Yamaha KODIAK 450 2020 Owner'S Manual Download

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8-47

Adjusting the brake pedal free play

Measure the brake pedal free play and adjust if
necessary.

TIP

The brake lever free play and brake pedal height
must be adjusted before adjusting the brake pedal
free play.

1. Loosen the locknut.

2. To increase the brake pedal free play, turn the

brake pedal free play adjusting nut in direc-
tion (a). To decrease the brake pedal free
play, turn the adjusting nut in direction (b).

3. Tighten the locknut.

EBU24231

Axle boots

The axle boots must be checked for damage at
the intervals specified in the periodic maintenance
and lubrication chart. Check the axle boots for
tears or damage. If any damage is found, have
them replaced by a Yamaha dealer.

1. Brake pedal free play

Brake pedal free play:

20.0 mm (0.79 in)

1. Brake pedal free play adjusting nut
2. Locknut

(a)

(b)

UBB562E0.book Page 47 Thursday, March 14, 2019 9:59 AM

Summary of Contents for KODIAK 450 2020

Page 1: ...PRIÉTAIRE MANUAL DEL PROPIETARIO BB5 F8199 62 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de sécurité LEA ESTE MANUAL ATENTAMENTE Contiene indicaciones importantes acerca de la seguridad ...

Page 2: ...DIC183 Original instructions Notice originale Manual original PRINTED IN USA 2019 03 0 8 1 CR E F S ...

Page 3: ...contains important safety information WARNING OWNER S MANUAL YFM45KDXL YFM45KPAL YFM450FWB YFM450FWBD This ATV should not be ridden by anyone under 16 years of age BB5 F8199 62 E0 UBB562E0 book Page 1 Thursday March 14 2019 9 59 AM ...

Page 4: ...ands Signature Akihiro Tsuzuki Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted Title and or number and date of issue of standards and or s...

Page 5: ...ty information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures 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 completely before operating your ATV Make sure you understand all instructions For ...

Page 6: ...he figures shown in this manual This is the safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicl...

Page 7: ... Please check your local riding laws and regulations before operating this ATV EBU17411 YFM45KDXL YFM45KPAL YFM450FWB YFM450FWBD OWNER S MANUAL 2020 by Yamaha Motor Co Ltd 1st edition March 2019 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A UBB562E0 book Page 1 Thursday March 14 2019 9 59 AM ...

Page 8: ...ke lever 4 14 Drive select lever 4 15 Fuel tank cap 4 16 Fuel 4 17 Seat 4 18 Storage compartment 4 19 Front carrier 4 20 Rear carrier 4 20 Front and rear shock absorbers 4 20 Winch for Europe 4 22 Trailer hitch equipped models 4 23 Auxiliary DC jack 4 24 Winch pre wiring for Oceania 4 25 PRE OPERATION CHECKS 5 1 Fuel 5 3 Engine oil 5 3 Final gear oil 5 3 Differential gear oil 5 3 Coolant 5 3 Front...

Page 9: ...m 8 3 Periodic maintenance chart General maintenance and lubrication 8 5 Removing and installing panels 8 10 Checking the spark plug 8 17 Engine oil and oil filter cartridge 8 19 Why Yamalube 8 23 Final gear oil 8 24 Changing the differential gear oil 8 27 Coolant 8 29 Cleaning the air filter 8 33 Cleaning the spark arrester 8 36 V belt cooling duct check hose 8 37 V belt case drain plug 8 37 Adju...

Page 10: ...he rear knuckle pivots 8 52 Lubricating the steering shaft 8 52 Battery 8 53 Replacing a fuse 8 57 Replacing a headlight bulb 8 59 Adjusting a headlight beam 8 62 Replacing the brake tail light bulb 8 63 Removing a wheel 8 63 Installing a wheel 8 64 Troubleshooting 8 65 Troubleshooting charts 8 66 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Ident...

Page 11: ...all of the labels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a re placement label from your Yamaha dealer UBB562E0 book Page 1 Thursday March 14 2019 9 59 AM ...

Page 12: ...1 2 1 For Europe 1 4 2 3 8 9 10 11 12 5 6 6 6 7 6 UBB562E0 book Page 2 Thursday March 14 2019 9 59 AM ...

Page 13: ...7S F817R 10 80 kg 176 lbs 1P0 F816P 20 YAMAHA BB5 F816M M0 35 0 kPa 0 35 kgf cm 5 0 psi 30 0 kPa 0 30 kgf cm 4 4 psi 50 0 kPa 0 50 kgf cm 7 3 psi 50 0 kPa 0 50 kgf cm 7 3 psi 1 2 3 4 UBB562E0 book Page 3 Thursday March 14 2019 9 59 AM ...

Page 14: ...1 4 1 5880 N 600 kgf 1322 lbf 147 N 15 kgf 33 lbf 37S F817S 00 1P0 F816R 00 BB5 F2259 20 B16 F811S 00 8 5 6 7 UBB562E0 book Page 4 Thursday March 14 2019 9 59 AM ...

Page 15: ...1 5 1 YAMAHA 1HP F811R 00 E10 E5 B4F F817K 00 9 10 11 UBB562E0 book Page 5 Thursday March 14 2019 9 59 AM ...

Page 16: ... IWATA JAPAN YFM450FWBD 20 0 kW 308 kg 2019 B5R F155A 00 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM450FWBD 20 0 kW 307 kg 2019 BB5 F155A 30 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM450FWBD 20 0 kW 313 kg 2019 B5R F155A 10 12 BJ5D BJ5E 12 B5R1 B5R3 12 BB5M 12 B5R2 UBB562E0 book Page 6 Thursday March 14 2019 9 59 AM ...

Page 17: ...ctive gear Use from 16 years old Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER use on paved roads NEVER carry passengers NEVER use with drugs or alcohol NEVER store fuel or flammable liquids This unit contains high pressure nitrogen gas Mishandling can cause an explosion Do not incinerate puncture or open UBB562E0 book Page 7 Thursday March...

Page 18: ...an cause loss of control Loss of control can result in severe injury or death This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading guidelines in this manual Load may include the driver passenger human protective gear accessories goods luggage and all other load related items Make sure you do not exceed the load limits Overloadin...

Page 19: ...1 9 1 For Oceania 1 2 4 3 6 8 9 5 7 7 7 7 UBB562E0 book Page 9 Thursday March 14 2019 9 59 AM ...

Page 20: ... or towing When riding with cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain Maximum Vehicle Load 240 kg 530 lbs Includes weight of operator cargo and accessories and if applicable trailer tongue weight WARNING B16 F816M 00 YAMAHA IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPER...

Page 21: ...1 11 1 4XE F1568 10 BB5 F2259 20 7 8 6 UBB562E0 book Page 11 Thursday March 14 2019 9 59 AM ...

Page 22: ...1 12 1 16 UNDER 1P0 F816L 01 9 UBB562E0 book Page 12 Thursday March 14 2019 9 59 AM ...

Page 23: ...ld under 16 years old should never oper ate an ATV with engine size greater than 90 cc 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 This vehicle is intended for off road use only Do not operate on any paved surfaces such ...

Page 24: ...ing to turn at faster speeds and never turn at excessive speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills 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...

Page 25: ... 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...

Page 26: ...sary If you can physically operate your vehicle inspect your vehicle If the vehicle is in safe operating con dition and you can safely operate it restart it and ride gently back to camp or other known location where you can receive medical at tention If necessary contact your riding party or local authorities to let them know where you are and what has happened In the event of a breakdown 1 If you...

Page 27: ...ange any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries re lated to changes in the vehicle Keep the following guidelines in mind as well as those found in the Loading section page 6 6 when mounting acces sories Never install accessories that would impair the performance of your ATV Carefully in...

Page 28: ...d you can quickly be overcome and unable to save yourself Also deadly levels of carbon monoxide can linger for hours or days in en closed or poorly ventilated areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors ...

Page 29: ... 8 Coolant reservoir 9 V belt cooling duct check hose 1 2 3 4 5 9 7 8 6 1 Spark arrester 2 Storage compartment and tool kit 3 Fuel tank cap 4 Spark plug 5 Auxiliary DC jack 6 Front shock absorber 7 Winch for Europe 8 Rear brake light switch 9 Brake pedal 10 V belt case drain plug 11 Rear shock absorber 1 11 7 2 3 4 5 6 8 109 UBB562E0 book Page 1 Thursday March 14 2019 9 59 AM ...

Page 30: ...r switches 3 Winch switch for Europe 4 Horn switch 5 Drive select lever 6 Display unit 7 Front brake fluid reservoir 8 On Command 4WD switches 9 Throttle lever 10 Front brake lever 11 Main switch 1 2 4 3 6 7 10 8 5 11 9 UBB562E0 book Page 2 Thursday March 14 2019 9 59 AM ...

Page 31: ... can be re moved EBU26699 Indicator lights and warning lights For non differential gear lock models OFF ON 1 Neutral indicator light N 2 Reverse indicator light R 3 Park indicator light P 4 Coolant temperature warning light 5 Electric Power Steering warning light EPS equipped models 6 Engine trouble warning light 7 Four wheel drive indicator light 1 2 3 4 6 7 5 UBB562E0 book Page 1 Thursday March ...

Page 32: ...down for about 10 minutes The electrical circuit of the warning light can be checked by turning the key to on The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to on or if the warning light remains on have a Yamaha dealer check the electrical circuit TIP The radiator fan turns on or off automatically ac cording...

Page 33: ...ystem For differential gear lock models This warning light comes on or flashes if a problem is detected in the electrical circuit monitoring the engine When this occurs the display will indicate an error code see page 4 6 Have a Yamaha dealer check the self diagnosis system EBU30572 Electric Power Steering warning light EPS equipped models This warning light comes on when the key is turned to on a...

Page 34: ... lock indicator light equipped models This indicator light comes on when the drivetrain is set to 4WD with the differential gear locked TIP When the On Command differential gear lock switch is set to LOCK the indicator light will flash until the differential gear is completely locked or unlocked Turn the handlebar or start moving to help the differential lock to engage or disengage EBU37053 Displa...

Page 35: ...the fuel gauge disappear from F full towards E empty as the fuel level decreases When the last segment starts flashing refuel as soon as possible TIP This fuel gauge is equipped with a self diagnosis system If a problem is detected all the display segments will flash repeatedly If this occurs have a Yamaha dealer check the vehicle Multi function display Push the select button SEL to switch the dis...

Page 36: ...o reset the service tripmeter push the select but ton SEL for one second TIP The service tripmeter will reset and continue counting after 9999 9 is reached Hour meter The hour meter shows the total time the engine has been running Self diagnosis device This model is equipped with a self diagnosis de vice for various electrical circuits For non differential gear lock models If a problem is detected...

Page 37: ...ode If the display indicates an error code note the code number and have a Yamaha dealer check the vehicle NOTICE ECB01181 To prevent engine damage be sure to consult a Yamaha dealer as soon as possible if this oc curs EBU18068 Handlebar switches For Oceania 1 Light switch OFF 2 Engine stop switch 3 Start switch 4 Horn switch 3 4 2 1 UBB562E0 book Page 7 Thursday March 14 2019 9 59 AM ...

Page 38: ... lock models 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Override switch OVERRIDE equipped models 5 Horn switch 6 Winch switch OUT IN 4 3 2 5 1 6 1 On Command drive switch 2WD 4WD UBB562E0 book Page 8 Thursday March 14 2019 9 59 AM ...

Page 39: ... and right headlights low beams and the taillight Set the switch to to turn on the left and right head lights high beams the handlebar mounted light equipped models and the taillight Set the switch to OFF to turn off all the lights NOTICE ECB00046 Do not use the headlights with the engine turned off for an extended period of time The battery may discharge to the point that the starter will not hav...

Page 40: ...e switch restores the speed limiting function While the override switch is pushed the segments of the speedometer digits will appear as shown in the figure TIP If the digits of the speedometer appear as shown when the switch is NOT being pushed this could indicate a malfunction in the electrical system In this case take the ATV to a Yamaha dealer at the first opportunity WARNING EWB00151 Always ri...

Page 41: ... four wheel drive or vice versa while moving may cause the ATV to unexpectedly handle differently This could distract the oper ator and increase the risk of losing control and of causing an accident EBU38760 On Command drive switch 4WD LOCK dif ferential gear lock models Stop the ATV and push this switch to change from standard four wheel drive to four wheel drive with the differential locked Sele...

Page 42: ...ng the handlebar back and forth will help the differen tial gear lock to engage or disengage Riding before the differential gear is properly en gaged or disengaged e g when the indicator light is flashing will cause the vehicle speed to be limited until the differential gear is completely engaged or disengaged When the ATV is in four wheel drive differential gear lock the maximum traveling speed i...

Page 43: ...ion when released Always check that the throttle le ver returns normally before starting the engine EBU18325 Speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum Adjusting the speed limiter 1 Loosen the locknut 2 To increase the maximum engine power available and the maximum speed of the ATV turn the adjusting screw in directio...

Page 44: ...nt of the speed limiter and throttle could cause throttle cable damage or improper throttle operation You could lose control resulting in an accident EWB00242 3 Tighten the locknut EBU18393 Front brake lever The front brake lever is located on the right han dlebar To apply the front brake pull the brake le ver toward the handlebar grip EBU18444 Brake pedal and rear brake lever 1 Front brake lever ...

Page 45: ...the brake pedal or pull the brake lever toward the handlebar grip EBU18614 Drive select lever The drive select lever is used to shift the transmis sion into the low range high range neutral re verse and park positions See page 6 2 for drive select lever operation 1 Rear brake lever 1 1 Drive select lever 1 UBB562E0 book Page 15 Thursday March 14 2019 9 59 AM ...

Page 46: ...l while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heat ers and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun...

Page 47: ...e gasoline with care Never siphon gasoline by mouth 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 For Europe TIP Confirm the gasoline pump nozzle has the same fuel identification mark Recommended fuel ...

Page 48: ... E10 Gas oline containing methanol is not recommended because it can cause damage to the fuel system or vehicle performance problems NOTICE ECB00071 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system EBU34141 Seat To remove the seat Pull up the seat at the rear and then pull th...

Page 49: ...ools in the storage compartment If they must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartment The storage compartment is located under the seat See page 4 18 When storing any documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the ATV be careful not to let any water enter the storage ...

Page 50: ...reload can be adjusted to suit the rid er s weight and the riding conditions WARNING EWB00401 Always adjust the shock absorber assemblies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead to an ac cident Adjust the spring preload as follows Turn the spring preload adjusting ring in direction a to increase the spring prel...

Page 51: ...pecial wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position indicator 1 2 3 4 5 a b 1 2 1 Special wrench 1 UBB562E0 book Page 21 Thursday March 14 2019 9 59 AM ...

Page 52: ...Never let anyone come between the winch and pulled object or the winch and anchor point Do not use the winch unless all Front spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 Rear spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 1 Winch 2 Hook 3 Hook strap 4 Fairlead 4 2 3 1 UBB562E0 book Page 22 Thursday March 14 2019 9 59 AM ...

Page 53: ... vehicle s battery even when the engine is idling Allow the winch mo tor to cool and the battery to recharge between uses EBU28972 Trailer hitch equipped models This ATV is equipped with a 5 cm 2 in trailer hitch receiver Trailer towing equipment can be obtained at a Yamaha dealer See page 6 6 for precaution in formation 1 Trailer hitch receiver 1 UBB562E0 book Page 23 Thursday March 14 2019 9 59 ...

Page 54: ... accessory such as a work light or radio with the proper adapter can be used when the main switch is turned on However to prevent bat tery drain use when the engine is running and the headlights are turned off 1 Start the engine 2 Turn the headlights off 3 Turn the accessory off 4 Open the auxiliary DC jack cap 5 Insert the accessory power plug into the jack 6 Turn the accessory on 1 Auxiliary DC ...

Page 55: ...ine off or with the headlights on the battery may dis charge to the point that the engine will not start Do not use an automotive cigarette lighter or other accessory with a plug that gets hot The DC jack may be damaged EBU37291 Winch pre wiring for Oceania This vehicle is equipped with pre wiring leads for a winch Consult your Yamaha dealer for details UBB562E0 book Page 25 Thursday March 14 2019...

Page 56: ... a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if necessary 4 17 5 3 Engine oil Check oil level in engine and add recommended oil to specified level if necessary Check ATV for oil leakage Correct if necessary 5 3 8 19 Final gear oil Check ATV for oi...

Page 57: ...r free play and adjust if necessary 5 4 8 38 Control cables Make sure that operation is smooth Lubricate if necessary 8 49 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pressure Correct if necessary 5 4 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 8 50 Brake levers Make...

Page 58: ...necessary See page 8 29 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU28533 Front and rear brakes Brake levers and brake pedal Check that there is no free play in the front brake lever If there is free play have a Yamaha dealer check the brake system Check for correct free play in the rear brake le ver and brake pedal If the free play is...

Page 59: ...smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU38062 Tires Check and adjust the tire pressure before each ride Check tires for wear and damage Tire pressure A low pressure tire gauge is included as standard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading...

Page 60: ...argo or trailer Front Recommended 35 0 kPa 0 350 kgf cm 5 0 psi Rear Recommended 30 0 kPa 0 300 kgf cm 4 4 psi Front Minimum 32 0 kPa 0 320 kgf cm 4 6 psi Rear Minimum 27 0 kPa 0 270 kgf cm 4 0 psi With cargo or trailer Front Recommended 50 0 kPa 0 500 kgf cm 7 3 psi Rear Recommended 50 0 kPa 0 500 kgf cm 7 3 psi Front Minimum 45 0 kPa 0 450 kgf cm 6 5 psi Rear Minimum 45 0 kPa 0 450 kgf cm 6 5 ps...

Page 61: ...xtensive tests only the tires list ed below are approved for this model by Yamaha WARNING EWB02552 Use of improper tires on this ATV may cause loss of control increasing your risk of an acci dent 1 Tire tread depth Front Manufacturer model CHENG SHIN CU905 Size AT25x8 12 Rear Manufacturer model CHENG SHIN CU906 Size AT25x10 12 Maximum tire seating pressure Front 250 kPa 2 5 kgf cm 36 psi Rear 250 ...

Page 62: ...f handling braking and comfort Other tires rims sizes and combinations may not be appropriate EBU19841 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened EBU19851 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary UBB562E0 book Page 7 Thursday March 14 2019 9 59 AM ...

Page 63: ...mmended to shift into neutral or park and apply the rear brake when starting the engine NOTICE ECB00151 See the Engine break in section on page 6 4 prior to operating the engine for the first time To start the engine 1 Turn the key to on and the engine stop switch to run The coolant temperature warning light and the engine trouble warning light should come on for a few seconds then go off For EPS ...

Page 64: ...n 10 seconds on any single attempt NOTICE ECB00164 For maximum engine life never accelerate hard when the engine is cold EBU36230 Operating the drive select lever and driving in reverse NOTICE ECB03330 Do not shift without coming to a complete stop and waiting for the engine to return to normal idle speed Damage to the engine or drivetrain may occur Shifting Neutral to High range and High range to...

Page 65: ...ple or ob stacles behind you When it is safe to proceed go slowly 1 Bring the ATV to a complete stop 2 Apply the brake pedal 3 Shift from neutral to reverse or from reverse to park and vice versa by moving the drive se lect lever along the shift guide 1 Drive select lever 2 L Low range 3 H High range 4 N Neutral 5 R Reverse 6 P Park 1 2 L 3 H 4 N 5 R 6 P 1 Drive select lever 2 L Low range 3 H High...

Page 66: ...r the first 240 km 150 mi or 20 hours During this period the various parts in the engine wear and polish themselves to the cor rect operating clearances Avoid prolonged full throttle operation or any condition that might re sult in engine overheating 0 120 km 0 75 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not oper ate it at one set throttl...

Page 67: ...applying the brakes 2 Stop the engine 3 With the brake pedal applied shift the drive select lever to the park position EBU20911 Accessories and loading EBU20922 Genuine Yamaha Accessories Choosing accessories for your ATV is an impor tant decision Genuine Yamaha Accessories which are available only from a Yamaha dealer have been designed tested and approved by Yamaha for use on your ATV Many compa...

Page 68: ...while you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use extra caution when ...

Page 69: ...d does not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer Allow more braking distance A heavier ATV takes longer to stop Avoid making sharp turns u...

Page 70: ...7 1 7 EBU21142 RIDING YOUR ATV UBB562E0 book Page 1 Thursday March 14 2019 9 59 AM ...

Page 71: ...2 6 Also read all warn ing and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01382 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain Do n...

Page 72: ...t are not recommended for their age can lead to severe injury or death of the child This ATV is designed to carry the operator and cargo only passengers prohibited The long seat is to allow the operator to shift posi tion as needed during operation It is not for carry ing passengers WARNING Never carry a passenger Carrying a passenger on this ATV greatly reduces your ability to balance and control...

Page 73: ... Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01412 Wear eye protection when operating your ATV to reduce the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating wit...

Page 74: ...ach time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and mainte nance procedures and schedules described in the Owner s Manual WARNING Failure to inspect the ATV before riding it or failure to maintain it properly increases the possibility of an acci dent and equipment damage EWB01433 Speed limiter ...

Page 75: ... centered side to side and as low as possible Be sure cargo is se cured a loose load could change handling unexpectedly Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo in the trailer cannot move around A shifting load can cause an accident Reduce speed and allow more room to stop A heavier vehicle ...

Page 76: ... your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident EWB01472 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including MAXIMUM LOADING LIMIT ATV loading limit total weight of cargo rid er accessories and...

Page 77: ...he engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching the exhaust system dur ing or after operation could be burned Do not touch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and other engine p...

Page 78: ...aces may seriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets EWB01512 While riding on unpaved public streets or roads may be legal in your area such operation can in crease the risk of collision with other vehicles Watch carefully for other vehicles Make sure you UBB562E0 book...

Page 79: ...may cause the ATV to upset WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV EWB01532 Do not operate on rough slippery or loose terrain until you have learned and practiced the skills nec essary to c...

Page 80: ...flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operating in areas where you cannot easily be seen Mount a cau tion flag on the ATV to make you more visible Watch carefully for other vehicles EWB01552 Do not ride in areas posted no trespassing Do not ride on private property without getting permission UBB562E0 book Page 11 Thurs...

Page 81: ...release the throttle and apply the brakes smoothly and evenly Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident NOTICE ECB00252 Do not shift from low range to high range or vice versa without coming to a complete stop Damage to the engine or drive train may occur TURNING YOUR ATV WARNING EWB01772 Always follow proper proc...

Page 82: ... your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throt tle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV be gins to tip over to the outside while...

Page 83: ...uddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a ...

Page 84: ... you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so and go down the hill If your ATV has stalled or stopped and you believe you can continue up the hill restart carefully to make sure you do not lift the front wheels which could cause you to ...

Page 85: ...xtremely steep hills than on level surfaces or small hills Shift your weight backward and to the up side of the hill Never go down a hill at high speed Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possi ble Improper braking can cause the wheels on the uphill side to come off the ground or cause loss of traction Apply brake...

Page 86: ...her the front or rear brake because the wheels on the uphill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to ob stacles which may appear CROSSING A SLOPE WARNING EWB01633 Imp...

Page 87: ... may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance grad ually steer again in the direction you wish to travel CR...

Page 88: ...ide your ATV without verifying that you have regained proper braking ability WARNING Wet brakes may have reduced stopping ability which could cause loss of control EWB02622 After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case and the V belt cooling duct check hose Also remove the V belt case drain plug to drain any water ...

Page 89: ...arge rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual Riding over rough terrain should be done with caution Look out for obstacles which could cause damage to the ATV or could lead to an upset or 1 Air filter case check hose 1 V belt cooling duct check hose left front side of ATV 1 1 1 V belt case drain plug 1 UBB562E0 book Page 20...

Page 90: ...slowly and be very cautious in order to re duce the chance of skidding or sliding out of control Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help ...

Page 91: ...Position your weight over the front wheels for better control See page 7 12 If your ATV begins to tip while turning Lean more into the turn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See page 7 12 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recomme...

Page 92: ...you discover that the ATV is going to tip over dismount on the uphill side See page 7 17 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability Se...

Page 93: ...urn off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 6 for more information about carbon monoxide WARNING EWB02691 ...

Page 94: ...ided in the tool kit are intended to assist you in the performance of preventive maintenance and minor repairs However additional tools such as a torque wrench are necessary to perform cer tain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Tool kit 2 Owner s Manual 3 Low pressure tire gauge 1 3 2 UB...

Page 95: ...ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary 2 Spark plug Check condition and clean regap or replace if necessary 3 Valves Check valve clearance and adjust if necessary 4 Crankcase breath er system Check...

Page 96: ...lve and hose for damage Check condition and clean or replace if neces sary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 UBB562E0 book Page 4 Thursday March 14 2019 9 59 AM ...

Page 97: ...cial tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Air filter element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Sub air filter ele ment Clean and replace if necessary Every 20 40 hours more often in wet or ...

Page 98: ...ssary 8 Tires Check tread depth and for damage and replace if necessary Check air pressure and balance and correct if necessary 9 Wheel hub bearings Check for looseness or damage and replace if necessary 10 V belt Check for wear cracks or other damage and re place if necessary 11 Drive shaft univer sal joint Lubricate with lithium soap based grease NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Wh...

Page 99: ...e 17 Steering system Check operation and repair or replace if dam aged Check toe in and adjust if necessary 18 Engine mount Check for cracks or other damage and replace if necessary 19 Axle boots Check for cracks or other damage and replace if necessary 20 Engine oil Change Check ATV for oil leakage and correct if neces sary 21 Engine oil filter car tridge Replace 22 Engine oil strainer Clean NO I...

Page 100: ...es Lubricate 27 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 28 Front and rear brake switches Check operation and correct if necessary 29 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1...

Page 101: ... full throttle Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinder and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged UBB562E0 book Page 9 Thursday March 14 2019 9 59 AM ...

Page 102: ...e removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed 1 Panel A 2 Panel B 2 1 1 Panel C 2 Panel D 3 Panel E 1 Panel F 1 3 2 1 UBB562E0 book Page 10 Thursday March 14 2019 9 59 AM ...

Page 103: ... sure that no foreign material enters the fuel tank ECB01052 To remove the panel 1 Remove the seat See page 4 18 2 Remove the bolts and quick fasteners 3 Remove the fuel tank cap and then pull the panel off 1 Bolt 1 1 Quick fastener 1 Fuel tank cap 1 1 1 UBB562E0 book Page 11 Thursday March 14 2019 9 59 AM ...

Page 104: ...he bolts and quick fasteners 4 Install the seat Panels B and C When removing or installing panel C the drive se lect lever must be moved out of the park position Apply the brake pedal and move the drive select lever to the reverse position To remove a panel 1 Remove panel A 2 Pull the panel upward to release the tabs as shown UBB562E0 book Page 12 Thursday March 14 2019 9 59 AM ...

Page 105: ...the bolts and then take the panel off To install the panel Place the panel in the original position and then install the bolts Panel E To remove the panel Pull outward on the areas shown to release the projections and then slide the panel out 1 Bolt 2 Panel D 1 2 UBB562E0 book Page 13 Thursday March 14 2019 9 59 AM ...

Page 106: ...remove the panel 1 Remove panels B and C 2 Remove the cover For handlebar mounted light cover equipped models Remove the handlebar mounted light cover See page 8 59 For handlebar mounted light cover non equipped models Remove the handlebar cover 1 Handlebar mounted light cover 1 UBB562E0 book Page 14 Thursday March 14 2019 9 59 AM ...

Page 107: ...e the carrier bolts under the fenders and then take the carrier off 1 Handlebar cover 1 Carrier bolt top 2 Panel F 1 1 1 1 2 1 Carrier bolt under the fenders 1 Carrier bolt under the fenders 1 1 UBB562E0 book Page 15 Thursday March 14 2019 9 59 AM ...

Page 108: ...ick fasteners 3 Place the carrier in the original position and then install the carrier bolts under the fenders 4 Install the carrier top bolts and then tighten all bolts to the specified torques 1 Quick fastener 1 Coupler 1 1 Tightening torques Carrier bolt top 34 N m 3 4 kgf m 25 lb ft Carrier bolt under fenders 7 N m 0 7 kgf m 5 2 lb ft UBB562E0 book Page 16 Thursday March 14 2019 9 59 AM ...

Page 109: ...is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in ac cordance with the periodic maintenance and lubri cation chart In addition the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included...

Page 110: ...spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specification To install the spark plug 1 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 2 Install the spark plug with the spark plu...

Page 111: ...fied in the periodic maintenance chart To check the engine oil level 1 Park the ATV on a level surface 2 Remove panel E See page 8 10 3 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level warm up the engine and then wait at least ten minutes until the oil settles for an accurate reading 4 Remove the engine oil filler cap and then wipe the dipstic...

Page 112: ...cessary 8 Install the engine oil filler cap and the panel To change the engine oil and replace the oil fil ter cartridge 1 Park the ATV on a level surface 2 Remove panel E See page 8 10 3 Start the engine warm it up for several min utes and then turn it off 4 Place an oil pan under the engine to collect the used oil 5 Remove the engine oil filler cap and then re move the engine oil drain bolt and ...

Page 113: ...is not be ing replaced 6 Remove panels C and D See page 8 10 7 Remove the oil filter cartridge with an oil filter wrench 1 Engine oil drain bolt 2 Gasket 1 2 1 Oil filter cartridge 1 Oil filter wrench 1 1 UBB562E0 book Page 21 Thursday March 14 2019 9 59 AM ...

Page 114: ...ge with an oil fil ter wrench and then tighten it to the specified torque with a torque wrench 10 Install panels D and C 11 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the spec ified torque 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 N m 1 7 kgf m 13 lb ft Tightening torque Engine oil drain bolt 27 N m 2 7 kgf m 20 lb ft 1 UBB562E0 book ...

Page 115: ...e engine off wait at least ten minutes and then check the oil level and correct it if necessary 16 Install panel E EBU38620 Why Yamalube YAMALUBE oil is a Genuine YAMAHA Part born of the engineers passion and belief that engine oil is an important liquid engine component We form teams of specialists in the fields of mechanical en gineering chemistry electronics and track test ing and have them dev...

Page 116: ... the final gear oil level 1 Park the ATV on a level surface 2 Remove the final gear oil filler bolt and its gas ket and then check the oil level in the final gear case The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 4 Check the oil filler bolt gasket for damage and r...

Page 117: ...ase 5 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque 6 Refill with the recommended final gear oil to the brim of the filler hole as shown NOTICE Be sure no foreign material enters the final gear case ECB00422 Tightening torque Final gear oil filler bolt 22 N m 2 2 kgf m 16 lb ft 1 Final gear case guard 2 Bolt 1 2 1 Final gear oil drain bolt 2 Gasket Tig...

Page 118: ...ck the final gear case for oil leakage If oil is leaking check for the cause 10 Install the final gear case guard by installing the bolts and then tightening them to the specified torque 1 Final gear oil filler bolt 2 Gasket 3 Final gear oil 4 Correct oil level Recommended final gear oil Yamaha Friction Modified Shaft Drive Gear Oil Oil quantity 0 38 L 0 40 US qt 0 33 Imp qt 1 2 3 4 Tightening tor...

Page 119: ...ws at the intervals specified in the periodic maintenance and lubrication chart For non differential gear lock models For differential gear lock models 1 Differential gear oil filler bolt 2 Gasket 2 1 Recommended differential gear oil Yamaha Friction Modified Shaft Drive Gear Oil or SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 35 L 0 37 US qt 0 31 Imp qt 1 Differential gear oil filler bolt 2 Gas...

Page 120: ... filling Overfilling will cause the oil to seep out of the breather hose during and af ter riding The differential gear case capacity is greater than the recommended oil quantity therefore the oil level cannot be accurately checked from the oil filler hole 6 Check the oil filler bolt gasket for damage and replace it if necessary 7 Install the oil filler bolt and its gasket and then tighten the bol...

Page 121: ...d water only Howev er if distilled water is not available soft water may be used for refilling Do not use hard water or salt water since they are harmful to the en gine EBU2712A To check the coolant level 1 Park the ATV on a level surface TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture 2 Check the coolant level in the coolant reser voir Tight...

Page 122: ...k in stall the reservoir cap and then install the panel NOTICE If coolant is not available use distilled water or soft tap water in stead Do not use hard water or salt water since they are harmful to the engine If wa ter has been used instead of coolant re place it with coolant as soon as possible otherwise the cooling system will not be protected against frost and corrosion If water has been adde...

Page 123: ...ce a thick rag over the cap when opening Allow any remaining pressure to escape before completely removing the cap 1 Park the ATV on a level surface 2 Remove the front carrier and panel F See page 8 10 3 Remove the radiator cap 4 Remove panels D and E See page 8 10 5 Place a container under the engine and then remove the coolant drain bolt and its gasket Use a trough or a similar object as shown t...

Page 124: ...water 9 Install the coolant drain bolt and its new gas ket and then tighten the bolt to the specified torque 10 Connect the coolant reservoir hose 11 Pour the recommended coolant into the res ervoir to the maximum level mark and then install the reservoir cap 1 Coolant drain bolt 2 Gasket 3 Trough 2 1 3 1 Coolant reservoir hose Tightening torque Coolant drain bolt 10 N m 1 0 kgf m 7 4 lb ft 1 UBB5...

Page 125: ...peration When servicing the air filter elements check the air filter case inlet for obstruc tions Check the air filter case rubber joint to the throttle body and the rubber joint manifold fittings for an air tight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine TIP Replace the air filter elements if damaged Service the air filter more frequently if...

Page 126: ... main air filter assembly and sub air filter element 1 Air filter case cover holder 2 Air filter case cover 1 1 2 1 Main air filter assembly 1 Sub air filter element 1 1 UBB562E0 book Page 34 Thursday March 14 2019 9 59 AM ...

Page 127: ...1943 7 Squeeze out the excess moisture and let dry NOTICE Do not twist the sponge material when squeezing it ECB00442 8 Check the air filter elements sponge material for damage replace if necessary 9 Apply YAMALUBE Foam Air Filter Oil or equivalent to the air filter elements TIP The sponge material should be wet but not drip ping 10 Install the sub air filter element 11 Install the main air filter...

Page 128: ...rformance and possible overheating ECB00763 13 Install the seat EBU28905 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester WARNING EWB02342 Always let the exhaust system cool prior to touching exhaust components Do not start the engine with the spark arrester removed Sparks or exhaust particulate can cause eye injury burns or start a fire...

Page 129: ...t cooling duct check hose If dust or water collects in the V belt cooling duct check hose remove the hose and clean it EBU23932 V belt case drain plug After riding in water deep enough to allow it to en ter the V belt case remove the V belt case drain plug to drain the water from the case TIP If water drains from the V belt case after removing the plug have a Yamaha dealer check the ATV as the wat...

Page 130: ...le lever free play For non differential gear lock models 1 V belt case drain plug 1 1 Throttle lever free play 2 Rubber cover 3 Locknut 4 Throttle lever free play adjusting bolt 2 4 3 1 UBB562E0 book Page 38 Thursday March 14 2019 9 59 AM ...

Page 131: ...ng in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenance and lu brication chart EBU29602 Brakes Replacement of brake components requires pro fessional knowledge Brake service should be performed by a Yamaha dealer WARNING EWB02572 Operating with improperly servi...

Page 132: ... dam aged or if the lining thickness reaches the specified limit have a Yamaha dealer replace the brake pads as a set TIP The wheels need to be removed to check the brake pads See page 8 63 EBU30321 Rear brake friction plates The rear brake friction plates must be checked and if necessary replaced by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EBU29...

Page 133: ...ve a Yamaha dealer check the brake sys tem before further riding WARNING EWB02721 Improper maintenance can result in loss of braking ability Observe these precautions Insufficient brake fluid may allow air to enter the brake system reducing braking perfor mance Clean the filler cap before removing Use only DOT 4 brake fluid from a sealed contain er Use only the specified brake fluid otherwise the ...

Page 134: ...es replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EBU24396 Checking the front brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer in spect the brake system EBU30348 Adjusting the rear brake lever and brake pedal The rear brake lever...

Page 135: ...e brake lever free play turn the adjusting bolt in direction b NOTICE Distance A must not measure more than 12 7 mm 0 50 in If distance A exceeds 12 7 mm 0 50 in the specified brake lever free play cannot be obtained therefore proceed with the following steps ECB01143 1 Brake lever free play Brake lever free play 10 0 mm 0 39 in 1 1 Locknut 2 Distance A 3 Brake lever free play adjusting bolt 1 2 3...

Page 136: ...CE Make sure that distance B measures 22 mm 0 87 in or less If distance B reaches 22 mm 0 87 in adjust the brake lever free play at the brake lever again If distance A exceeds 12 7 mm 0 50 in have a Yamaha dealer check the vehicle ECB01153 7 Tighten the brake cable adjuster locknut 8 Slide the rubber cover to its original position 9 Tighten the locknut at the brake lever Adjusting the brake pedal ...

Page 137: ...ight is within the specified limits 4 Tighten the locknut 5 Install the footboard by installing the quick fasteners bolts and nuts and then tighten the bolts to the specified torques Brake pedal height 80 0 mm 3 15 in 1 Footboard 2 Quick fastener 3 Bolt and nut 4 Bolt 4 2 3 3 1 2 1 Locknut 2 Adjusting bolt Tightening torque Locknut 7 N m 0 7 kgf m 5 2 lb ft 2 1 UBB562E0 book Page 45 Thursday March...

Page 138: ...rder shown 1 Footboard bolt A 2 Footboard bolt B 3 Quick fastener 3 1 2 1 3 Tightening torques Footboard bolt A 4 0 N m 0 40 kgf m 3 0 lb ft Footboard bolt B 8 N m 0 8 kgf m 5 9 lb ft 1 4 3 2 5 5 UBB562E0 book Page 46 Thursday March 14 2019 9 59 AM ...

Page 139: ...direc tion a To decrease the brake pedal free play turn the adjusting nut in direction b 3 Tighten the locknut EBU24231 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart Check the axle boots for tears or damage If any damage is found have them replaced by a Yamaha dealer 1 Brake pedal free play Brake pedal free play 20...

Page 140: ...uld be adjusted by a Yamaha dealer Turn the rear brake light switch adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b 1 Front axle boot each side 1 Rear axle boot each side 1 1 1 1 1 Rear brake light switch 2 Rear brake light switch adj...

Page 141: ...ntrols and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding in cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an accident or collision EBU28712 Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be che...

Page 142: ...ach ride and the pedal pivot should be lubricated if necessary EBU24964 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play Recommended lubricant Lithium soap based grease UBB562E0 book Page 50 Thursday March 14 2019 9 59 AM ...

Page 143: ... periodic mainte nance chart TIP For parts equipped with a grease nipple use a grease gun EBU25023 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the stabilizer bush es if necessary Recommended lubricant Lithium soap based grease 1 Grease nipple 1 UBB...

Page 144: ...quipped with a grease nipple use a grease gun EBU25095 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the pe riodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease 1 Grease nipple Recommended lubricant Lithium soap based grease 1 1 UBB562E0 book Page 52 Thursday March 14 2019 9 59 AM ...

Page 145: ...o add distilled water However the battery lead connections need to be checked and tightened and the bat tery terminals cleaned if corroded If the battery seems to have discharged recharge it as soon as possible TIP Wear gloves and eye protection in a ventilated area away from sparks and open flames Wash hands after handling It is recommended to have the battery serviced by a Yamaha dealer UBB562E0...

Page 146: ...sive gases Keep sparks flame cigarettes or other sources of ignition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN To remove the battery 1 Remove the seat NOTICE When removing the battery the main switch must be off and the negative lead must be disconnect ed before the positive lead ECB01002 2 Remove the battery holding plate by remov ing the bolts 3 Dis...

Page 147: ...e it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB00942 Always keep the battery charged Storing the battery in a discharged state for an extended period of time will cause permanent battery damage Do not store the battery in an excessively cold or warm place below freezing or a...

Page 148: ...stalling the bolts TIP Make sure the negative battery lead is routed un derneath the battery holding plate 4 Install the seat 1 Positive battery lead red 2 Negative battery lead black 3 Guide 1 2 3 1 Bolt 2 Battery holding plate 3 Negative battery lead black 3 1 1 2 UBB562E0 book Page 56 Thursday March 14 2019 9 59 AM ...

Page 149: ...cking or replacing a fuse 1 Turn off all electrical systems See page 4 1 1 Fuel injection system spare fuse 2 Fuel injection system fuse 3 Main fuse 4 EPS fuse equipped models 5 Fuse box 1 2 3 4 5 1 Auxiliary DC jack fuse 2 Four wheel drive motor fuse 3 Ignition fuse 4 Radiator fan motor fuse 5 Signaling system fuse 6 Headlight fuse 7 Spare fuse 1 2 3 4 5 6 7 UBB562E0 book Page 57 Thursday March 1...

Page 150: ... EWB02173 4 Turn on the main switch start the engine and then turn on the circuit in question 5 If the fuse immediately blows again have a Yamaha dealer check the vehicle Specified fuses Main fuse 40 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Four wheel drive motor fuse 10 0 A B5R1 B5R2 B5R3 3 0 A BJ5H BB5R BJ5D BJ5E BB5M Signaling system fuse 10 0 A Radiator fan motor fuse 20 0 A Auxiliary DC...

Page 151: ...t and right headlight bulbs 1 Remove the cover at the rear of the headlight by pulling it off 2 Remove the bulb cover by pulling it off 3 Remove the socket by pushing it in and turn ing it counterclockwise 1 Cover at the rear of the headlight 1 1 Bulb cover 1 Socket 1 1 UBB562E0 book Page 59 Thursday March 14 2019 9 59 AM ...

Page 152: ...e socket by pushing it in and turning it clockwise 7 Install the bulb cover and the cover at the rear of the headlight NOTICE Make sure the bulb cover is securely fitted over the sock et and seated properly ECB03320 8 Adjust the headlight beam if necessary Handlebar mounted light bulb equipped mod els 1 Remove the handlebar mounted light cover by removing the quick fasteners 2 Remove the bulb cove...

Page 153: ...ncy of the glass luminosity of the bulb and bulb life Thoroughly clean off any dirt and fin gerprints using a cloth moistened with al cohol or thinner ECB00653 6 Install the socket by pushing it in and turning it clockwise 7 Install the bulb cover NOTICE Make sure the bulb cover is securely fitted over the socket and seated properly ECB03320 1 Bulb cover 1 Socket 1 1 1 Do not touch the glass part ...

Page 154: ... NOTICE ECB00691 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting screw in direction a To lower a headlight beam turn the adjusting screw in direction b For equipped models 1 Headlight beam adjusting screw 1 Handlebar mounted light beam adjusting screw a b 1 1 a b UBB562E0 book Page 62 Thursday March 14 2019 9 59 AM ...

Page 155: ...burnt out bulb by pushing it in and turning it counterclockwise 3 Insert a new bulb into the bulb holder push it in and then turn it clockwise until it stops 4 Install the bulb holder together with the bulb by turning it clockwise EBU25653 Removing a wheel 1 Park the ATV on a level surface 2 Loosen the wheel nuts 1 Brake tail light bulb holder 1 1 Brake tail light bulb 1 UBB562E0 book Page 63 Thur...

Page 156: ...tall the wheel with the arrow mark pointing in the forward rotating direction of the wheel and then install the wheel nuts TIP For models with tapered nuts be sure to install the nuts with their tapered side towards the wheel 1 Wheel nut 1 1 1 Arrow mark 2 Forward rotating direction 3 Wheel nut 1 2 3 UBB562E0 book Page 64 Thursday March 14 2019 9 59 AM ...

Page 157: ...o a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02281 Do not smoke when checking the fuel system Fuel can ignite or explode causing sev...

Page 158: ... the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engine does not start Check the compression Dry Wet Operate the electric starter Have a Yamaha dealer check the ATV The engine does not start Check the ignition Operate the electric starter 2 Battery The engine turns over quic...

Page 159: ...ended coolant as soon as possible The engine will tend to overheat if the radiator is caked with mud or if the ATV is overloaded Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See TIP Start the engine If t...

Page 160: ...on dry out the linings EWB02312 NOTICE Excessive wa ter pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure de tergent applications such as those avail able in coin operated car washers ECB00712 4 Once most of the dirt has been hosed off wash all surfaces with war...

Page 161: ...e following steps to protect the en gine from internal corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparking during the next step d Turn the engine over several times with the star...

Page 162: ...9 3 9 8 Remove the battery and fully charge it See page 8 53 UBB562E0 book Page 3 Thursday March 14 2019 9 59 AM ...

Page 163: ...289 0 kg 637 lb YFM45KDXL 295 0 kg 650 lb YFM45KPAL 301 4 kg 664 lb YFM450FWB 307 4 kg 678 lb BB5M 308 3 kg 680 lb B5R1 B5R3 313 5 kg 691 lb B5R2 Loading Maximum loading limit 240 0 kg 530 lb Total weight of rider cargo accessories and tongue Noise and vibration level Noise level 77 311 EEC 78 0 dB A at 3125 r min YFM450FWB YFM450FWBD Uncertainty of measurement 3 0 dB A YFM450FWB YFM450FWBD Vibrat...

Page 164: ...m Wet sump Engine oil Recommended brand SAE viscosity grades 5W 30 10W 30 10W 40 15W 40 20W 40 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Quantity Oil change 2 30 L 2 43 US qt 2 02 Imp qt With oil filter removal 2 40 L 2 54 US qt 2 11 Imp qt Final gear oil Type Yamaha Friction Modified Shaft Drive Gear Oil Quantity 0 38 L 0 40 US qt 0 33 Imp qt 0 10 30 50 70...

Page 165: ...ement Wet element Air filter oil grade Foam air filter oil Fuel Recommended fuel Regular unleaded gasoline Gasohol E10 acceptable Minimum research octane 91 Fuel tank capacity 14 L 3 7 US gal 3 1 Imp gal Fuel reserve amount 4 0 L 1 06 US gal 0 88 Imp gal Throttle body ID mark BB51 00 Spark plug s Manufacturer model NGK DR7EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Drivetrain Primary reduction rat...

Page 166: ...i Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum Front 32 0 kPa 0 320 kgf cm 4 6 psi Rear 27 0 kPa 0 270 kgf cm 4 0 psi With cargo or trailer For Europe Recommended Front 50 0 kPa 0 500 kgf cm 7 3 psi Rear 50 0 kPa 0 500 kgf cm 7 3 psi Minimum Front 45 0 kPa 0 450 kgf cm 6 5 psi Rear 45 0 kPa 0 450 kgf cm 6 5 psi Front wheel Rim size 12 x 6 0AT Rear wheel Rim size 12 x 7 5AT Front brake Type Hydraulic...

Page 167: ...bar mounted light T15H 35 0 W 36 5 W YFM450FWBD YFM45KPAL Brake tail light 21 0 W 5 0 W Meter lighting LED Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Park indicator light LED Four wheel drive indicator light LED Engine trouble warning light LED Differential gear lock indicator light LED B5R1 B5R2 B5R3 EPS warning light LED YFM450FWBD YFM45KPAL Fus...

Page 168: ...sure of work force include the characteristics of the work room the other sources of noise etc i e the number of machines and other adjacent process es and the length of time for which an operator is exposed to the noise Also the permissible expo sure level can vary from country This information however will enable the user of the machine to make a better evaluation of the hazard and risk EBU38670...

Page 169: ...ON EBU26032 Vehicle identification number The vehicle identification number is stamped into the frame This 17 digit number is used to identify your individual ATV EBU26052 Model label The model label is affixed at the location shown The model label information is used to identify your specific model and its color code 1 Vehicle identification number front left side 1 UBB562E0 book Page 1 Thursday ...

Page 170: ...combustion engines of non road mobile machinery Your Yamaha engine was designed and tested to give an optimal blend of performance without ex cessive emissions Therefore do not attempt to alter the engine specifications or tamper with the intake engine or exhaust systems NOTICE ECB03790 Tampering with the engine or emissions con trol system will void the European Union type approval of this engine...

Page 171: ... warning light 4 2 D Differential gear lock indicator equipped models 4 4 Differential gear oil 5 3 Differential gear oil changing 8 27 Display unit 4 4 Drive select lever 4 15 Drive select lever and driving in reverse 6 2 Drive shaft universal joint lubricating 8 51 E Emissions Certification label for Europe 11 2 Engine break in 6 4 Engine oil 5 3 Engine oil and oil filter cartridge 8 19 Engine s...

Page 172: ...ur ATV 7 1 S Safety information 2 1 Seat 4 18 Shock absorber assemblies adjusting the front and rear 4 20 Spark arrester cleaning 8 36 Spark plug checking 8 17 Specifications 10 1 Speed limiter 4 13 Stabilizer bushes checking 8 51 Starting the engine 6 1 Start switch 4 9 Steering shaft lubricating 8 52 Storage 9 2 Storage compartment 4 19 T Throttle lever 4 13 5 4 Throttle lever free play adjustin...

Page 173: ...12 3 12 Y Yamalube 8 23 UBB562E0 book Page 3 Thursday March 14 2019 9 59 AM ...

Page 174: ...APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PAVED ROADS NEVER CARRY PASSENGERS NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND ...

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Yamaha KODIAK 450 2020, Owner'S Manual

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Summary of Contents for KODIAK 450 2020

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