Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM45KDXP/YFM45KPAP YFM45KPHP/YFM45KPSP WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-36-07 BEY-F8199-12...
Page 2 EBU37021 Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves or wash your...
Page 3 Congratulations on your purchase of the Yamaha YFM45KDXP / YFM45KPAP / YFM45KPHP / YFM45KPSP. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now ap- preciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
Page 4: Important Manual Information
EBU17331 IMPORTANT MANUAL INFORMATION EBU17344 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 5: Important Notice
Please check your local riding laws and regulations before operating this ATV. EBU17403 YFM45KDXP / YFM45KPAP / YFM45KPHP / YFM45KPSP OWNER’S MANUAL ©2023 by Yamaha Motor Corporation, U.S.A. 1st edition, May 2022 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.
Page 6: Table Of Contents
Display unit ..........5-4 EWB00012 WARNING Handlebar switches ........5-7 Throttle lever..........5-13 Indicates a hazardous situation which, if not Speed limiter..........5-14 avoided, could result in death or serious injury. Front brake lever........5-14 Brake pedal and rear brake lever ..... 5-15 Drive select lever ........
Page 7 Tires ............6-4 PERIODIC MAINTENANCE AND Chassis fasteners........6-6 ADJUSTMENT ..........9-1 Instruments, lights and switches ....6-6 Owner’s Manuals........9-2 Periodic maintenance chart: Emission OPERATION ........... 7-1 control system .......... 9-3 Starting the engine........7-1 Periodic maintenance chart: General Operating the drive select lever and maintenance and lubrication ....
Page 8 Lubricating the drive shaft universal U.S.A. 2020 AND LATER MODEL ATV joint ............9-51 LIMITED WARRANTY (for USA)....12-4 Checking the stabilizer bushes ....9-51 YAMAHA EXTENDED SERVICE (Y.E.S.) Lubricating the rear knuckle pivots...9-52 (for USA) ..........12-6 Lubricating the steering shaft ....9-52 Battery............9-53 INDEX ............
Page 9: Vehicle Identification
EBU38860 VEHICLE IDENTIFICATION EBU26016 EBU26032 Vehicle identification number Identification numbers The vehicle identification number is stamped into Record the vehicle identification number, model the frame. This 17-digit number is used to identify label information and key identification number in your individual ATV. the spaces provided below.
Page 10 EBU26021 Key identification number The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key. 1. Model label Your specific model can be identified by checking the model type code found on the model label.
Page 11: Location Of The Warning And Specification Labels
EBU17661 LOCATION OF THE WARNING AND SPECIFICATION LABELS 10 11 12...
Page 12 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. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN Overloading this ATV or carrying cargo improperly can change CAUSE LOSS OF CONTROL.
Page 13 ( 6 0 0 k g f ) Overloading this ATV or carrying cargo improperly can change 5880 N 1322 handling, stability and braking performance and can lead to an ( 1 5 k g f ) accident. Never exceed the maximum rear cargo limit of : 176 lbs (80 kg) : 187 lbs.
Page 14 • avoid paved surfaces - pavement may seriously affect handling and control. LOCATE AND READ OWNER’S MANUAL. BAS-F8459-00 FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) 4XE-F1568-00 YAMAHA...
Page 15 Certification of Compliance This ATV complies with applicable provisions of ANSI/SVIA 1-2017 and is subject to an approved ATV action plan submitted by YAMAHA and on file with the U.S. Consumer Product Safety Commission. YAMAHA MOTOR CORPORATION U.S.A. 6555 Katella Avenue, Cypress, California 90630-5101, U.S.A.
Page 16: Safety Information
EBU17432 SAFETY INFORMATION SAFETY INFORMATION  Never allow a child under age 16 to operate an EBU27236 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 17  Always inspect your ATV each time you use it to  Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
Page 18  Always use proper procedures if you stall or roll reduced stopping ability. Test your brakes after backwards when climbing a hill. To avoid stall- leaving water. If necessary, apply them several ing, use the proper gear range and maintain a times to let friction dry out the linings.
Page 19 In the event of an accident tention. If necessary, contact your riding party 1. If serious injuries are incurred, you may be or local authorities to let them know where safer staying next to your vehicle; it may you are and what has happened. shield you from oncoming riders.
Page 20 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 21  Do not run engine outdoors where engine EWB00073 WARNING exhaust can be drawn into a building through openings such as windows and doors. Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, FOR MORE INFORMATION ABOUT ATV SAFE- a deadly gas.
Page 22: Description
EBU17681 DESCRIPTION EBU17691 EBU17701 Left view Right view 3 4 5 1. Radiator cap 1. Spark arrester 2. Air filter 2. Storage compartment 3. Battery 3. Fuel tank cap 4. Fuses 4. Spark plug 5. Brake/tail light 5. Auxiliary DC jack 6.
Page 23: Controls And Instruments
EBU17715 Controls and instruments 1. Rear brake lever 2. Handlebar switches 3. Winch switch (YFM45KPSP) 4. Drive select lever 5. Display unit 6. Front brake fluid reservoir 7. On-Command four-wheel-drive switch 8. Throttle lever 9. Front brake lever 10.Main switch...
Page 24: Instrument And Control Functions
EBU1772C INSTRUMENT AND CONTROL FUNCTIONS “ ” (off) EWB00012 WARNING All electrical systems are off. The key can be re- moved. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU26699 Indicator lights and warning lights EBU29913 Main switch For non-differential gear lock models...
Page 25 If the warning light does not come on initially when the key is turned to “ ” (on), or if the warning EBU17861 light remains on, have a Yamaha dealer check the Neutral indicator light “ ” electrical circuit. This indicator light comes on when the transmis- sion is in the neutral position.
Page 26 When this occurs, the display will indicate loaded. Reduce the load to specification.  The engine may overheat if mud or dirt has an error code (see page 5-6). Have a Yamaha accumulated on the radiator. Gently clean dealer check the self-diagnostic system.
Page 27: Display Unit
 If the steering load is too heavy (i.e., excessive EBU37054 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. EBU17955 Four-wheel drive indicator light “ ” This indicator light comes on when the drivetrain is set to “4WD”...
Page 28 “km/h”, and the odometer and tripmeter units will segments will flash repeatedly. If this occurs, have switch to miles or kilometers accordingly. a Yamaha dealer check the vehicle. To switch the display units: turn the key to “ ” (off), then hold the select button “SEL” pushed Multi-function display and turn the key to “...
Page 29 The service tripmeter will reset and continue flash. counting after 9999.9 is reached. If this occurs, have a Yamaha dealer check the ve- hicle. Hour meter The hour meter shows the total time the engine...
Page 30: Handlebar Switches
Yamaha dealer check the vehicle. ECB01181 NOTICE To prevent engine damage, be sure to consult a Yamaha dealer as soon as possible if this oc- curs. 1. Light switch “ /OFF” 2. Engine stop switch “...
Page 31 For differential gear lock models 1. On-Command drive switch “2WD/4WD” 1. Light switch “ /OFF” 2. Start switch “ ” 3. Engine stop switch “ ” 4. Override switch “OVERRIDE” 5. Winch switch “OUT/IN” (YFM45KPSP)
Page 32 EBU18102 Start switch “ ” Push this switch to crank the engine with the start- er. See the starting instructions on page 7-1 prior to starting the engine. LOCK EBU34123 Light switch “ /OFF” Set this switch to “ ” to turn on the left and right headlights (low beams) and the taillight.
Page 33 In While the override switch is pushed, the segments this case, take the ATV to a Yamaha dealer at the of the speedometer digits will appear as shown in first opportunity.
Page 34 EWB00151 EWB00164 WARNING WARNING Always ride at a slow speed when the ATV is in Always stop the ATV before changing from four-wheel-drive differential gear lock, and al- two-wheel drive to four-wheel drive and vice low extra time and distance for maneuvers. versa.
Page 35  “LOCK” (four-wheel drive with the differential gear locked): power is supplied to the front and rear wheels and the differential gear is locked. Unlike in four-wheel drive, all wheels turn at the same speed, giving maximum traction. LOCK EWB00132 WARNING Always stop the ATV before changing from four-wheel drive to four-wheel-drive differen-...
Page 36: Throttle Lever
 Riding before the differential gear is properly en- EBU18286 Throttle lever 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 is limit- ed to 35 km/h (22 mi/h).
Page 37: Speed Limiter
the adjusting screw in direction (b). Do not EBU18325 Speed limiter turn the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be damaged. Always make sure the throttle lever free play is adjusted to 2.0–4.0 mm (0.08– 0.16 in).
Page 38: Brake Pedal And Rear 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. Rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar.
Page 39: Drive Select Lever
EBU18614 EBU37980 Drive select lever Fuel tank cap 1. Drive select lever 1. Fuel tank cap The drive select lever is used to shift the transmis- Remove the fuel tank cap by turning it counter- sion into the low-range, high-range, neutral, re- clockwise.
Page 40: Fuel
of sparks, open flames, or other sources of 3. Wipe up any spilled fuel immediately. NOTICE: Immediately wipe off spilled fuel ignition such as the pilot lights of water heat- ers and clothes dryers. with a clean, dry, soft cloth, since fuel may 2.
Page 41: Seat
ECB00071 Recommended fuel: NOTICE Regular unleaded gasoline (Gasohol [E10] Use only unleaded gasoline. The use of leaded acceptable) gasoline will cause severe damage to internal Fuel tank capacity: engine parts, such as the valves and piston 14 L (3.7 US gal, 3.1 Imp.gal) rings, as well as to the exhaust system.
Page 42: Storage Compartment
To install the seat EBU37061 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 43: Front Carrier
EBU18974 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. EBU1914A Front and rear shock absorbers The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions.
Page 44 1. Spring preload adjusting ring 1. Special wrench 2. Position indicator A special wrench can be obtained at a Yamaha dealer to make this adjustment. 5-21...
Page 45: Winch (Yfm45Kpsp)
EBU39230 Front spring preload setting: Winch (YFM45KPSP) Minimum (soft): Standard: Maximum (hard): Rear spring preload setting: Minimum (soft): Standard: Maximum (hard): 1. Winch 2. Fairlead 3. Hook 4. Hook strap 5-22...
Page 46: Trailer Hitch (Equipped Models)
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 7-6 for precaution in- formation.) 5-23...
Page 47: Auxiliary Dc Jack
EBU19187 ECB03760 NOTICE Auxiliary DC jack Do not use any single electrical accessory or combination of accessories that require more than the stated capacity at any one time. This may overload the circuit and cause the fuse to blow. When using a winch or other electrical accesso- ries, the power taken from the DC jack must be re- duced accordingly.
Page 48: Winch Pre-Wiring (Non-Winch Models)
The DC jack may be damaged. EBU37291 Winch pre-wiring (non-winch models) This vehicle is equipped with pre-wiring leads for a winch. Consult your Yamaha dealer for details. EWB00012 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Page 49: 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 50 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 6-3, 9-40, 9-40, 9-42 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.
Page 51: Fuel
Add oil as necessary. (See page 9-19.)  Check that there is no free play in the front EBU19591 brake lever. If there is free play, have a Yamaha Final gear oil dealer check the brake system. Make sure that the final gear oil is at the specified ...
Page 52: Throttle Lever
If there is any leakage, the brake system should be checked by a Yamaha dealer. Brake operation Test the brakes at slow speed after starting out to make sure they are working properly.
Page 53 Tire information go, and trailer tongue weight. This ATV is equipped with tubeless tires and tire air valves. After extensive tests, only the tires list- ed below are approved for this model by Yamaha.
Page 54: Chassis Fasteners
Aftermarket tires and rims EWB02552 WARNING The tires and rims that came with your ATV were designed to match the performance capabilities Use of improper tires on this ATV may cause and to provide the best combination of handling, loss of control, increasing your risk of an acci- dent.
Page 55: Operation
See the “Engine break-in” section on page 7-4 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 WARNING To start the engine 1.
Page 56: Operating The Drive Select Lever And Driving In Reverse
ECB03330 on. If the indicator light does not come on, NOTICE have a Yamaha dealer check the electrical Do not shift without coming to a complete stop circuit. and waiting for the engine to return to normal 3.
Page 57 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 58: 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 8–15 hours ...
Page 59: 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 60 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 61  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 62 EWB00012 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Page 63: Riding Your Atv
EBU21133 RIDING YOUR ATV...
Page 64: Getting To Know Your Atv
Before you begin to ride, be complete the certified training course offered by sure you have read this Owner’s Manual com- Yamaha. They should then regularly practice the pletely and understand the operation of the con- skills learned in the course and the operating tech-...
Page 65 more information about the training course, con- tact an authorized ATV dealer or call 1-800-887- 2887. Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics.
Page 66 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.
Page 67 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 68 Do not operate after or while consuming alco- nance procedures and schedules described in the hol or drugs. Owner’s Manual. WARNING! Failure to inspect The operator’s performance capability is reduced the ATV before riding it or failure to maintain it by the influence of alcohol or drugs.
Page 69  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. ...
Page 70 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 71 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 72: 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 off-road use only. children are not likely to touch it. WARNING! Paved surfaces may seriously af- fect handling and control of the ATV, and may cause the ATV to go out of control.
Page 73 WARNING! Never operate this ATV on any pub- lic street, road or highway, even a dirt or gravel one. You could collide with another vehicle. [EWB01032] Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset.
Page 74 Do not operate on rough, slippery, or loose terrain with another vehicle if operating in off-road ar- until you have learned and practiced the skills nec- eas where you cannot easily be seen. Mount a essary to control the ATV on such terrain. Always caution flag on the ATV to make you more vis- be especially cautious on these kinds of terrain.
Page 75: Turning Your Atv
resulting in a loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. When slowing down or stopping, 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.
Page 76 To achieve maximum traction while riding off- road, the two rear wheels turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turn- ing technique must be used to allow the ATV to make turns quickly and easily.
Page 77 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 negotiating a turn, lean more to the inside.
Page 78: Climbing Uphill
 Avoid crossing the side of a steep hill if pos- CLIMBING UPHILL sible. When crossing the side of a hill, shift EWB01672 WARNING your weight to the uphill side of the ATV. Climbing hills improperly can cause overturns or loss of control. Use proper riding techniques described in this Owner’s Manual.
Page 79 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning forward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars. When- ever possible, ride straight up hills.
Page 80: Riding Downhill
If you start to roll backwards, DO NOT apply either brake abruptly. If you are in “2WD”, apply only the front brake. When fully stopped, apply the rear brake as well, and then shift to the park position. If you are in “4WD”, because all wheels are inter- connected by the drive train, applying either brake will brake all wheels, therefore, avoid sudden ap- plication of either the front or rear brake as the...
Page 81  Shift your weight backward and to the up rear brake will brake all wheels. When descending side of the hill. hills, using either brake lever or the brake pedal  Never go down a hill at high speed. will brake the wheels on the downhill side. Avoid ...
Page 82: Crossing A Slope
CROSSING A SLOPE As you travel across a slope, lean your body in the uphill direction. It may be necessary to correct the EWB01633 WARNING steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to slopes, be sure not to make sharp turns either up...
Page 83: Crossing Through Shallow Water
CROSSING THROUGH SHALLOW WATER EWB01642 WARNING Operating this vehicle through deep or fast- flowing water can lead to loss of control or an overturn. To reduce your risk of drowning or other injuries, use care when crossing through water. Never operate this ATV water deeper than the depth specified in your Owner’s Man- ual, as tires may float, increasing the risk of an overturn.
Page 84 Test your brakes after leaving the water. If neces- Wash the ATV in fresh water if it has been operat- sary, apply them several times to let friction dry ed in salt water or muddy conditions. out the linings. Do not continue to ride your ATV without verifying that you have regained proper braking ability.
Page 85: Riding Over Rough Terrain
accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. SLIDING AND SKIDDING EWB01663 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.
Page 86: What To Do If
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. With practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting If the rear wheels of your ATV start to slide side- such maneuvers, since both stability and control...
Page 87  If your ATV is traversing a sloping surface: WHAT TO DO...  If your ATV doesn’t turn when you want it to: Be sure to ride with your weight positioned to- Bring the ATV to a stop and practice the turning wards the uphill side of the ATV to maintain maneuvers again.
Page 88: 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 89: Owner's Manuals
Owner’s Manuals If you do not have the tools or experience required Store this manual and the Winch Owner’s Manual for a particular job, have a Yamaha dealer perform (YFM45KPSP) in a plastic bag and always carry it for you.
Page 90: Periodic Maintenance Chart: Emission Control System
 For odometer or hour meter-equipped vehicles, follow the month maintenance interval if the ATV isn’t ridden for the stated distance or engine operating hours.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 91 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours √ √ √ Spark arrester • Clean. • Check the air cut-off valve, reed valve, and hose Air induction sys- for damage.
Page 92: Periodic Maintenance Chart: General Maintenance And Lubrication
 For odometer or hour meter-equipped vehicles, follow the month maintenance interval if the ATV isn’t ridden for the stated distance or engine operating hours.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 93 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 and correct if necessary. √ √ √ √ √ • Check brake lever and pedal free play, and adjust if necessary.
Page 94 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Make sure that all nuts, bolts, and screws are √ √ √ √ √ Chassis fasteners properly tightened.
Page 95 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (150) (800) (1600) (1600) (3200) hours • Change. √ √ Differential gear oil • Check ATV for oil leakage, and correct if neces- sary.
Page 96 EBU28392  Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at 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.
Page 97: Removing And Installing Panels
EWB00012 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 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.
Page 98 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 5-18.) 2. Remove the bolts and quick fasteners. 1.
Page 99 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 100 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 101 Panel F To remove the panel 1. Remove panels B and C. 2. Remove the cover.  For handlebar-mounted light equipped models: Remove the handlebar-mounted light cover. (See page 9-59.)  For non-equipped models: Remove the handlebar cover. To install the panel Insert the right side of the panel into position, and then press the projections into place.
Page 102 4. Remove the carrier bolts under the fenders, and then take the carrier off. 1. Handlebar cover 3. Remove the carrier top bolts. 1. Carrier bolt (under the fenders) 1. Carrier bolt (top) 2. Panel F 1. Carrier bolt (under the fenders) 9-15...
Page 103 5. Remove the quick fasteners. To install the panel 1. Connect the coupler, and then place the pan- el in the original position. 1. Quick fastener 6. Lift up the panel and disconnect the coupler. 2. Install the quick fasteners. 3.
Page 104: Checking The Spark Plug
5. Install the cover.  For handlebar-mounted light equipped models: Install the handlebar-mounted light cover.  For non-equipped models: Install the han- dlebar cover. 6. Install the panels. EBU40350 Checking the spark plug The spark plug is an important engine component, which is easy to check.
Page 105 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. 1. Spark plug gap 2. Check the spark plug for electrode erosion...
Page 106: Engine Oil And Oil Filter Cartridge
Tightening torque: Spark plug: If the engine was started before checking the oil 18 N·m (1.8 kgf·m, 13 lb·ft) level, warm up the engine, and then wait at least ten minutes until the oil settles for an accurate reading. If a torque wrench is not available when installing 4.
Page 107 7. Check the filler cap O-ring for damage, and replace it if necessary. The engine oil should be between the tip of the 8. Install the engine oil filler cap and the panel. dipstick and the maximum level mark. To change the engine oil (and replace the oil fil- ter cartridge) 1.
Page 108 1. Engine oil drain bolt 1. Oil filter cartridge 2. Gasket Skip steps 6–10 if the oil filter cartridge is not be- ing replaced. 6. Remove panels C and D. (See page 9-10.) 7. Remove the oil filter cartridge with an oil filter wrench.
Page 109 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. Torque wrench Tightening torque: Oil filter cartridge: 17 N·m (1.7 kgf·m, 13 lb·ft) 10.
Page 110: Why Yamalube
EBU38620 Why Yamalube Be sure to wipe off spilled oil on any parts after the YAMALUBE oil is a Genuine YAMAHA Part born of engine and exhaust system have cooled down. the engineers’ passion and belief that engine oil is an important liquid engine component.
Page 111: Final Gear Oil
If any leakage is found, have 3. If the oil is below the brim of the filler hole, add a Yamaha dealer check and repair the ATV. In ad- sufficient oil of the recommended type to dition, the final gear oil level must be checked and raise it to the correct level.
Page 112 To change the final gear oil 1. Park 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 113 10. Install the final gear case guard by installing the bolts, and then tightening them to the Recommended final gear oil: specified torque. Yamaha Friction Modified Shaft Drive Gear Tightening torque: Oil quantity: Final gear case guard bolt: 0.38 L (0.40 US qt, 0.33 Imp.qt) 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Page 114: Changing The Differential Gear Oil
Oil or SAE 80 API GL-4 Hypoid gear oil leakage before each ride. If any leakage is found, Oil quantity: have a Yamaha dealer check and repair the ATV. 0.35 L (0.37 US qt, 0.31 Imp.qt) In addition, the differential gear oil must be...
Page 115 1. Park the ATV on a level surface. 5. Refill with the specified amount of the recom- mended differential gear oil. NOTICE: Be 2. Place an oil pan under the differential gear case to collect the used oil. sure no foreign material enters the differ- 3.
Page 116: Coolant
1.32 L (1.40 US qt, 1.16 Imp.qt) gine since the level varies with engine tempera- ture. If genuine Yamaha coolant is not available, use an 2. Check the coolant level in the coolant reser- ethylene glycol antifreeze containing corrosion in- voir.
Page 117 [EWB02672] protected against frost and corrosion. If water has been added to the coolant, have a Yamaha dealer check the antifreeze con- 9-30...
Page 118 tent of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. [ECB01012] EBU37131 To change the coolant EWB01891 WARNING Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by hot fluid and steam blown out under pressure.
Page 119 1. Coolant drain bolt 1. Coolant reservoir hose 2. Gasket 8. After draining the coolant, thoroughly flush 3. Trough the cooling system with clean tap water. 6. Remove the coolant reservoir cap. 9. Install the coolant drain bolt and its new gas- 7.
Page 120: Cleaning The Air Filter
12. Pour the recommended coolant into the radi- ator until it is full, and then install the radiator  Replace the air filter elements if damaged. cap.  Service the air filter more frequently if you often 13. Start the engine, let it idle for several minutes, ride in wet or dusty areas.
Page 121 1. Air filter case cover holder 1. Main air filter assembly 2. Air filter case cover 4. Pull out the main air filter assembly and sub air filter element. 1. Sub air filter element 9-34...
Page 122 5. Pull off the lock plate from the main air filter 7. Squeeze out the excess moisture, and let dry. NOTICE: Do not twist the sponge material assembly, and then remove the air filter ele- ment (sponge material) from the frame. when squeezing it.
Page 123: Cleaning The Spark Arrester
12. Install the air filter case cover by hooking the holders onto the cover. NOTICE: Make sure that the air filter element is properly seated in the air filter case. Never operate the en- gine with the air filter element removed. Doing so would allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage.
Page 124: 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. If water drains from the V-belt case after removing the plug, have a Yamaha dealer check the ATV as the water may affect other engine parts. 9-37...
Page 125: Adjusting The Throttle Lever Free Play
EBU29705 Adjusting the throttle lever free play For non-differential gear lock models 1. V-belt case drain plug 1. Throttle lever free play 2. Rubber cover 3. Locknut 4. Throttle lever free play adjusting bolt 9-38...
Page 126: Valve Clearance
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- 1. Throttle lever free play 2. Rubber cover vals specified in the periodic maintenance chart.
Page 127: Checking The Front Brake Pads And Rear Brake Friction Plates
EBU24174 Front brake pads EBU30322 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 chart. EBU29845 Checking the brake fluid level Before riding, check that the brake fluid is above the minimum level mark.
Page 128 Therefore, be sure to check the brake pads for wear and the brake system for leakage. If the brake fluid level suddenly goes down, have a Yamaha dealer check the brake sys- tem before further riding. EWB02721 WARNING Improper maintenance can result in loss of braking ability.
Page 129: Changing The Brake Fluid
 Brake hoses: Replace every four years. 1. No 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...
Page 130 Adjusting the brake lever free play 1. Locknut 2. Distance A 1. Brake lever free play 3. Brake lever free play adjusting bolt Brake lever free play: 2. To increase the brake lever free play, turn the 10.0 mm (0.39 in) brake lever free play adjusting bolt in direction (a).
Page 131 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 132 Brake pedal height: 80.0 mm (3.15 in) Measure the brake pedal height and adjust if nec- essary. 1. Remove the footboard by removing the quick fasteners, bolts, and nuts. 1. Locknut 2. Adjusting bolt 3. Turn the adjusting bolt in or out until the brake pedal height is within the specified limits.
Page 133 1. Footboard bolt A Tightening torques: 2. Footboard bolt B Footboard bolt A: 3. Quick fastener 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) Tighten the footboard bolts in the order shown. 9-46...
Page 134: Axle Boots
Check the axle boots for tears or damage. If 1. Loosen the locknut. any damage is found, have them replaced by a Yamaha dealer. 9-47...
Page 135: Brake Light Switches
The rear brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should 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).
Page 136: Checking And Lubricating The Cables
EBU28712 essary. If a cable is damaged or does not move Checking and lubricating the front and smoothly, have a Yamaha dealer check or replace rear brake levers The operation of the front and rear brake levers should be checked before each ride, and the lever Recommended lubricant: pivots should be lubricated if necessary.
Page 137: Checking And Lubricating The Brake Pedal
Front brake lever EBU28872 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease Rear brake lever 9-50...
Page 138: Checking The Wheel Hub Bearings
If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bearings. 1. Grease nipple For parts equipped with a grease nipple, use a EBU24974 grease gun.
Page 139: Lubricating The Rear Knuckle Pivots
EBU25096 chart. Lubricating the steering shaft The steering shaft must be lubricated by a Recommended lubricant: Yamaha dealer at the intervals specified in the pe- Lithium-soap-based grease riodic maintenance chart. Recommended lubricant: Lithium-soap-based grease 9-52...
Page 140: Battery
 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. 9-53...
Page 141 2. Remove the battery holding plate by remov- EWB02161 WARNING ing the bolts. Battery electrolyte is poisonous and danger- ous, as it contains sulfuric acid, which can cause severe burns. Avoid contact with skin, eyes or clothing. Always shield your eyes when working near batteries.
Page 142 ECB00622 ECB00942 NOTICE NOTICE  Always keep the battery charged. Storing the Never attempt to open the battery or remove the battery cell seals, as this would permanent- battery in a discharged state for an extended ly damage the battery. period of time will cause permanent battery damage.
Page 143 1. Positive battery lead (red) 1. Bolt 2. Negative battery lead (black) 2. Battery holding plate 3. Guide 3. Negative battery lead (black) Make sure the positive battery lead is routed be- Make sure the negative battery lead is routed un- hind the guides.
Page 144: Replacing A Fuse
EBU30806 Replacing a fuse 3 4 5 1. Auxiliary DC jack fuse 2. Four-wheel-drive motor fuse 1. Fuel injection system spare fuse 3. Ignition fuse 2. Fuel injection system fuse 4. Radiator fan motor fuse 3. Main fuse 5. Signaling system fuse 4.
Page 145 2. Remove the seat. (See page 5-18.) Specified fuses: 3. Remove the blown fuse, and then install a Main fuse: new fuse of the specified amperage. 40.0 A WARNING! Always use a fuse of the spec- Headlight fuse: ified rating, and never use a substitute ob- 15.0 A ject in place of the proper fuse.
Page 146: Replacing A Headlight Bulb
5. If the fuse immediately blows again, have a Yamaha dealer check the vehicle. 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.
Page 147 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 148 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 149: 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 150: Replacing The Brake/Tail Light Bulb
EBU25615 Replacing the brake/tail light bulb If the brake/tail light bulb burns out, replace it as follows. 1. Remove the brake/tail light bulb holder (to- gether with the bulb) by turning it counter- clockwise. 1. Brake/tail light bulb 3. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops.
Page 151: 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 models with tapered nuts: be sure to install the nuts with their tapered side towards the wheel.
Page 152: 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 153: 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 154 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK.  Tap water can be used in an emergency. Change to the recommended coolant as soon as possible.
Page 155: Cleaning And Storage
EBU25861 CLEANING AND STORAGE and deterioration of wheel bearings, EBU25883 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 156: Storage
8. If the headlight lens has fogged up, start the 3. Fill up the fuel tank and add fuel stabilizer (Fu- engine and turn on the headlight to help re- el Med Rx if available), and then run the en- move the moisture.
Page 157 6. Put the frame on stands or blocks to raise all wheels off the ground. (Alternatively, turn the wheels each month to prevent the tires from degrading in one spot.) 7. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.
Page 158: Specifications
EBU25964 SPECIFICATIONS Dimensions: Cooling system: Liquid cooled Overall length: Valve train: 2035 mm (80.1 in) (YFM45KDXP, YFM45KPAP, SOHC YFM45KPHP) Number of cylinders: 2042 mm (80.4 in) (YFM45KPSP) Single cylinder Overall width: Displacement: 1180 mm (46.5 in) 421 cm³ Overall height: Bore ×...
Page 159 Yamaha Friction Modified Shaft Drive Gear Oil AT25x8-12 Quantity: Manufacturer/model: 0.38 L (0.40 US qt, 0.33 Imp.qt) CHENG SHIN/CU905 Differential gear oil: Rear tire: Type: Size: Yamaha Friction Modified Shaft Drive Gear Oil or SAE 80 AT25x10-12 API GL-4 Hypoid gear oil Manufacturer/model: CHENG SHIN/CU906 11-2...
Page 160 Front brake: Type: Hydraulic disc brake Rear brake: Type: Mechanical wet multiple disc brake Front suspension: Type: Double wishbone Rear suspension: Type: Double wishbone Electrical system: System voltage: 12 V Battery: Model: YTX20L-BS Voltage, capacity: 12 V, 18.0 Ah Lights: Headlight: T19L, 30.0 W/30.0 W Handlebar-mounted light:...
Page 161: Consumer Information
EBU25984 CONSUMER INFORMATION EBU29663 Vehicle Emission Control Information label The Vehicle Emission Control Information label is affixed at the location in the illustration. This label shows specifications related to exhaust emissions as required by federal law, state law and Environ- ment Canada.
Page 162: Noise Regulation (For Usa)
EBU26062 Noise regulation (for USA) TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Page 163: Maintenance Record
EBU36901 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work. MAINTENANCE INTERVAL DATE OF SERVICING DEALER...
Page 164: Yamaha Motor Corporation, U.s.a. 2020 And Later Model Atv Limited Warranty (For Usa)
EBU30973 YAMAHA MOTOR CORPORATION, U.S.A. 2020 AND LATER MODEL ATV LIMITED WARRANTY (for USA) Yamaha Motor Corporation, U.S.A. hereby warrants THE CUSTOMER’S RESPONSIBILITY under this YAMAHA MOTOR CORPORATION, U.S.A. MAKES that new Yamaha ATVs purchased from warranty shall be to:...
Page 165 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.
Page 166: Yamaha Extended Service (Y.e.s.) (For Usa)
Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to “moving par ts” or the “drive train” like many other plans.
Page 167: Extended Service
Yamaha. See your dealer today! YAMAHA EXTENDED SERVICE A special note: If visiting your dealer isn’t convenient, contact Yamaha with your VIN number (vehicle identification number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O. Box 6555...
Page 168: Index
INDEX Differential gear oil ............6-3 Differential gear oil, changing ........9-27 Accessories and loading ..........7-5 Display unit ..............5-4 Accessories, DC jack ...........5-24 Drive select lever ............5-16 Air filter, cleaning ............9-33 Drive select lever and driving in reverse ......7-2 Axle boots ..............9-47 Drive shaft universal joint, lubricating ......
Page 169 Key identification number ..........1-2 Safety information ............3-1 Seat ................5-18 Shock absorber assemblies, adjusting the front and Label locations ............... 2-1 rear ................5-20 Light switch ..............5-9 Spark arrester, cleaning ..........9-36 Spark plug, checking ........... 9-17 Main switch ..............
Page 170 Wheel hub bearings, checking ........9-51 Wheel, installing ............9-64 Wheel, removing ............9-63 Winch pre-wiring (non-winch models) ......5-25 Winch switch (YFM45KPSP) ........5-10 Winch (YFM45KPSP) ...........5-22 Yamalube ..............9-23 13-3...
Page 171 EBU30393 For your best ownership experience, think Genuine Yamaha! Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect.
Page 172 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate: ALWAYS without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough...

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Yamaha KODIAK 450 2023 Owner's Manual

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