The display unit on a Yamaha Kodiak 450 could stop working due to several reasons:

1. Battery Issues – A dead battery can cause power loss, which may affect the display.
2. CDI Failure – A failed CDI unit could impact the electrical system, leading to display failure.
3. Corroded Wiring – Corrosion in the wiring, particularly the brown and blue power wires, can prevent the display from receiving power.
4. Damaged Harness – A chewed or broken wiring harness can interrupt the power supply to the display.
5. Cracked Screen – Physical damage, such as a cracked display cover, could impact functionality.
6. PCB Damage – If the display unit's circuit board is damaged or riveted incorrectly, it may stop working.

These issues should be inspected and repaired accordingly to restore display functionality.

This answer is automatically generated

Summary of Contents for Yamaha Kodiak 450

Page 1 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. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM45KDXJ/YFM45KPXJ YFM45KDHJ/YFM45KPAJ YFM45KPHJ BB5-F8199-60...
Page 2 Original instructions Notice originale Manual original PRINTED IN USA 2017.03-1.1×2 CR (E,F,S)
Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM45KDXJ/YFM45KPXJ YFM45KDHJ/YFM45KPAJ YFM45KPHJ WARNING This ATV should not be ridden by anyone under 16 years of age. BB5-F8199-60-E0...
Page 4: Ec Declaration Of Conformity
Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM450FWB (YFM45KDXJ) (5Y4AJ81W0H0500101–)
Page 5 EC Declaration of Conformity conforming to Directive 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM450FWBD (YFM45KPXJ) (5Y4AJ79W0H0500100–) (YFM45KPAJ) (5Y4AJ79W0H0500101–) (YFM45KPHJ) (5Y4AJ79W0H0500101–) (Make, model) to which this declaration applies, conforms to the essential health and...
Page 6 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.
Page 7 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: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
Page 8 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.
Page 9: Table Of Contents
EBU17421 TABLE OF CONTENTS LOCATION OF THE WARNING AND Seat ............4-13 SPECIFICATION LABELS ......1-1 Storage compartment....... 4-14 Front carrier ..........4-15 SAFETY INFORMATION ........ 2-1 Rear carrier ..........4-15 Adjusting the front and rear shock DESCRIPTION..........3-1 absorber assemblies ......4-15 Left view............
Page 10 Operating the drive select lever and Periodic maintenance chart: Emission driving in reverse........6-2 control system .......... 8-3 Engine break-in ...........6-4 Periodic maintenance chart: General Parking ............6-4 maintenance and lubrication ....8-4 Parking on a slope ........6-5 Removing and installing panels....8-8 Accessories and loading ......6-5 Checking the spark plug......
Page 11 Checking and lubricating the front and SPECIFICATIONS........10-1 rear brake levers ........8-47 Checking and lubricating the brake CONSUMER INFORMATION....... 11-1 pedal ............8-48 Identification numbers ......11-1 Checking the wheel hub bearings..... 8-48 Lubricating the drive shaft universal INDEX ............12-1 joint ............8-48 Checking the stabilizer bushes ....
Page 12: Location Of The Warning And Specification Labels
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.
Page 13 For Europe 9,10...
Page 14 < 40 kg ( 88 lbs) 37S-F817R-00 35.0 kPa 30.0 kPa 0.35 kgf/cm² 0.30 kgf/cm² 5.0 psi 4.4 psi YAMAHA 1HP-F816M-M0 < 80 kg ( 176 lbs) 37S-F817R-10 1P0-F816P-20...
Page 15 < 5880 N < 600 kgf < 1322 lbf < 147 N < 15 kgf < 33 lbf 37S-F817S-00 BB5-F2259-20 1P0-F816R-00...
Page 16 11 YFM45KDXJ / YFM45KDHJ 11 YFM45KPXJ / YFM45KPAJ / YFM45KPHJ YFM450FWB YFM450FWBD 2017 2017 20.0 kW 20.0 kW YAMAHA MOTOR CO., LTD. YAMAHA MOTOR CO., LTD. 289 kg 295 kg 2500 SHINGAI, IWATA, JAPAN 2500 SHINGAI, IWATA, JAPAN BJ5-F155A-00 BB5-F155A-00...
Page 17 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. NEVER use on paved roads. ALWAYS use an approved helmet and NEVER carry passengers. protective gear.
Page 18 Loss of control can result in severe injury or Year of construction death. Model Name **** ****** **.* kPa **.* kPa *** kW *.** kgf/cm² *.** kgf/cm² YAMAHA MOTOR CO., LTD. Max. Power *** kg 2500 SHINGAI, IWATA, JAPAN *.* psi *.* psi Mass In Running Order...
Page 19 For Oceania...
Page 20 When riding with cargo or towing a trailer : Reduce speed 37S-F151K-00 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). YAMAHA B16-F816M-00...
Page 21 BB5-F2259-20 1-10...
Page 22 UNDER 1P0-F816L-00 1-11...
Page 23: Safety Information
EBU17432 SAFETY INFORMATION SAFETY INFORMATION  Never allow a child under age 16 to operate an EBU27255 ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
Page 24  Never operate at speeds too fast for your skills  Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
Page 25  Never operate an ATV in fast flowing water or in technique described in this manual on level ground. Avoid crossing the side of a steep hill if water deeper than that recommended in this possible. manual. Remember that wet brakes may have ...
Page 26  Never maintain an ATV without proper knowl- vehicle. If the vehicle is in safe operating con- edge. Contact an authorized ATV dealer to in- dition and you can safely operate it, restart it form you on basic ATV maintenance. Certain and ride gently back to camp or other known maintenance can only be carried out by certified location where you can receive medical at-...
Page 27 While you may find aftermarket products similar in of the operator and may limit control ability, design and quality to genuine Yamaha accesso- therefore, such accessories are not recom- ries, recognize that some aftermarket accessories mended.
Page 28  Do not run engine in poorly ventilated or par- gerous loss of lights or engine power. Also, the battery tends to discharge more quickly if elec- tially enclosed areas such as barns, garages, trical accessories are added. or carports. ...
Page 29: Description
EBU17681 DESCRIPTION EBU17691 EBU17701 Left view Right view 3 4 5 1. Radiator cap 1. Spark arrester 2. Air filter case 2. Storage compartment and tool kit 3. Battery 3. Fuel tank cap 4. Fuses 4. Spark plug 5. Tail/brake light 5.
Page 30: Controls And Instruments
EBU17714 Controls and instruments 1. Rear brake lever 2. Handlebar switches 3. Horn switch 4. Drive select lever 5. Display unit 6. Front brake fluid reservoir 7. On-Command four-wheel-drive switch “2WD”/“4WD” 8. Throttle lever 9. Front brake lever 10.Main switch The ATV you have purchased may differ slightly from the figures shown in this manual.
Page 31: Instrument And Control Functions
EBU17739 INSTRUMENT AND CONTROL FUNCTIONS EBU29912 Main switch The positions of the main switch are as follows: “ ” (on) All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.
Page 32: Indicator Lights And Warning Lights
7. On-Command four-wheel-drive indicator light “ ” the key is turned to “ ” (on), or if the warning light remains on, have a Yamaha dealer check the EBU17861 electrical circuit. Neutral indicator light “ ” This indicator light comes on when the transmis-...
Page 33 “ ” (on), or if the warning  The engine may overheat if the ATV is over- light remains on, have a Yamaha dealer check the electrical circuit. loaded. In this case, reduce the load to spec- ification.
Page 34: Display Unit
 If the steering load is too heavy (i.e., excessive EBU37051 Display unit steering use when the ATV is traveling at a slow speed), the power assist is reduced to protect the EPS motor from overheating. EBU17954 On-Command four-wheel-drive indicator light “...
Page 35 If this occurs, have The tripmeter shows the distance traveled since it a Yamaha dealer check the vehicle. was last reset. To reset the tripmeter, push the select button “SEL” for one second.
Page 36: Self-Diagnosis Device
Service tripmeter To prevent engine damage, be sure to consult The service tripmeter shows the distance traveled a Yamaha dealer as soon as possible if this oc- since it was reset at the last maintenance. curs. To reset the service tripmeter, push the select but- ton “SEL”...
Page 37 EBU18081 ECB00046 Engine stop switch “ ” NOTICE Set this switch to “ ” before starting the engine. Do not use the headlights with the engine The engine stop switch controls the ignition and turned off for an extended period of time. The stops the engine when it is running.
Page 38: Throttle Lever
handle differently. This could distract the oper- ator and increase the risk of losing control and of causing an accident. This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice ver- sa. Select the appropriate drive according to the terrain and the conditions.
Page 39: Speed Limiter
decrease the maximum engine power avail- able and the maximum speed of the ATV, turn the adjusting screw in direction (b). Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be damaged.
Page 40: Front Brake Lever
3. Tighten the locknut. EBU18392 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. 1. Brake pedal 1. Front brake lever EBU18443 Brake pedal and rear brake lever The brake pedal is located on the right side of the...
Page 41: Drive Select Lever
EBU18613 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. Fuel tank cap EBU18758 Fuel Make sure there is sufficient gasoline in the tank. EWB02522 WARNING 1.
Page 42 of sparks, open flames, or other sources of Recommended fuel: ignition such as the pilot lights of water heat- Regular unleaded gasoline only ers and clothes dryers. Fuel tank capacity: 2. Do not overfill the fuel tank. When refueling, 14.0 L (3.70 US gal, 3.08 Imp.gal) be sure to insert the pump nozzle into the fuel Fuel reserve amount: tank filler hole.
Page 43: Seat
3. Wipe up any spilled fuel immediately. Your Yamaha engine has been designed to use NOTICE: Immediately wipe off spilled fuel regular unleaded gasoline with a research octane with a clean, dry, soft cloth, since fuel may number of 91 or higher (95 or higher for Europe). If...
Page 44: Storage Compartment
To install the seat EBU37060 Storage compartment ECB00131 NOTICE Do not store metal or sharply edged objects, like tools, 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.
Page 45: Front Carrier
EBU18973 Rear carrier  Do not exceed the load limit of 80.0 kg (176 lb) for the rear carrier.  Do not exceed the maximum load of 240.0 kg (530 lb) for the ATV. EBU19148 Adjusting the front and rear shock ab- sorber assemblies The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions.
Page 46 1. Special wrench Spring preload setting: 1. Spring preload adjusting ring Minimum (soft): 2. Position indicator Standard: A special wrench can be obtained at a Yamaha Maximum (hard): dealer to make this adjustment. 4-16...
Page 47: Auxiliary Dc Jack
EBU37290 Winch pre-wiring 1. Auxiliary DC jack cap This vehicle is equipped with pre-wiring leads for 2. Auxiliary DC jack a winch. Consult your Yamaha dealer for details. 4-17...
Page 48: Pre-Operation Checks
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
Page 49 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-3, 8-37, 8-38, 8-39 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.
Page 50: Fuel
 Check that there is no free play in the front EBU19591 Final gear oil brake lever. If there is free play, have a Yamaha Make sure that the final gear oil is at the specified dealer check the brake system.
Page 51: Throttle Lever
If there is any leakage, the brake proper tire pressure may cause severe injury or system should be checked by a Yamaha dealer. death from loss of control or rollover. Tire pressure below the minimum specified could...
Page 52 A low-pressure tire gauge is included as standard air valves. After extensive tests, only the tires list- equipment with your vehicle. (See page 8-2.) ed below are approved for this model by Yamaha. When using the tire pressure gauge, make two EWB02552...
Page 53: Chassis Fasteners
Aftermarket tires and rims Front: The tires and rims that came with your ATV were Manufacturer/model: designed to match the performance capabilities CHENG SHIN/C-828 and to provide the best combination of handling, (YFM45KDXJ_AUS/NZL, braking, and comfort. Other tires, rims, sizes, and YFM45KPXJ_AUS/NZL) combinations may not be appropriate.
Page 54: Operation
See the “Engine break-in” section on page 6-4 the ATV. If there is a control or function you do not prior to operating the engine for the first time. understand, ask your Yamaha dealer. EWB00632 To start the engine WARNING 1.
Page 55: Operating The Drive Select Lever And Driving In Reverse
If the indicator light does not come on, EBU36230 Operating the drive select lever and have a Yamaha dealer check the electrical driving in reverse circuit. 3. Apply the rear brake lever or brake pedal. ECB03330 NOTICE 4. Completely close the throttle lever, then push...
Page 56 reverse, make sure there are no people 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.
Page 57: Engine Break-In
Vary the speed of the ATV regularly. Do not oper- should come on. If the indicator light does not ate it at one set throttle position. come on, have a Yamaha dealer check the elec- trical circuit. 120–240 km (75–150 mi) or 10–20 hours ...
Page 58: Parking On A Slope
Yamaha for use on your ATV. Many companies with no connection to Yamaha manufacture parts and accessories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket compa- nies produce. Therefore, Yamaha can neither en-...
Page 59 Yamaha or modifications not specifically bulky object attached to the handlebars which recommended by Yamaha, even if sold and in- could make steering difficult, an accessory that stalled by a Yamaha dealer. limits your ability to move around on the seat, or one that limits your view.
Page 60  Never exceed the weight limits shown. An over- the weight on the hitch. If you are carrying cargo loaded ATV can be unstable. and towing a trailer, include the tongue weight in the maximum ATV load limit.  Load cargo on the carriers as close to the center MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, car- of the ATV as possible.
Page 61: Riding Your Atv
EBU21142 RIDING YOUR ATV...
Page 62: Getting To Know Your Atv
RIDE WITH CARE AND GOOD JUDGMENT EBU37070 Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01382 This ATV is for recreation and utility use. This sec- WARNING tion, Riding your ATV, provides general ATV riding  Do not operate this ATV or allow anyone else instructions for recreational riding.
Page 63 the time to learn the basic techniques well before This ATV is designed to carry the operator and attempting more difficult maneuvers. Become fa- cargo only – passengers prohibited. miliar with this ATV at slow speeds first, even if you The long seat is to allow the operator to shift posi- are an experienced operator.
Page 64 Apparel Always wear the following to reduce risk of injury in an accident:  Approved motorcycle helmet that fits properly  Eye protection (goggles, helmet face shield, or protective eyewear)  Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
Page 65 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and mainte- Do not operate after or while consuming alco- nance procedures and schedules described in the hol or drugs.
Page 66  Do not exceed the maximum loading limits fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting for the vehicle (see “MAXIMUM LOADING screw limits the maximum engine power available LIMIT” in this section or vehicle labeling). ...
Page 67 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during ATV loading limit (total weight of cargo, rid- operation; otherwise, they may contact the rear er, accessories, and tongue): wheels. WARNING! Removing even one hand or 240.0 kg (530 lb) foot can reduce your ability to control the ATV Front carrier: or could cause you to lose your balance and...
Page 68 ATV should during operation or after leaving the ATV, do not be genuine Yamaha or equivalent components let brush, grass and other materials collect under designed for use on this ATV and should be in- the vehicle, near the muffler or exhaust pipe, or stalled and used according to instructions.
Page 69: Be Careful Where You Ride
To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for use on unpaved surfaces children are not likely to touch it. only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control.
Page 70 know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do ways be alert to changing terrain conditions not ride on any paved public street, road or motor- when operating the ATV.
Page 71 terrain could cause loss of traction or ATV con- trol, which could result in an accident, includ- ing an overturn. [EWB01542] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.
Page 72: Turning Your Atv
Select a large, flat, unpaved area to become famil- ECB00252 NOTICE iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice Do not shift from low-range to high-range or control of the throttle, brakes, shifting procedures, vice versa without coming to a complete stop.
Page 73: Climbing Uphill
As you approach a curve, slow down and begin to may continue to go straight. If the ATV doesn’t turn the handlebars in the desired direction. As turn, come to a stop and then practice the proce- you do so, put your weight on the footboard to the dure again.
Page 74  Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills.  Always check the terrain carefully before you start up any hill.
Page 75 Do not attempt to climb hills until you have mas- If you are climbing a hill and you find that you have tered basic maneuvers on flat ground. Always not properly judged your ability to make it to the check the terrain carefully before attempting any top, you should turn the ATV around while you still hill.
Page 76: Riding Downhill
 Always check the terrain carefully before you around and remount, following the procedure de- scribed in the Owner’s Manual. WARNING! Stall- start down any hill.  Never operate the ATV on hills too steep for ing, rolling backwards improperly dismounting while climbing a hill could result in the ATV or for your abilities.
Page 77: Crossing A Slope
Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. When this ATV is in “4WD”, all wheels (front and rear) are interconnected by the drive train.
Page 78: Crossing Through Shallow Water
 Shift your weight to the uphill side of the ATV.  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.
Page 79 The ATV can be used to cross slow moving, shal- braking ability. WARNING! Wet brakes may have low water of up to a maximum of 35 cm (14 in) in reduced stopping ability, which could cause depth. Before entering the water, choose your loss of control.
Page 80: Riding Over Rough Terrain
1. Air filter case check hose 1. V-belt case drain plug RIDING OVER ROUGH TERRAIN EWB01652 WARNING Riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never at- tempt to ride over large obstacles, such as lar- ge rocks or fallen trees.
Page 81: Sliding And Skidding
accident. Be sure to keep your feet firmly mounted To reduce the tendency for the front wheels to on the footboards at all times. Avoid jumping the slide in loose or slippery conditions, positioning ATV as loss of control and damage to the ATV may your weight over the front wheels will sometimes result.
Page 82: What To Do If
WHAT TO DO...  If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn.
Page 83  If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned to- wards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.
Page 84: Periodic Maintenance And Adjustment
The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.
Page 85: Owner's Manual And Tool Kit
 Items marked with an asterisk should be per- formed by a Yamaha dealer as they require spe- cial tools, data and technical skills. EBU21692 Owner’s manual and tool kit Be sure to put this owner’s manual and the low-...
Page 86: Periodic Maintenance Chart: Emission Control System
EBU36871 Periodic maintenance chart: Emission control system INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Check fuel hoses for cracks or other damage, and √...
Page 87: Periodic Maintenance Chart: General Maintenance And Lubrication
EBU36891 Periodic maintenance chart: General maintenance and lubrication INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element •...
Page 88 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Check tread depth and for damage, and replace if necessary. √ √ √ √ Tires • Check air pressure and balance, and correct if necessary.
Page 89 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ Engine mount necessary. • Check for cracks or other damage, and replace if √...
Page 90 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Check operation. • Check throttle lever free play, and adjust if neces- √ √ √ √ √...
Page 91: Removing And Installing Panels
EBU23091 Removing and installing panels The panels shown need to be 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 C 2.
Page 92 EBU27605 Panel A When removing or installing panel A, the fuel tank cap must be removed. NOTICE: Make sure that no foreign material enters the fuel tank. [ECB01052] To remove the panel 1. Remove the seat. (See page 4-13.) 2. Remove the bolts and quick fasteners. 1.
Page 93 4. Install the fuel tank cap. To remove a panel 1. Remove panel A. To install the panel 2. Pull the panel upward to release the tabs as 1. Remove the fuel tank cap. shown. 2. Place the panel over the fuel tank filler tube, and then install the fuel tank cap.
Page 94 To install a panel Panel D 1. Push the panel to secure the tabs. To remove the panel Remove the bolts, and then take the panel off. 1. Bolt 2. Panel D To install the panel Place the panel in the original position, and then install the bolts.
Page 95 Panel F To remove the panel 1. Remove panels B and C. 2. Remove the cover.  For YFM45KPXJ / YFM45KPAJ / YFM45KPHJ: Remove the handlebar- mounted light cover. (See page 8-57.)  For YFM45KDXJ / YFM45KDHJ: Remove the handlebar cover. YFM45KPXJ / YFM45KPAJ / YFM45KPHJ To install the panel Insert the right side of the panel into position, and...
Page 96 YFM45KDXJ / YFM45KDHJ 1. Carrier bolt (top) 1. Handlebar cover 2. Panel F 3. Remove the carrier top bolts. 4. Remove the carrier bolts under the fenders, and then take the carrier off. 8-13...
Page 97 1. Carrier bolt (under the fenders) 1. Quick fastener 6. Lift up the panel and disconnect the coupler. 1. Carrier bolt (under the fenders) 1. Coupler 5. Remove the quick fasteners. 8-14...
Page 98: Checking The Spark Plug
To install the panel 5. Install the cover.  For 1. Connect the coupler, and then place the pan- YFM45KPXJ / YFM45KPAJ / el in the original position. YFM45KPHJ: Install the handlebar-mount- ed light cover.  For YFM45KDXJ / YFM45KDHJ: Install the handlebar cover.
Page 99 (the ideal color when the ATV is ridden normally). If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-16...
Page 100: Engine Oil And Oil Filter Cartridge
2. Check the spark plug for electrode erosion To install the spark plug and excessive carbon or other deposits, and 1. Clean the surface of the spark plug gasket replace it if necessary. and its mating surface, and then wipe off any grime from the spark plug threads.
Page 101 To check the engine oil level 5. Insert the dipstick into the filler hole (without 1. Place the ATV on a level surface. screwing it in), and then remove it again to 2. Remove panel E. (See page 8-8.) check the oil level. 3.
Page 102 raise it to the correct level. NOTICE: Be sure the engine oil is at the correct level, other- wise engine damage may result. [ECB00852] 7. Check the filler cap O-ring for damage, and replace it if necessary. 8. Install the engine oil filler cap and the panel. To change the engine oil (and replace the oil fil- ter cartridge) 1.
Page 103 An oil filter wrench is available at a nearby Yamaha dealer. 8. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. 1. Oil filter cartridge 1. O-ring Make sure that the O-ring is properly seated.
Page 104 12. Refill with the specified amount of the recom- mended engine oil. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.30 L (2.43 US qt, 2.02 Imp.qt) With oil filter cartridge replacement: 2.40 L (2.54 US qt, 2.11 Imp.qt) 1.
Page 105: Final Gear Oil
If any leakage is found, have 4. Correct oil level a Yamaha dealer check and repair the ATV. In ad- 3. If the oil is below the brim of the filler hole, add dition, the final gear oil level must be checked and...
Page 106 To change the final gear oil 1. Place the ATV on a level surface. 2. Remove the final gear case guard by remov- ing the bolts. 1. Final gear oil drain bolt 2. Gasket 5. Install the drain bolt and its new gasket, and then tighten the bolt to the specified torque.
Page 107: Changing The Differential Gear Oil
If any leakage is found, However, when using this oil, noise from the final have a Yamaha dealer check and repair the ATV. gear case may occur when applying the rear In addition, the differential gear oil must be brake.
Page 108 1. Place the ATV on a level surface. 2. Place an oil pan under the differential gear case to collect the used oil. 3. Remove the differential gear oil filler bolt, the differential gear oil drain bolt and their gasket to drain the oil from the differential gear case.
Page 109: Coolant
EBU23471 Coolant  Do not exceed the specified differential gear oil The coolant level should be checked before each quantity when filling. Overfilling will cause the oil ride. In addition, the coolant must be changed at to seep out of the breather hose during and af- the intervals specified in the periodic maintenance ter riding.
Page 110 If water has been added to the coolant, have a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. [ECB01012] 1. Maximum level mark 2.
Page 111  The radiator fan is automatically switched on or off according to the coolant temperature in the radiator.  If the engine overheats, see page 8-65 for fur- ther instructions. EBU37130 To change the coolant EWB01891 WARNING 1. Radiator cap Wait for the engine and radiator to cool before removing the radiator cap.
Page 112 7. Disconnect the coolant reservoir hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. 1. Coolant drain bolt 2. Gasket 1. Coolant reservoir hose 8. After draining the coolant, thoroughly flush the cooling system with clean tap water. 9.
Page 113: Cleaning The Air Filter
[ECB00992] If any leakage is found, have a Yamaha dealer 12. Pour the recommended coolant into the radi- check the cooling system. ator until it is full. 16. Install the panels and the front carrier.
Page 114  Service the air filter more frequently if you often ride in wet or dusty areas.  There is a check hose at the bottom of the air fil- ter case. If dust or water collects in this hose, empty the hose and clean the air filter case and air filter elements.
Page 115 5. Pull off the lock plate from the main air filter assembly, and then remove the air filter ele- ment (sponge material) from the frame. 1. Main air filter assembly 1. Frame 2. Air filter element (sponge material) 3. Lock plate 6.
Page 116: Cleaning The Spark Arrester
7. Squeeze out the excess moisture, and let dry. 12. Install the air filter case cover by hooking the NOTICE: Do not twist the sponge material holders onto the cover. NOTICE: Make sure when squeezing it. that the air filter element is properly seated [ECB00442] in the air filter case.
Page 117 1. Tailpipe bolt 1. Gasket 2. Spark arrester 2. Remove the tailpipe by pulling it out of the 3. Tailpipe muffler, and then remove the gasket. 4. Check the gasket for damage, and replace it 3. Tap the tailpipe lightly, and then use a wire if necessary.
Page 118: V-Belt Cooling Duct Check Hose
Always let the exhaust system cool prior to If water drains from the V-belt case after removing touching exhaust components. the plug, have a Yamaha dealer check the ATV as the water may affect other engine parts. EBU23921 V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct check hose, remove the hose and clean it.
Page 119: Adjusting The Throttle Lever Free Play
The valve clearance changes with use, resulting 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.
Page 120: Brakes
If a brake pad is dam- fessional knowledge. Brake service should be aged or if the lining thickness is less than 1.0 mm performed by a Yamaha dealer. (0.04 in), have a Yamaha dealer replace the brake EWB02572 pads as a set. WARNING...
Page 121: Checking The Brake Fluid Level
EBU30321 Specified brake fluid: Rear brake friction plates DOT 4 The rear brake friction plates must be checked and, if necessary, replaced by a Yamaha dealer at ECB01161 the intervals specified in the periodic maintenance NOTICE and lubrication chart. Brake fluid may damage painted surfaces or plastic parts.
Page 122: Changing The Brake Fluid
EBU24283 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrication chart. In addition, have the oil seals 1. No brake lever free play...
Page 123: Adjusting The Rear Brake Lever And Brake Pedal
EBU30346 Adjusting the rear brake lever and brake pedal The rear brake lever free play, brake pedal free play, and the brake pedal height must be checked and adjusted at the intervals specified in the peri- odic maintenance chart. Adjusting the brake lever free play The brake lever free play should measure 10.0 mm (0.39 in).
Page 124 22 mm (0.87 in), adjust the brake lever free play at the brake lever again. If distance A 3. Fully turn the adjusting bolt in direction (a) to exceeds 12.7 mm (0.50 in), have a Yamaha loosen the brake cable. dealer check the vehicle.
Page 125 1. Distance between brake pedal and footboard bracket 1. Footboard 2. Quick fastener 1. Remove the footboard by removing the quick 3. Bolt and nut fasteners, bolts, and nuts. 4. Bolt 2. Loosen the locknut. 8-42...
Page 126 1. Locknut 1. Footboard bolt A 2. Adjusting bolt 2. Footboard bolt B 3. Quick fastener 3. Turn the adjusting bolt in or out until the brake pedal height is within the specified limits. 4. Tighten the locknut. Tighten the footboard bolts in the order shown. Tightening torque: Locknut: 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Page 127 The brake lever free play and brake pedal height must be adjusted before adjusting the brake pedal free play. 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. Brake pedal free play 1.
Page 128: 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 1. Rear axle boot (each side) tears or damage. If any damage is found, have them replaced by a Yamaha dealer. 8-45...
Page 129: Brake Light Switches
If a cable is damaged or does not move be adjusted as follows, but the other brake light smoothly, have a Yamaha dealer check or replace switches should be adjusted by a Yamaha dealer. Turn the rear brake light switch adjusting nut while Recommended lubricant: holding the brake light switch in place.
Page 130: Checking And Lubricating The Front And Rear Brake Levers
do not work smoothly, you could be unable Front brake lever 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 checked before each ride, and the lever pivots should be lubricated if necessary.
Page 131: Checking And Lubricating The Brake Pedal
EBU28872 Checking and lubricating the brake ly, have a Yamaha dealer check the wheel hub pedal bearings. The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary.
Page 132: Checking The Stabilizer Bushes
Recommended lubricant: Checking the stabilizer bushes Lithium-soap-based grease 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. 8-49...
Page 133: Lubricating The Steering Shaft
For parts equipped 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 8-50...
Page 134: Battery
KEEP OUT OF REACH OF CHILDREN. hands after handling.  It is recommended to have the battery serviced by a Yamaha dealer. To remove the battery 1. Remove the seat. (See page 4-13.) 2. Remove the battery holding plate by remov- ing the bolts.
Page 135 ECB00622 NOTICE Never attempt to open the battery or remove the battery cell seals, as this would permanent- ly damage the battery. To charge the battery  Confirm the recommended charging rate as specified on the battery itself.  Select a suitable charger and follow the manu- facturer’s instructions.
Page 136 ECB00942 NOTICE  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 above 30 °C (90 °F)].
Page 137: Replacing A Fuse
EBU30804 Replacing a fuse 3 4 5 For non-EPS models 1. Auxiliary DC jack fuse 2. Four-wheel-drive motor fuse 3. Ignition fuse 4. Radiator fan motor fuse 1. Fuel injection system spare fuse 5. Signaling system fuse 2. Fuel injection system fuse 6.
Page 138 For EPS models 3 4 5 1. Auxiliary DC jack fuse 1. Fuel injection system spare fuse 2. Four-wheel-drive motor fuse 2. Fuel injection system fuse 3. Ignition fuse 3. Main fuse 4. Radiator fan motor fuse 4. EPS fuse 5.
Page 139 10.0 A EPS fuse: 40.0 A (YFM45KPAJ, YFM45KPHJ, YFM45KPXJ) 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. 8-56...
Page 140: Replacing A Headlight Bulb
EBU34223 Replacing a headlight bulb If a headlight bulb burns out, replace it with the specified bulb as follows. Left and right headlight bulbs 1. Remove the cover at the rear of the headlight by pulling it off. 1. Bulb cover 3.
Page 141 4. Remove the burnt-out bulb. 7. Install the bulb cover and the cover at the rear 5. Place a new bulb into position. NOTICE: Do of the headlight. NOTICE: Make sure the not touch the glass part of the bulb. Oil bulb cover is securely fitted over the sock- from your fingers or other contamination et and seated properly.
Page 142 4. Remove the burnt-out bulb. 5. Place a new bulb into position. NOTICE: Do not touch the glass part of the bulb. Oil from your fingers or other contamination will adversely affect the transparency of the glass, luminosity of the bulb, and bulb life.
Page 143: Adjusting A Headlight Beam
EBU25553 Adjusting a headlight beam ECB00691 NOTICE 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). 1. Handlebar-mounted light beam adjusting screw To lower a headlight beam, turn the adjusting screw in direction (b).
Page 144: Replacing The Tail/Brake Light Bulb
EBU25614 Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows. 1. Remove the tail/brake light bulb holder (to- gether with the bulb) by turning it counter- clockwise. 1. Tail/brake light bulb 3. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops.
Page 145: Installing A Wheel
1. Wheel nut 1. Arrow mark 2. Forward rotating direction 3. Elevate the ATV and place a suitable stand 3. Wheel nut under the frame. 4. Remove the nuts from the wheel. 5. Remove the wheel. For YFM45KDXJ / YFM45KPXJ / YFM45KDHJ / YFM45KPHJ: be sure to install the nuts with their EBU36243 tapered side towards the wheel.
Page 146: Troubleshooting
The following troubleshooting charts represent quick and easy procedures for checking these vi- tal systems yourself. However, should your ATV require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary 1. Tapered nut tools, experience, and know-how to service the 2.
Page 147: Troubleshooting Charts
Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the compression. 4. Compression The engine does not start. There is compression.
Page 148 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.
Page 149: Cleaning And Storage
EBU25861 CLEANING AND STORAGE and deterioration of wheel bearings, EBU25882 Cleaning brakes, transmission seals and electrical Frequent, thorough cleaning of your ATV will not devices. Many expensive repair bills have only enhance its appearance but will improve its resulted from improper high-pressure de- general performance and extend the useful life of tergent applications such as those avail- many components.
Page 150: Storage
4. Perform the following steps to protect the en- EBU27264 Storage gine from internal corrosion. a. Remove the spark plug cap and spark Short-term plug. Always store your ATV in a cool, dry place and, if b. Pour a teaspoonful of engine oil into the necessary, protect it against dust with a porous spark plug bore.
Page 151 8. Remove the battery and fully charge it. (See page 8-51.)
Page 152: Specifications
EBU25962 SPECIFICATIONS Dimensions: Uncertainty of measurement: 3.0 dB(A) (YFM45KDHJ, YFM45KDXJ_EUR/FRA/GBR, Overall length: YFM45KPAJ, YFM45KPHJ, 2035 mm (80.1 in) YFM45KPXJ_EUR/FRA/GBR) Overall width: Vibration on seat (EN1032, ISO5008): 1180 mm (46.5 in) 0.6 m/s² (YFM45KDHJ, YFM45KDXJ_EUR/FRA/GBR) Overall height: Will not exceed 0.5 m/s² (YFM45KPAJ, YFM45KPHJ, 1160 mm (45.7 in) YFM45KPXJ_EUR/FRA/GBR) Seat height:...
Page 153 Recommended brand: Differential gear oil: YAMALUBE Type: Type: Yamaha Friction Modified Shaft Drive Gear Oil or SAE 80 SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- API GL-4 Hypoid gear oil Quantity: 0.35 L (0.37 US qt, 0.31 Imp.qt) 130 ˚F...
Page 154 Fuel injection: Caster angle: 3.00 ° Throttle body: Trail: ID mark: 14.2 mm (0.56 in) BB51 00 Front tire: Spark plug (s): Type: Manufacturer/model: Tubeless NGK/DR7EA Size: Spark plug gap: AT25 x 8-12 0.6–0.7 mm (0.024–0.028 in) Manufacturer/model: Clutch: CHENG SHIN/C-828 (YFM45KDXJ_AUS/NZL, Clutch type: YFM45KPXJ_AUS/NZL) Wet, centrifugal automatic...
Page 155 Tire air pressure (measured on cold tires): Specified brake fluid: DOT 4 Recommended: Rear brake: Front: 35.0 kPa (0.350 kgf/cm², 5.0 psi) Type: Rear: Wet multiple disc brake 30.0 kPa (0.300 kgf/cm², 4.4 psi) Operation: Minimum: Left hand and right foot operation Front: Front suspension: 32.0 kPa (0.320 kgf/cm², 4.6 psi)
Page 156 Headlight(s): Fuses: Bulb type: Main fuse: Krypton bulb 40.0 A Handlebar-mounted light: Fuel injection system fuse: 10.0 A Bulb type: EPS fuse: Halogen bulb (YFM45KPAJ, YFM45KPHJ, YFM45KPXJ) Bulb voltage, wattage × quantity: 40.0 A (YFM45KPAJ, YFM45KPHJ, YFM45KPXJ) Headlight fuse: Headlight: 12 V, 30.0/30.0 W ×...
Page 157 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.
Page 158: Consumer Information
Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number (front left side)
Page 159 1. Model label 11-2...
Page 160: Index
INDEX Display unit ..............4-4 Drive select lever ............4-11 Accessories and loading ..........6-5 Drive select lever and driving in reverse ......6-2 Accessories, auxiliary jack ...........4-17 Drive shaft universal joint, lubricating ......8-48 Air filter, cleaning ............8-30 Axle boots ..............8-45 Engine break-in ..............
Page 161 Stabilizer bushes, checking ......... 8-49 Starting the engine ............6-1 Main switch ..............4-1 Start switch ..............4-7 Maintenance and lubrication chart ........ 8-4 Steering shaft, lubricating ..........8-50 Maintenance chart, emission control system ....8-3 Storage ................9-2 Model label ..............11-1 Storage compartment ..........
Page 162 EBU26173 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. NEVER USE ALWAYS USE NEVER USE NEVER CARRY AN APPROVED PASSENGERS WITH DRUGS ON PAVED HELMET AND OR ALCOHOL ROADS PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...

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