2024 Yamaha KODIAK 450 EPS Service & Repair Manual

Repair&ServiceManual YAMAHA KODIAK450EPS KODIAK450 4WD ServiceManual -ieee—.~ Fe ur1616-3107 es

eBs20009 IMPORTANT ThismanualwasproducedbytheYamahaMotorCompany,Ltd.primarilyforusebyYamahadealers andtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanual.Therefore,anyonewhousesthisbooktoperformmaintenanceandrepairsonYamahavehicles shouldhaveabasicunderstandingofmechanicsandthetechniquestorepairthesetypesofvehicles. Repairandmaintenanceworkattemptedbyanyonewithoutthisknowledgeislikelytorenderthevehicleunsafeandunfitforuse. Thismodelhasbeendesignedandmanufacturedtoperformwithincertainspecificationsinregardto performanceandemissions.Properservicewiththecorrecttoolsisnecessarytoensurethatthevehiclewilloperateasdesigned.Ifthereisanyquestionaboutaserviceprocedure,itisimperativethatyou contactaYamahadealerforanyserviceinformationchangesthatapplytothismodel.Thispolicyis intendedtoprovidethecustomerwiththemostsatisfactionfromtheirvehicleandtoconformtofederal environmentalqualityobjectives. YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallofitsmodels.Modificationsandsig- nificantchangesinspecificationsorprocedureswillbeforwardedtoallauthorizedYamahadealersand willappearinfutureeditionsofthismanualwhereapplicable. TIP *ThisServiceManualcontainsinformationregardingperiodicmaintenancetotheemissioncontrolsystem.Pleasereadthismaterialcarefully. *Designsandspecificationsaresubjecttochangewithoutnotice. EBS20001 IMPORTANTMANUALINFORMATION Particularlyimportantinformationisdistinguishedinthismanualbythefollowingnotations. Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonal ainjuryhazards.Obeyallsafetymessagesthatfollowthissymboltoavoid possibleinjuryordeath. AWARNINGindicatesahazardoussituationwhich,ifnotavoided,couldre- AWARNINGsultindeathorseriousinjury. ANOTICEindicatesspecialprecautionsthatmustbetakentoavoiddam- NOTICEagetothevehicleorotherproperty. TIPATIPprovideskeyinformationtomakeprocedureseasierorclearer. eas20002 YFM45KDXJ/YFM45KDHJ/YFM45KPXJ/ YFM45KPAJ/YFM45KPHJ SERVICEMANUAL ©2017byYamahaMotorCorporation,U.S.A. Firstedition,June2017 Allrightsreserved. Anyreproductionorunauthorizeduse withoutthewrittenpermissionof YamahaMotorCorporation,U.S.A. isexpresslyprohibited. PrintedinU.S.A. LIT-11616-31-07

Easco00e HOWTOUSETHISMANUAL Thismanualisintendedasahandy,easy-to-readreferencebookforthemechanic.Comprehensive explanationsofallinstallation,removal,disassembly,assembly,repairandcheckproceduresarelaid outwiththeindividualstepsinsequentialorder. *Themanualisdividedintochaptersandeachchapterisdividedintosections.Thecurrentsectiontitle “1”isshownatthetopofeachpage. *Sub-sectiontitles“2”appearinsmallerprintthanthesectiontitle. *Tohelpidentifypartsandclarifyproceduresteps,thereareexplodeddiagrams“3”atthestartofeach removalanddisassemblysection. *Numbers“4”aregivenintheorderofthejobsintheexplodeddiagram.Anumberindicatesadisassemblystep. *Symbols“5”indicatepartstobelubricatedorreplaced. Referto“SYMBOLS”. «Ajobinstructionchart“6”accompaniestheexplodeddiagram,providingtheorderofjobs,namesof parts,notesinjobs,etc.Thisstepexplainsremovalanddisassemblyprocedureonly.Forinstallation andassemblyprocedure,reversethesteps. *Jobs“7”requiringmoreinformation(suchasspecialtoolsandtechnicaldata)aredescribedsequen- tially. <a CLUTCH ‘enenaryyan «nanurnheathRouleg GiigexoaTHECLUTCHSHOE aeraetlerbfroll moro‘GiazedareasSandwihcoarsesandpe AergegepssSaPach 6 =anea

SYMBOLS Thefollowingsymbolsareusedinthismanualforeasierunderstanding. TIP Thefollowingsymbolsarenotrelevanttoeveryvehicle. SYMBOL DEFINITION SYMBOL DEFINITION 0%) Serviceablewithenginemounted Gearoil Dp |B |H— FillingfluidMolybdenumdisulfideoil LubricantBrakefluid Specialtool=a5P4Wheelbearinggrease Tighteningtorque Lithium-soap-basedgrease Wearlimit,clearance Molybdenumdisulfidegrease Enginespeed Siliconegrease Electricaldata Applylockingagent(LOCTITE®). e- (S| DI LIN We Engineoil Replacethepartwithanewone.

~TABLEOFCONTENTS GENERALINFORMATION SPECIFICATIONS PERIODICCHECKSAND ADJUSTMENTS CHASSIS ENGINE COOLINGSYSTEM FUELSYSTEM DRIVETRAIN ELECTRICALSYSTEM TROUBLESHOOTING lelel~folal=le[s| =

IDENTIFICATION VEHICLEIDENTIFICATIONNUMBER MODELLABEL. FEATURES INSTRUMENTFUNCTIONS IMPORTANTINFORMATION...............c:ccccscscscsesssteseessteestenssesestsnsseessneeeseeses PREPARATIONFORREMOVALANDDISASSEMBLY. REPLACEMENTPARTG...........0c0000+ GASKETS,OILSEALSANDO-RINGS LOCKWASHERS/PLATESANDCOTTERPINS BEARINGSANDOILSEALS CIRCLIPS......... RUBBERPARTS. BASICSERVICEINFORMATION. QUICKFASTENERS.. ELECTRICALSYSTEM. SPECIALTOOLS..00....esecccccceccsescseseeeseeceseseseecsseesseesaneesseensnesssesnaneesseenaneees1-11

IDENTIFICATION eBss0003 VEHICLEIDENTIFICATIONNUMBER Thevehicleidentificationnumber“1”isstamped intotheframe. MODELLABEL Themodellabel“1”isaffixedatthelocationin theillustration.Thisinformationwillbeneededto orderspareparts. 1-1 IDENTIFICATION

2024 Yamaha KODIAK 450 EPS Service & Repair Manual

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