temperature warning light “”
When the coolant temperature reaches a
specified level, this light comes on to warn
that the coolant temperature is too hot. If the
light comes on during operation, stop the engine as soon as it is safe to do so and allow
the engine to cool down for about 10 minutes.
The electrical circuit of the warning light can
be checked according to the following procedures.
1. Set the engine stop switch to “” and
turn the key to “ON”.
2. Shift the drive select lever into the neutral
position or park position.
3. Push the start switch. If the warning light
does not come on while the start switch is
pushed, have a Yamaha dealer check
the electrical circuit.
4-2
CAUTION:
_
The engine may overheat if the ATV is
●
overloaded. If this happens, reduce
the load to specification.
Restart after making sure that the light
●
is out. Continuous use while the light
is on may cause damage to the engine.
_
4-3
EBU15390
ACB-09E
Coolant temperature warning light checking method
Turn the main switch to “ON” and
the engine stop switch to “”.
Coolant temperature warning
light does not come on.
Push the start switch with the transmission
in the neutral position or park position.
Coolant temperature
warning light comes on
momentarily.
Coolant temperature and
electrical circuit are OK.
Go ahead with riding.
Coolant temperature
warning light comes on.
Coolant temperature
warning light does not
come on.
Ask a Yamaha dealer to
inspect the electrical circuit.
4-4
EBU12500
Reverse indicator light “R”
This indicator light comes on when the drive
select lever is in the “R” position.
EBU00605
Four-wheel-drive indicator light “”
This indicator light comes on when the 2WD/
4WD switch is in the 4WD position.
NOTE:
Due to the synchronizing mechanism in the
differential gear case, the light may not come
on until the ATV starts moving.
EBU09720
Neutral indicator light “N”
This indicator light comes on when the drive
select lever is in the “N” position.
4-5
EBU00447
Speedometer
The speedometer shows riding speed. This
speedometer is equipped with a trip odometer. The trip odometer can be reset to “0” with
the reset knob. Use the trip odometer to estimate how far you can ride on a tank of fuel before going to reserve. This information will
enable you to plan fuel stops in the future.
1. Speedometer 2. Trip odometer
3. Reset knob
EBU00052
Fuel gauge
The fuel gauge indicates the amount of fuel in
the fuel tank. When the needle reaches the
red line, refill the tank at the first opportunity.
1. Fuel gauge 2. Red line
NOTE:
If the machine runs out of fuel, move the fuel
cock lever to the “RES” position. Approximately 4.5 L (0.99 Imp gal, 1.19 US gal) of
fuel will be remaining in the tank.
4-6
EBU00053
Handlebar switches
1. Light switch “ //OFF”
2. Engine stop switch “ / ”
3. Start switch “”
EBU12510
Light switch “ //OFF”
Set the switch to “” to turn on the low
beams, the taillight and the meter lighting.
Set the switch to “” to turn on the high
beams, the taillight and the meter lighting.
Set the switch to “OFF” to turn off all the lights.
CAUTION:
_
Do not use the headlights with the engine
turned off for more than thirty minutes.
The battery may discharge to the point
that the starter motor will not operate
properly. If this should happen, remove
the battery and recharge it.
_
EBU12050
Engine stop switch “ / ”
Make sure that the engine stop switch is set to
“” before starting the engine. The engine
stop switch controls ignition and can be used
at all times to stop the engine, especially in an
emergency. The engine will not start or run
when the engine stop switch is set to “”.
4-7
EBU00607
Start switch “”
The starter motor cranks the engine when this
switch is pushed.
CAUTION:
See starting instructions prior to starting
the engine. (See pages 6-1–6-3 for details.)
1. Four-wheel drive switch “2WD/4WD”
EBU00601
On-Command four-wheel drive switch
“2WD/4WD”
To change from two-wheel drive (2WD) to
four-wheel drive (4WD), stop the ATV and set
the switch to the 4WD position.
To change from four-wheel drive (4WD) to
two-wheel drive (2WD), stop the ATV and set
the switch to the 2WD position.
4-8
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