Yamaha KODIAK ULTRAMATIC YFM400FWAN 2000 User manual

PRINTED IN JAPAN
2000 ·4-5.8 ×1CR
(E)
PRINTED ON RECYCLED PAPER
WARNING
ALWAYS:
• use proper riding techniques to avoid
vehicle overturns on hills and rough terrain
and in turns.
• avoid paved surfaces-pavement may
seriously affect handling and control.
Improper ATV use can result in SEVERE INJURY or DEATH.
NEVER USE
WITH DRUGS
OR ALCOHOL
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE GEAR
NEVER USE
ON PUBLIC
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 WARNINGS.
(For replacement manual, call 1-800-532-1558)
YAMAHA MOTOR CO.,LTD.
5GH-28199-11LIT-11626-14-05
READ THIS MANUAL CAREFULLY!
It contains important safety information.
This ATV should not be ridden by anyone under 16 years of age.
WARNING
YFM400FWAN(C)
OWNER’S MANUAL

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INTRODUCTION
Congratulations on your purchase of the Yamaha YFM400FWAN. It represents the result of
many years of Yamaha experience in the production of fine sporting, touring, and pace-set-
ting 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 opera-
tion of this machine. This manual includes important safety information. It provides infor-
mation about special techniques and skills necessary to ride your machine. It also includes
basic maintenance and inspection procedures. If you have any questions regarding the op-
eration or maintenance of your machine, 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 MACHINE. MAKE SURE YOU UNDERSTAND
ALL INSTRUCTIONS.
●
PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE MACHINE.
●
NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE
TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-447-4700
FOR MORE INFORMATION.
● THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE
UNDER 16 YEARS OF AGE.

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IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN
SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following nota-
tions:
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 clear-
er.

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IMPORTANT NOTICE
This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe
to operate this machine on any public street, road or highway.
This machine 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 machine.
EBU00711
AFFIX DEALER
LABEL HERE
YFM400FWAN(C)
OWNER’S MANUAL
© 2000 by Yamaha Motor Corporation,
U.S.A.
1st Edition, March 2000
All rights reserved. Any reprinting or
unauthorized use without the written
permission of
Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in Japan.
P/N LIT-11626-14-05

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WARNING
Indicates a potential hazard that could re-
sult in serious injury or death.
CONTENTS
CONTROL FUNCTIONS...................4-1
Main switch.....................................4-1
Indicator lights................................4-2
Coolant temperature warning
light checking method..................4-4
Fuel gauge ......................................4-5
Handlebar switches .......................4-6
Throttle lever ..................................4-9
Speed limiter ................................4-10
Front brake lever ..........................4-11
Rear brake pedal and lever .........4-11
Drive select lever..........................4-12
Recoil starter.................................4-12
Fuel tank cap.................................4-13
Fuel cock .......................................4-14
Starter (choke) “ ”....................4-15
Seat................................................4-16
Storage box ..................................4-17
Front carrier ..................................4-17
Rear carrier ...................................4-17
Front shock absorber
adjustment...................................4-18
4
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
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Rear shock absorber
adjustment ..................................4-20
Auxiliary DC jack..........................4-21
PRE-OPERATION CHECKS ............. 5-1
Front and rear brakes .................... 5-2
Fuel.................................................. 5-4
Engine oil........................................ 5-6
Final gear oil................................... 5-7
Differential gear oil ........................ 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
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PERIODIC MAINTENANCE AND
ADJUSTMENT .................................8-1
Owner’s manual and tool kit ........8-1
Periodic maintenance/
lubrication .....................................8-3
Panel removal and
installation.....................................8-5
Engine oil......................................8-12
Final gear oil.................................8-15
Differential gear oil ......................8-18
Cooling system ............................8-20
Changing the coolant ..................8-21
Front axle boots ...........................8-25
Spark plug ....................................8-25
Air filter cleaning..........................8-28
V-belt cooling duct check
hose .............................................8-31
Spark arrester cleaning ...............8-32
Carburetor adjustment................8-33
Idle speed adjustment .................8-34
Valve clearance adjustment........8-34
Throttle lever adjustment............8-35
Front brake pad inspection .........8-36
Rear brake pad inspection...........8-37
Inspecting the brake fluid
level ..............................................8-37
Brake fluid replacement ..............8-39
Front brake adjustment ...............8-39
Rear brake lever adjustment.......8-41
Rear brake pedal height
adjustment...................................8-41
Cable inspection and
lubrication....................................8-43
Brake lever and brake pedal
lubrication....................................8-43
Wheel removal .............................8-44
Wheel installation ........................8-45
Battery ...........................................8-46
Battery maintenance....................8-47
Fuse replacement.........................8-47
Replacing the headlight
bulb ..............................................8-49
Headlight beam adjustment .......8-51
Taillight bulb replacement ..........8-51
Troubleshooting...........................8-53
Troubleshooting chart .................8-54
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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
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LOCATION OF THE WARNING AND
SPECIFICATION LABELS

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Read and understand all of the labels on
your machine. They contain important in-
formation for safe and proper operation of
your ATV.
Never remove any labels from your ATV. If
a label becomes difficult to read or comes
off, a replacement label is available from
your Yamaha dealer.
1
2
40 kg (88 lbs)
4GB-24877-A0
LOAD LIMIT
WARNING
NEVER sit here.
3MX-24875-A0
3
4

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5
6
80 kg (176 lbs)
4SH-24877-A0
LOAD LIMIT
UNDER
WARNING
5FE-21697-01
NEVER operate this ATV if you are
under age 16.
Operating this ATV if you are under
the age of 16 increases your chance
of severe injury or death.
7

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SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differ-
ently from other vehicles including motorcycles and cars. A collision or rollover can occur
quickly, even during routine maneuvers such as turning and riding on hills or over obsta-
cles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
●
Read this manual and all labels carefully and follow the operating procedures described.
●
Never operate an ATV without proper training or instruction. Take a Training Course. Be-
ginners should receive training from a certified instructor. Contact an authorized ATV
dealer or call 1-800-447-4700 to find out about the training courses nearest you.
●
Always follow the age recommendation:
– A child under 16 years old should never operate an ATV with engine size greater than
90cc.
●
Never allow a child under age 16 to operate an ATV without adult supervision, and never
allow continued use of an ATV by a child if he or she does not have the abilities to oper-
ate it safely.
●
Never carry passenger on an ATV.
●
Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways,
parking lots and streets.
●
Never operate an ATV on any public street, road or highway, even a dirt or gravel one.

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●
Never operate an ATV without wearing an approved motorcycle helmet that fits proper-
ly. You should also wear eye protection (goggles or face shield), gloves, boots, long-
sleeved shirt or jacket, and long pants.
●
Never consume alcohol or drugs before or while operating this ATV.
● Never operate at speeds too fast for your skills or the conditions. Always go at a speed
that is proper for the terrain, visibility and operating conditions, and your experience.
●
Never attempt wheelies, jumps, or other stunts.
●
Always inspect your ATV each time you use it to make sure it is in safe operating condi-
tion. Always follow the inspection and maintenance procedures and schedules de-
scribed in this manual.
●
Always keep both hands on the handlebars and both feet on the footboards of the ATV
during operation.
●
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be
alert to changing terrain conditions when operating the ATV.
●
Never operate on excessively rough, slippery or loose terrain until you have learned and
practiced the skills necessary to control the ATV on such terrain. Always be especially
cautious on these kinds of terrain.
●
Always follow proper procedures for turning as described in this manual. Practice turn-
ing at low speeds before attempting to turn at faster speeds. Do not turn at excessive
speed.
●
Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on
smaller hills before attempting larger hills.
2
2
2
2
2
2
2
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●
Always follow proper procedures for climbing hills as described in this manual. Check
the terrain carefully before you start up any hill. Never climb hills with excessively slip-
pery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or
make sudden gear changes. Never go over the top of a hill at high speed.
● Always follow proper procedures for going down hills and for braking on hills as de-
scribed in this manual. Check the terrain carefully before you start down any hill. Shift
your weight backward. Never go down a hill at high speed. Avoid going down a hill at an
angle that would cause the vehicle to lean sharply to one side. Go straight down the hill
where possible.
●
Always follow proper procedures for crossing the side of a hill as described in this man-
ual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill
side of the ATV. Never attempt to turn the ATV around on any hill until you have mas-
tered the turning technique described in this manual on level ground. Avoid crossing the
side of a steep hill if possible.
●
Always use proper procedures if you stall or roll backwards when climbing a hill. To
avoid stalling, use proper gear and maintain a steady speed when climbing a hill. If you
stall or roll backwards, follow the special procedure for braking described in this manual.
Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around
and remount, following the procedure described in this manual.
●
Always check for obstacles before operating in a new area.
Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always
follow proper procedures when operating over obstacles as described in this manual.

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●
Always be careful when skidding or sliding. Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces,
such as ice, go slowly and be very cautious in order to reduce the chance of skidding or
sliding out of 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 no obstacles or people behind you when you operate in re-
verse. When it is safe to proceed in reverse, go slowly.
●
Always use the size and type tires specified in this manual.
●
Always maintain proper tire pressure as described in this manual.
●
Never modify an ATV through improper installation or use of accessories.
●
Never exceed the stated load capacity for an ATV. Cargo should be properly distributed
and securely attached. Reduce speed and follow instructions in this manual for carrying
cargo or pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Com-
mission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.

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WARNING
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could be
burned.
HOW TO AVOID THE HAZARD
Always turn off the engine when refuel-
ing.
Do not refuel right after the engine has
been running and is still very hot.
Do not spill gasoline on the engine or
exhaust pipe/muffler when refueling.
Never refuel while smoking, or while in
the vicinity of sparks, open flames, or
other sources of ignition such as the pi-
lot lights of water heaters and clothes
dryers.
When transporting the machine in an-
other vehicle, be sure it is kept upright
and that the fuel cock is in the “OFF” po-
sition. Otherwise, fuel may leak out of
the carburetor or fuel tank.
WHAT CAN HAPPEN
Gasoline is poisonous and can cause in-
juries.
HOW TO AVOID THE HAZARD
If you should swallow some gasoline or
inhale a lot of gasoline vapor, or get
some gasoline in your eyes, see your
doctor immediately. If gasoline spills on
your skin, wash with soap and water. If
gasoline spills on your clothing, change
your clothes.

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WARNING
POTENTIAL HAZARD
Starting or running the engine in a
closed area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your machine in an area
with adequate ventilation.

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DESCRIPTION AND MACHINE IDENTIFICATION
1. Rear spring preload
adjusting ring
2. Spark arrester
3. Storage compartment
and tool kit
4. Spark plug
5. Rear brake fluid reservoir
6. Radiator cap
7. Front spring preload
adjusting ring
8. V-belt case
9. Rear brake pedal
10. Front spring preload
adjusting ring
11. Fuel cock
12. Air filter case
13. Fuses
14. V-belt cooling duct check hose
15. Coolant reservoir
16. Oil filter cartridge
17. Engine oil dipstick
18. Rear brake lever
19. Left handlebar switches
20. Starter (choke)
21. Drive select lever
22. Speedometer
23. Main switch
24. Fuel tank cap
25. Auxiliary DC jack
26. Right handlebar switch
27. Throttle lever
28. Front brake lever
N
O
TE:
The machine you have purchased may differ slight-
ly from those shown in the figures of this manual.