Yamaha KODIAK 450 User manual

DIC183
YFM45KDXJ/YFM45KPXJ
YFM45KDHJ/YFM45KPAJ
YFM45KPHJ
OWNER’S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
BB5-F8199-60
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.

DIC183
Original instructions
Notice originale
Manual original
PRINTED IN USA
2017.03-1.1×2 CR
(E,F,S)

READ THIS MANUAL CAREFULLY!
It contains important safety information.
WARNING
OWNER’S MANUAL
YFM45KDXJ/YFM45KPXJ
YFM45KDHJ/YFM45KPAJ
YFM45KPHJ
This ATV should not be ridden by anyone under 16 years of age.
BB5-F8199-60-E0
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EBU37040
Read this manual carefully before operating this vehicle. This manual should stay with this ve-
hicle if it is sold.
EN15997, ANSI/SVIA 1-2010
General Manager
Engineering Division
Recreational Vehicle Business Unit
Vehicle & Solution Business Operations
YAMAHA MOTOR CO., LTD.
23 January, 2017
We,YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan,
declare in sole responsibility, that the product
(Make, model)
(If applicable)
and to the other relevant Directives of EEC
2014/30/EU
(Title and/or number and date of issue of the other Directives of EEC)
(If applicable)
YAMAHA MOTOR EUROPE N.V.
Koolhovenlaan 101, 1119 NC Schiphol-Rijk, The Netherlands
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 specifications)
Authorized Representative
EC Declaration of Conformity
conforming to Directive 2006/42/EC
Manufacturer
YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA
1000 GA Highway 34 East, Newnan, Georgia 30265-1320, U.S.A.
YFM450FWB (YFM45KDXJ) (5Y4AJ81W0H0500101–)
(YFM45KDHJ) (5Y4AJ81W0H0500101–)
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EN15997, ANSI/SVIA 1-2010
General Manager
Engineering Division
Recreational Vehicle Business Unit
Vehicle & Solution Business Operations
YAMAHA MOTOR CO., LTD.
23 January, 2017
We,YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan,
declare in sole responsibility, that the product
(Make, model)
(If applicable)
and to the other relevant Directives of EEC
2014/30/EU
(Title and/or number and date of issue of the other Directives of EEC)
(If applicable)
YAMAHA MOTOR EUROPE N.V.
Koolhovenlaan 101, 1119 NC Schiphol-Rijk, The Netherlands
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 specifications)
Authorized Representative
EC Declaration of Conformity
conforming to Directive 2006/42/EC
Manufacturer
YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA
1000 GA Highway 34 East, Newnan, Georgia 30265-1320, U.S.A.
YFM450FWBD (YFM45KPXJ) (5Y4AJ79W0H0500100–)
(YFM45KPAJ) (5Y4AJ79W0H0500101–)
(YFM45KPHJ) (5Y4AJ79W0H0500101–)
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EBU17171
INTRODUCTION
EBU17293
Congratulations on your purchase of the Yamaha YFM45KDXJ / YFM45KPXJ / YFM45KDHJ /
YFM45KPAJ / YFM45KPHJ. This ATV represents the result of many years of Yamaha experience in the
production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha,
you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader
in these fields.
This manual will provide you with a good basic understanding of the features and operation of this ATV.
This manual includes important safety information. It provides information about special techni-
ques 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.
Pay close attention to the warning and notice labels on the ATV.
This ATV should not be ridden by anyone under 16 years of age.
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EBU17331
IMPORTANT MANUAL INFORMATION
EBU17343
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN-
JURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
* Product and specifications are subject to change without notice.
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 vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP
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EBU17351
IMPORTANT NOTICE
EBU17373
This ATV is designed and manufactured for use on unpaved surfaces only. It is unsafe to operate this ATV
on any paved surface, paved street, paved road or motorway.
Please check your local riding laws and regulations before operating this ATV.
EBU17411
YFM45KDXJ/YFM45KPXJ/YFM45KDHJ/
YFM45KPAJ / YFM45KPHJ
OWNER’S MANUAL
©2017 by Yamaha Motor Co., Ltd.
1st edition, February 2017
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.
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EBU17421
TABLE OF CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS .............................. 1-1
SAFETY INFORMATION ................................ 2-1
DESCRIPTION................................................3-1
Left view......................................................3-1
Right view.................................................... 3-1
Controls and instruments............................3-2
INSTRUMENT AND CONTROL
FUNCTIONS...................................................4-1
Main switch ................................................. 4-1
Indicator lights and warning lights ..............4-2
Display unit ................................................4-4
Self-diagnosis device..................................4-6
Handlebar switches .................................... 4-6
Throttle lever ............................................... 4-8
Speed limiter ............................................... 4-9
Front brake lever .......................................4-10
Brake pedal and rear brake lever.............. 4-10
Drive select lever....................................... 4-11
Fuel tank cap ............................................4-11
Fuel ...........................................................4-11
Seat .......................................................... 4-13
Storage compartment............................... 4-14
Front carrier .............................................. 4-15
Rear carrier ............................................... 4-15
Adjusting the front and rear shock
absorber assemblies ............................. 4-15
Auxiliary DC jack....................................... 4-17
Winch pre-wiring ...................................... 4-17
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 and rear brakes ................................. 5-3
Throttle lever............................................... 5-4
Tires ............................................................ 5-4
Chassis fasteners ....................................... 5-6
Instruments, lights and switches ................ 5-6
OPERATION .................................................. 6-1
Starting the engine ..................................... 6-1
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Operating the drive select lever and
driving in reverse....................................... 6-2
Engine break-in ...........................................6-4
Parking ........................................................6-4
Parking on a slope ......................................6-5
Accessories and loading.............................6-5
RIDING YOUR ATV ........................................7-1
GETTING TO KNOW YOUR ATV ................ 7-2
RIDE WITH CARE AND GOOD
JUDGMENT .............................................. 7-2
BE CAREFUL WHERE YOU RIDE...............7-9
TURNING YOUR ATV................................7-12
CLIMBING UPHILL ...................................7-13
RIDING DOWNHILL ..................................7-16
CROSSING A SLOPE................................7-17
CROSSING THROUGH SHALLOW
WATER....................................................7-18
RIDING OVER ROUGH TERRAIN .............7-20
SLIDING AND SKIDDING..........................7-21
WHAT TO DO IF........................................7-22
WHAT TO DO............................................7-22
PERIODIC MAINTENANCE AND
ADJUSTMENT................................................8-1
Owner’s manual and tool kit .......................8-2
Periodic maintenance chart: Emission
control system .......................................... 8-3
Periodic maintenance chart: General
maintenance and lubrication .................... 8-4
Removing and installing panels.................. 8-8
Checking the spark plug........................... 8-15
Engine oil and oil filter cartridge ............... 8-17
Final gear oil ............................................. 8-22
Changing the differential gear oil.............. 8-24
Coolant ..................................................... 8-26
Cleaning the air filter................................. 8-30
Cleaning the spark arrester ...................... 8-33
V-belt cooling duct check hose................ 8-35
V-belt case drain plug............................... 8-35
Adjusting the throttle lever free play......... 8-36
Valve clearance......................................... 8-36
Brakes....................................................... 8-37
Checking the front brake pads and rear
brake friction plates ................................ 8-37
Checking the brake fluid level .................. 8-38
Changing the brake fluid .......................... 8-39
Checking the front brake lever free play... 8-39
Adjusting the rear brake lever and brake
pedal....................................................... 8-40
Axle boots................................................. 8-45
Brake light switches ................................. 8-46
Checking and lubricating the cables ........ 8-46
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Checking and lubricating the front and
rear brake levers ..................................... 8-47
Checking and lubricating the brake
pedal .......................................................8-48
Checking the wheel hub bearings............. 8-48
Lubricating the drive shaft universal
joint .........................................................8-48
Checking the stabilizer bushes ................. 8-49
Lubricating the rear knuckle pivots...........8-49
Lubricating the steering shaft ................... 8-50
Battery....................................................... 8-51
Replacing a fuse ....................................... 8-54
Replacing a headlight bulb .......................8-57
Adjusting a headlight beam ......................8-60
Replacing the tail/brake light bulb ............ 8-61
Removing a wheel..................................... 8-61
Installing a wheel....................................... 8-62
Troubleshooting ........................................8-63
Troubleshooting charts .............................8-64
CLEANING AND STORAGE ........................... 9-1
Cleaning ...................................................... 9-1
Storage........................................................ 9-2
SPECIFICATIONS........................................ 10-1
CONSUMER INFORMATION....................... 11-1
Identification numbers .............................. 11-1
INDEX .......................................................... 12-1
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1-1
1
EBU29681
LOCATION OF THE WARNING AND SPECIFICATION LABELS
EBU37160
Read and understand 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.
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1-2
1
For Europe
1 42 3
7 8 9,10 11
5
6 666
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1-3
1
37S-F817R-00
< 40 kg
( 88 lbs)
37S-F817R-10
< 80 kg
( 176 lbs)
35.0 kPa
0.35 kgf/cm²
5.0 psi
30.0 kPa
0.30 kgf/cm²
4.4 psi
1HP-F816M-M0YAMAHA
1P0-F816P-20
12
34
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1-4
1
< 5880 N
< 600 kgf
< 1322 lbf
< 147 N
< 15 kgf
< 33 lbf
37S-F817S-00
1P0-F816R-00
BB5-F2259-20
75
6
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1-5
1
YAMAHA
1HP-F811R-00
YAMAHA MOTOR CO., LTD.
2500 SHINGAI, IWATA, JAPAN
YFM450FWBD
20.0 kW
295 kg
2017
BB5-F155A-00
YAMAHA MOTOR CO., LTD.
2500 SHINGAI, IWATA, JAPAN
YFM450FWB
20.0 kW
289 kg
2017
BJ5-F155A-00
E10
B42-F817K-00
8910
11 YFM45KDXJ / YFM45KDHJ 11 YFM45KPXJ / YFM45KPAJ / YFM45KPHJ
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1-6
1
Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check
the pictograms that apply to your model.
Read the Owner’s manual.
ALWAYS use an approved helmet and
protective 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.
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1-7
1
E10
**.* kPa
*.** kgf/cm²
*.* psi
**.* kPa
*.** kgf/cm²
*.* psi
YAMAHA MOTOR CO., LTD.
2500 SHINGAI, IWATA, JAPAN
******
*** kW
*** kg
****
1 2 3
4
This pictogram shows trailer Hitch Tow
weight limit. (Combined weight of the trailer
and all cargo in the trailer.)
Overloading can cause loss of control.
Loss of control can result in severe injury or
death.
EN228 fuel identification mark.
Gasoline of ethanol 10% or less can be
used.
Use unleaded gasoline only.
Measure the tire pressure when the tires are
cold.
Adjust the tire pressure.
Improper tire pressure can 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.
Overloading can cause loss of control.
Loss of control can result in severe injury or
death.
This pictogram shows trailer Hitch Tongue
weight limit. (Weight on the trailer tongue.)
Overloading can cause loss of control.
Loss of control can result in severe injury or
death.
1
2
3
4
Year of construction
Model Name
Max. Power
Mass In Running Order
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1-8
1
For Oceania
1 2 43 6
8 9
5
7 777
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1-9
1
Wait for the engine to return to normal idle speed
before shifting.
2UD-F151E-00
Recommended
Minimum
: FRONT
REAR
: FRONT
REAR
: 35 kPa, (5.0 psi)
: 30 kPa, (4.4 psi)
: 32 kPa, (4.6 psi)
: 27 kPa, (4.0 psi)
Never set tire pressure below minimum. It could cause
the tire to dislodge from the rim.
Cargo or a trailer can affect stability and handling.
Read owner’s manual before loading 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.
OPERATING TIRE PRESSURE : Set with tires cold
LOADING/TRAILER TOWING
5880 N
1322
(600 kgf)
( 15 kgf)
37S-F151K-00
12
34
5
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