2003-2007 Yamaha Kodiak 450 (YFM450) Service & Repair Manual (incl. Owner's Manual)

1D9-F8199-10 LIT-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 1- 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 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 YFM450FAT OWNER’S MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st edition, May 2004 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-11626-18-35

EBU00014 WARNING Indicates a potential hazard that could result in serious injury or death. CONTENTS 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 1 2 3 4 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 5 6 7

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 8

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 9 10 11 12 13 14

1-1 EBU00464 1- LOCATION OF THE WARNING AND SPECIFICATION LABELS

2003-2007 Yamaha Kodiak 450 (YFM450) Service & Repair Manual (incl. Owner's Manual)

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