Yamaha KODIAK 450 User Manual

1D9-F8199-10LIT-11626-18-35

READ THIS MANUAL CAREFULLY!

It contains important safety information.

This ATV should not be ridden by anyone under 16 years of age.

WARNING

YFM450FAT

OWNER’S MANUAL

EBU00776

EBU00941

INTRODUCTION

Congratulations on your purchase of the Yamaha YFM450FA. 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 crafts-

manship 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

IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SE-

RIOUS 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!

WARNING

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.

CAUTION:

A CAUTION indicates special precautions that must be taken to

avoid damage to the machine.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

AFFIX DEALER

LABEL HERE

EBU15000

IMPORTANT NOTICE

This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to oper-

ate this ATV on any public street, road or highway.

This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regu-

lations in effect at the time of manufacture.

Please check your local riding laws and regulations before operating this ATV.

EBU01067

YFM450FAT

OWNER’S MANUAL

U.S.A.

1st edition, May 2004

unauthorized use without the written

permission of

Yamaha Motor Corporation,

U.S.A. is expressly prohibited.

Printed in U.S.A.

P/N LIT-11626-18-35

EBU00014

WARNING

Indicates a potential hazard that could

result in serious injury or death.

LOCATION OF THE WARNING

AND SPECIFICATION LABELS....... 1-1

SAFETY INFORMATION.................. 2-1

DESCRIPTION AND MACHINE

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

Main switch...................................... 4-1

Indicator and warning lights.............4-2

Fuel gauge .......................................4-4

Speedometer unit ............................4-5

Handlebar switches .........................4-7

Throttle lever ..................................4-13

Speed limiter ..................................4-14

Front brake lever............................4-15

Brake pedal and rear brake

lever .............................................4-15

Drive select lever ...........................4-16

Recoil starter..................................4-17

Fuel tank cap .................................4-18

Fuel cock........................................4-18

Starter (choke) ..............................4-20

Seat................................................4-20

Storage compartment ....................4-21

Front carrier ...................................4-22

Rear carrier ....................................4-22

Front and rear shock absorber

adjustment ...................................4-23

Auxiliary DC jack............................4-25

PRE-OPERATION CHECKS ........... 5-1

Front and rear brakes ..................... 5-2

Fuel ................................................. 5-4

Engine oil ........................................ 5-6

Final gear oil.................................... 5-6

Differential gear oil .......................... 5-6

Coolant............................................ 5-7

Throttle lever ................................... 5-7

Fittings and fasteners...................... 5-8

Lights............................................... 5-8

Switches.......................................... 5-8

Tires ................................................ 5-8

How to measure tire pressure....... 5-10

Tire wear limit................................ 5-11

OPERATION..................................... 6-1

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

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

ADJUSTMENT.................................. 8-1

Owner’s manual and tool kit............ 8-1

Periodic maintenance/

lubrication ...................................... 8-3

Panel removal and installation ........ 8-6

Engine oil and oil filter cartridge .... 8-12

Final gear oil .................................. 8-17

Differential gear oil......................... 8-20

Cooling system.............................. 8-22

Changing the coolant ....................8-24

Axle boots...................................... 8-27

Spark plug inspection.................... 8-28

Air filter element cleaning.............. 8-31

V-belt cooling duct check hose .....8-34

V-belt case drain plug.................... 8-34

Spark arrester cleaning ................. 8-35

Carburetor adjustment................... 8-36

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 .................8-42

Front brake lever free play.............8-43

Adjusting the rear brake lever and

brake pedal ..................................8-44

Adjusting the rear brake light

switch ...........................................8-46

Cable inspection and

lubrication.....................................8-47

Lubricating the brake levers and

brake pedal ..................................8-47

Rear knuckle upper and lower

pivot lubrication ............................8-48

Wheel removal...............................8-49

Wheel installation...........................8-49

Battery............................................8-50

Battery maintenance......................8-52

Fuse replacement ..........................8-52

Replacing a headlight bulb ............8-54

Headlight beam adjustment...........8-57

Tail/brake light bulb

replacement ................................ 8-58

Troubleshooting ............................ 8-59

Troubleshooting charts ................. 8-61

CLEANING AND STORAGE............ 9-1

A. Cleaning...................................... 9-1

B. Storage ....................................... 9-3

SPECIFICATIONS.......................... 10-1

NOISE REGULATION.................... 11-1

MAINTENANCE RECORD ............ 12-1

ATV LIMITED WARRANTY............ 13-1

YAMAHA EXTENDED SERVICE

(Y.E.S.) ........................................... 14-1

1-1

EBU00464

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

1-2

Read and understand all of the labels on your

machine. They contain important information

for safe and proper operation of your ATV.

Never remove any labels from your ATV. If a

label becomes difficult to read or comes off, a

replacement label is available from your

Yamaha dealer.

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

WARNING

1-3

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

WARNING

PULLING LOAD: 4900 N

(

500kgf

)

1102 l b f

TONGUE WEIGHT: 147 N

(

15kgf

)

33 lbf

5ND-F151K-00

MAXIMUM

LOADING LIMITMAXIMUM

LOADING LIMIT

1-4

UNDER

WARNING

YAMAHA 4XE-F415A-00

NEVER operate this ATV if you are

under age 16.

Operating this ATV if you are under

the age of 16 increases your chance

of severe injury or death.

Turning the ATV in 4WD-LOCK

(

“DIFF. LOCK”

)

takes more effort.

Operate at a slow speed and allow

extra time and distance for maneuvers

to avoid loss of control.

5ND-F1558-00

WARNING

2-1

SAFETY INFORMATION

EBU13351

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.

Begin-

ners 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, park-

ing lots and streets.

●

Never operate an ATV on any public street, road or highway, even a dirt or gravel one.

2-2

●

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

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. Al-

ways follow the inspection and maintenance procedures and schedules described in this man-

ual.

●

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 prac-

ticed 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.

2-3

●

Always follow proper procedures for climbing hills as described in this manual. Check the ter-

rain 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 or make sudden gear

changes. 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 back-

ward. 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. To avoid stall-

ing, use the proper gear and 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 op-

erating over obstacles as described in this manual.

2-4

●

Always be careful when skidding or sliding. Learn to safely control skidding or sliding by prac-

ticing 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 con-

trol.

●

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.

2-5

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 refuel-

ing.

Do not refuel immediately after the en-

gine 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 vi-

cinity of sparks, open flames, or other

sources of ignition such as the pilot

lights of water heaters and clothes dry-

ers.

When transporting the ATV in another

vehicle, be sure it is kept upright and

that the fuel cock is in the “OFF” posi-

tion. 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.

2-6

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.

3-1

EBU00032

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 unit

23. Main switch

24. Fuel tank cap

25. Auxiliary DC jack

26. Right handlebar switch

27. Throttle lever

28. Front brake lever

TE:

The machine you have purchased may differ slightly

from those shown in the figures of this manual.

3-2

EBU00600

Identification number records

Record the key identification number, vehicle

identification number and model label infor-

mation 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:

3. MODEL LABEL INFORMATION:

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. Key identification number

3-3

EBU00036

Vehicle identification number

The vehicle identification number is stamped

into the frame.

1. Vehicle identification number

TE:

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 la-

bel in the space provided. This information will

be needed to order spare parts from your

Yamaha dealer.

1. Model label

4-1

EBU00039

CONTROL FUNCTIONS

WARNING

Indicates a potential hazard that could

result in serious injury or death.

EBU09420

Main switch

Functions of the respective switch positions

are as follows:

ON:

The engine can be started only at this position

and the headlights and taillight 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

4-2

EBU08020

Indicator and warning lights

1. Differential gear lock indicator light “DIFF. LOCK”

2. Low-range indicator light “L”

3. High-range indicator light “H”

4. Neutral indicator light “N”

5. Reverse indicator light “R”

6. Park indicator light “P”

7. Differential gear lock indicator “”

8. Coolant temperature warning light “”

EBU10601

Differential gear lock indicator light “DIFF.

LOCK”

This indicator light and the differential gear

lock indicator in the display come on when the

differential gear lock switch is set to the “4WD-

LOCK” position.

NOTE:

When the switch is set to “LOCK”, the differ-

ential gear lock indicator light will flash until

the differential gear is locked.

EBU11220

Low-range indicator light “L”

This indicator light comes on when the drive

select lever is in the “L” position.

EBU01064

High-range indicator light “H”

This indicator light comes on when the drive

select lever is in the “H” position.

DIFF.

LOCK

4-3

EBU09720

Neutral indicator light “N”

This indicator light comes on when the drive

select lever is in the “N” position.

EBU12500

Reverse indicator light “R”

This indicator light comes on when the drive

select lever is in the “R” position.

EBU00609

Park indicator light “P”

This indicator light comes on when the drive

select lever is in the “P” (park) position.

EBU11312

Four-wheel-drive indicator “”/“”

This indicator comes on when the “2WD”/

“4WD” switch is set to the “4WD” position. The

differential gear lock indicator “DIFF.LOCK” in

the four-wheel-drive indicator also comes on

when the “LOCK”-“4WD” switch is set to the

“4WD-LOCK” position.

NOTE:

Due to the synchronizing mechanism in the

differential gear case, the four-wheel drive in-

dicator may not come on until the ATV starts

moving.

DIFF.

LOCK

4-4

EBU00860

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 en-

gine as soon as it is safe to do so and allow

the engine to cool down for about 10 minutes.

CAUTION:

●

The engine may overheat if the ATV is

overloaded. If this happens, reduce

the load to specification.

●

After restarting, make sure that the

light is out. Continuous use while the

light is on may cause damage to the

engine.

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. Approxi-

mately 4.5 L (0.99 Imp gal, 1.19 US gal) of

fuel will be remaining in the tank.

4-5

EBU11322

Speedometer unit

1. Speedometer 2. Odometer/Tripmeter A/Tripmeter B

3. Clock/Hour meter 4. TRIP/ODO button

5. Clock/Hour button “”/“”

6. “H” button 7. “M” button

The speedometer unit is equipped with the

following:

●

a speedometer (which shows the riding

speed)

●

an odometer (which shows the total dis-

tance traveled)

●

two tripmeters (which show the distance

traveled since they were last set to zero)

●

a clock

●

an hour meter (which shows the total time

the key has been turned to “ON”)

4-6

Odometer and tripmeter modes

Pushing the “TRIP/ODO” button switches the

display between the odometer mode “ODO”

and the tripmeter modes “A” and “B” in the fol-

lowing order:

ODO

→

TRIP A

→

TRIP B

→

ODO

To reset a tripmeter, select it by pushing the

“TRIP/ODO” button, and then push the “TRIP/

ODO” button for at least three seconds. The

tripmeters can be used to estimate the dis-

tance that can be traveled with a full tank of fu-

el. This information will enable you to plan

future fuel stops.

NOTE:

Holding in the “TRIP/ODO” button and then

turning the key to “ON” switches the display

between “mph” and “km/h”.

Clock mode

Pushing the “”/“” button switches the

display between the clock mode “CLOCK”

and the hour meter mode “HOUR” in the fol-

lowing order:

CLOCK

→

HOUR

→

CLOCK

To set the clock

1. Set the display to the clock mode.

2. Push the “”/“” button until the clock

starts flashing.

3. Set the hours by pushing the “H” button.

4. Set the minutes by pushing the “M” but-

ton.

5. Push the “”/“” button, and then re-

lease it to start the clock.

4-7

EBU00053

Handlebar switches

1. Light switch “ //OFF”

2. Start switch “”

3. Engine stop switch “ / ”

4. Override switch “OVERRIDE”

EBU12040

Light switch “ //OFF”

Set the switch to “” to turn on the low beam

and the taillight.

Set the switch to “” to turn on the high

beam and the taillight.

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 “”.

4-8

EBU00607

Start switch “”

The starter motor cranks the engine when this

switch is pushed.

CAUTION:

See starting instructions prior to starting

the engine. (See page 6-1 for details.)

1. Override switch “OVERRIDE”

EBU13781

Override switch “OVERRIDE”

Top speed is normally limited when operating

in 4WD-LOCK. If conditions require more en-

gine power when riding forward, push and

hold this switch to override the 4WD-LOCK

speed limiting function. (See page 4-11 for a

detailed explanation about the differential

gear lock switch and its function.) Releasing

the switch restores the speed limiting function.

While this switch is pushed, the segments of

the speedometer digits will appear as shown

in the figure.

+ 164 hidden pages

Yamaha KODIAK 450 User Manual

INTRODUCTION

CONTENTS

SAFETY INFORMATION

DESCRIPTION AND MACHINE IDENTIFICATION

Identification number records

Vehicle identification number

CONTROL FUNCTIONS

Main switch

Indicator and warning lights

Handlebar switches

Start switch “”