2005-2006 Yamaha Kodiak 400 4×4 Service Manual And Atv Owners Manual Workshop Repair Download

2005-2006 Yamaha Kodiak 400 4×4 Service Manual And Atv Owners Manual Workshop Repair

TABLE OF CONTENTS:

SPECIFICATIONS 1
GENERAL SPECIFICATIONS 1
MAINTENANCE SPECIFICATIONS 3
ENGINE 3
CHASSIS 4
ELECTRICAL 6
CABLE ROUTING 7
PERIODIC CHECKS AND ADJUSTMENTS 18
INTRODUCTION 18
PERIODIC MAINTENANCE/LUBRICATION 18
SEAT, CARRIERS, FENDERS AND FUEL TANK 20
FRONT CARRIER, FRONT BUMPER AND FRONT FENDER 20
CHASSIS 22
ADJUSTING THE REAR BRAKE 22
CHECKING THE BRAKE FLUID LEVEL 24
CHECKING THE REAR BRAKE PADS 25
CHECKING THE BRAKE HOSES 25
BLEEDING THE HYDRAULIC BRAKE SYSTEM 26
ADJUSTING THE SELECT LEVER CONTROL CABLE
AND SHIFT ROD 27
CHECKING THE FINAL GEAR OIL LEVEL 29
CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS 29
ADJUSTING THE REAR SHOCK ABSORBERS 30
ENGINE 31
CRANKCASE 31
STARTER MOTOR, TIMING CHAIN AND OIL FILTER 31
CRANKCASE 34
INSTALLING THE SHIFT LEVER 35
TRANSMISSION 36
CHECKING THE STOPPER LEVER AND STOPPER WHEEL 38
MIDDLE GEAR 39
MIDDLE DRIVEN SHAFT 39
DRIVE TRAIN 41
TROUBLESHOOTING 41
FRONT CONSTANT VELOCITY JOINTS
AND DIFFERENTIAL GEAR 44
MEASURING AND ADJUSTING THE DIFFERENTIAL
GEAR LASH 44
REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR
AND DRIVE SHAFT 46
ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS 51
DISASSEMBLING THE FINAL DRIVE GEAR 52
CHECKING THE DRIVE SHAFT/UNIVERSAL JOINT YOKE 52
CHECKING THE FINAL DRIVE GEAR 53
REPLACING THE FINAL DRIVE ROLLER BEARING 53
REPLACING THE FINAL DRIVE PINION GEAR AND BEARING 54
POSITIONING THE FINAL DRIVE PINION GEAR 56
MEASUREMENT AND ADJUSTING THE FINAL GEAR LASH 57
ASSEMBLING THE FINAL DRIVE GEAR 60
CHASSIS 62
FRONT AND REAR WHEELS 62
REAR WHEELS 62
INSTALLING THE REAR BRAKE DISC 64
INSTALLING THE REAR WHEEL HUBS 64
REAR BRAKE 65
REAR BRAKE PADS 65
REPLACING THE REAR BRAKE PADS 66
REAR BRAKE MASTER CYLINDER 68
CHECKING THE MASTER CYLINDER 71
ASSEMBLING THE REAR BRAKE MASTER CYLINDER 71
INSTALLING THE REAR BRAKE MASTER CYLINDER 72
REAR BRAKE CALIPER 74
DISASSEMBLING THE REAR BRAKE CALIPER 76
CHECKING THE REAR BRAKE CALIPER 76
ASSEMBLING THE REAR BRAKE CALIPER 77
INSTALLING THE REAR BRAKE CALIPER 78
STEERING SYSTEM 80
STEERING STEM 80
FRONT ARMS AND FRONT SHOCK ABSORBERS 82
REAR KNUCKLES AND STABILIZER 84
CHECKING THE REAR KNUCKLES 85
CHECKING THE STABILIZER 85
REAR ARMS AND REAR SHOCK ABSORBERS 86
CHECKING THE REAR ARMS 87
INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBERS 87
ELECTRICAL 88
ELECTRICAL COMPONENTS 88
CHECKING THE SWITCHES 90
CHECKING THE SWITCH CONTINUITY 90
SIGNAL SYSTEM 92
CIRCUIT DIAGRAM 92
CHECKING THE SIGNAL SYSTEM 94

DESCRIPTION:

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

This Supplementary Service Manual has been prepared to introduce new service and data for the YFM400FAT. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.

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