Yamaha Kodiak 450 2003 Manuals

Manuals and User Guides for Yamaha Kodiak 450 2003. We have 1 Yamaha Kodiak 450 2003 manual available for free PDF download: Service Manual

Yamaha Kodiak 450 2003 Service Manual (692 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 87 MB

Table of Contents
10
General Information
13
Features
13
Outline of the Eps (Electric Power Steering)
13
System
13
Diagram
14
Special Tools
15
Specifications
16
General Specifications
16
Maintenance Specifications
18
Engine
18
Tightening Torques
19
Chassis
20
Electrical
23
Cable Routing (Yfm45Fga/Yfm45Fgha)
26
Cable Routing (Yfm45Fgpa/Yfm45Fgpha)
35
Periodic Checks and Adjustments
51
Introduction
51
Periodic Maintenance Chart for the Emission Control System
51
General Maintenance and Lubrication Chart
52
Seat, Carriers, Fenders and Fuel Tank
54
Rear Carrier and Rear Fender
54
Chassis
56
Adjusting the Rear Brake
56
Checking the Rear Brake Friction Plates
59
Checking the Final Gear Oil Level
60
Changing the Final Gear Oil
60
Checking the Steering System (Yfm45Fgpa/Yfm45Fgpha)
62
Drive Train
64
Troubleshooting
64
Checking Noises
64
Rear Constant Velocity Joints and Final Gear Case Assembly
67
Disassembling the Rear Constant Velocity Joints
73
Assembling the Rear Constant Velocity Joints
74
Removing the Final Drive Pinion Gear and Bearing
76
Installing the Final Drive Pinion Gear and Bearing
77
Positioning the Final Dr Ive Pinion Gear
77
Measuring the Final Gear Backlash
80
Adjusting the Final Gear Backlash
81
Adjusting the Ring Gear Thrust Clearance
82
Adjusting the Ring Gear Stopper
83
Assembling the Final Gear Case
83
Installing the Final Gear Case
85
Chassis
86
Front and Rear Brakes
86
Brake Pedal
86
Final Gear Case (Rear Brake)
87
Disassembling the Final Gear Case (Rear Brake)
89
Checking the Friction Plates
89
Checking Th Erear Brake Plates
89
Checking the Rear Brake Springs
90
Checking Th Esplined Collar
90
Assembling the Final Gear Case (Rear Brake)
90
Steering System
91
Steering Stem (Yfm45Fga/Yfm45Fgha)
91
Steering Stem (Yfm45Fgpa/Yfm45Fgpha)
93
Installing the Steering Stem (Yfm45Fga/Yfm45Fgha)
95
Installing the Steering Stem
96
(Yfm45Fgpa/Yfm45Fgpha)
96
Eps Control Unit's Self-Diagnostic Function
101
Eps Warning Light During Normal Operation
102
Diagnostic Mode
103
Self-Diagnostic Function Table (Eps System)
106
Troubleshooting Details
107
Checking the Eps Motor
109
Checking the Eps Torque Sensor
111
Specifications
125
General Specifications
125
Maintenance Specifications
127
Engine
127
Chassis
128
Electrical
130
Cable Routing
131
Periodic Checks and Adjustments
141
Introduction
141
Periodic Maintenance/Lubrication
141
Seat, Carriers, Fenders and Fuel Tank
143
Chassis
145
Adjusting the Rear Brake
145
Checking the Final Gear Oil Level
147
Checking the Constant Velocity Joint Dust Boots
147
Adjusting the Rear Shock Absorbers
148
Engine
149
Middle Gear
149
Middle Driven Shaft
150
Drive Train
151
Troubleshooting
151
Front Constant Velocity Joints and Differential Gear
154
Measuring and Adjusting the Differential Gear Lash
154
Rear Constant Velocity Joints, Final Drive Gear and Drive Shaft
156
Assembling the Rear Constant Velocity Joints
161
Disassembling the Final Drive Gear
162
Checking the Drive Shaft/Universal Joint Yoke
162
Front and Rear Wheels
172
Rear Wheels
172
Installing the Rear Brake Disc
174
Installing the Rear Wheel Hubs
174
Front and Rear Brakes
175
Rear Brake Pads
175
Rear Brake Caliper
176
Installing the Rear Brake Caliper
178
Front Arms and Front Shock Absorbers
180
Rear Knuckles and Stabilizer
182
Checking the Rear Knuckles
183
Checking the Stabilizer
183
Rear Arms and Rear Shock Absorbers
184
Checking the Rear Arms
185
Installing the Rear Arms and Rear Shock Absorbers
185
General Information
196
Features
196
Override Switch (Deactivating the Speed Limiter When the Differential Is Locked)
196
Specifications
198
General Specifications
198
Maintenance Specifications
199
Engine
199
Chassis
201
Front and Rear Brakes
201
Rear Brake Master Cylinder
201
Steering System
203
Steering Stem
203
Tie Rod and Steering Knuckle
205
Electrical
208
Checkin Gth Eswitch
208
Checking the Switch Continuity
208
Signal System
210
Circuit Diagram
210
Checking the Final Drive Gear
221
Positioning the Final Drive Pinion Gear
221
Assembling the Final Drive Gear
221
General Information
223
Special Tools
223
Specifications
225
General Specifications
225
Engine Specifications
228
Chassis Specifications
229
Electrical Specifications
230
Tightening Torques
231
Chassis Tightening Torques
231
Cable Routing
232
Periodic Checks and Adjustments
241
Introduction
241
Periodic Maintenance Chart for the Emission Control System
241
General Maintenance and Lubrication Chart
242
Chassis
244
Adjusting the Brake Pedal Height
244
Adjusting the Rear Brake
246
Checking the Rear Brake Friction Plates
246
Adjusting the Select Lever Control Cable and Shiftrod
247
Adjusting the Brake Pedal Light Switch
249
Checking the Final Gear Oil Level
249
Changing the Final Gear Oil
250
Checking the Differential Gear Oil Level
251
Changing the Differential Gear Oil
252
Drive Train
253
Front Constant Velocity Joints and Differential Gear
254
Checking the Differential Gear Motor
257
Assembling the Front Constant Velocity Joints
257
Assembling the Differential Gear
258
Measuring the Differential Gear Lash
260
Adjusting the Differential Gear Lash
261
Rear Constant Velocity Joints, Final Drive Gear and Drive Shaft
263
Checking the Final Drive Gear
267
Disassembling the Final Drive Pinion Gear and Bearing
267
Installing the Final Drive Pinion Gear and Bearing
267
Positioning the Final Drive Pinion Gear and Ring Gear
268
Measuring the Ring Gear Thrust Clearance
268
Measurement the Final Gear Lash
269
Adjusting the Final Gear Lash
270
Assembling the Final Drive Gear
271
Installing the Final Gear Case
273
Chassis
274
Front and Rear Wheels
274
Front Wheels
274
Installing the Wheel Hubs
276
Front and Rear Brakes
277
Brake Pedal
277
Checking the Friction Plates
280
Checking the Rear Brake Plates
280
Checking the Rear Brake Springs
281
Checking the Pressure Plate
281
Checking the Ring Gear
281
Steering System
282
Tie Rod and Steering Knuckle
282
Rear Knuckles and Stabilizer
284
Electrical
285
Electrical Components
285
Checking the Switches
288
Checking the Switch Continuity
288
Lighting System
290
Circuit Diagram
290
Troubleshooting
291
Checking the Lighting System
292
Specifications
304
General Specifications
304
Chassis Specifications
305
Electrical Specifications
305
Tightening Torques
306
Engine Tightening Torques
306
Cable Routing
307
Periodic Checks and Adjustments
310
Seat, Carriers, Fenders and Fuel Tank
310
Engine
312
Middle Gear
312
Middle Driven Shaft
312
Chapter 1. General Information
336
Machine Identification
336
Vehicle Identification Number
336
Model Label
336
Features
337
Liquid Cooling Engine
337
Park Position
337
Front Differential
338
Important Information
343
Preparation for Removal Procedures
343
Bearings and Oil Seals
344
Checking of Connections
345
Special Tools
346
Chapter 2. Specifications
351
General Specifications
351
Maintenance Specifications
354
Engine
354
Chassis
364
Electrical
368
How to Use the Conversion Table
370
General Torque Specifications
370
Lubrication Points and Lubricant Types Engine
371
Coolant Flow Diagrams
372
Oil Flow Diagrams
374
Cable Routing
377
Chapter 3. Periodic Checks and Adjustments
387
Periodic Maintenance/Lubrication
387
Seat and Side Panels
395
Footrest Boards
395
Adjusting the Valve Clearance
396
Adjusting the Idling Speed
399
Adjusting the Starter Cable
403
Free Play
404
Spark Plug
405
Engine Oil Level
409
Engine Oil
410
Coolant Level
415
T He Coolant
416
Adjusting the Rear Brake
422
Checking the Brake Fluid Level
424
Checking the Front Brake Pad
425
Checking the Rear Brake Pad
425
Checking the Brake Hose
426
Bleeding the Hydraulic Brake System
427
Adjusting the Select Lever Control Cable and Shift Rod
428
Adjusting the Rear Brake Light Switch
430
Checking the Final Gear Oil Level
430
Changing the Final Gear Oil
431
Checking the Differential Gear Oil
432
Changing the Differential Gear Oil
432
Checking the Constant Velocity Joint Dust Boot
433
Checking the Steering System Adjusting the Toe-In
434
Adjusting the Front Shock Absorber
436
Adjusting the Rear Shock Absorber
436
Checking the Tire
437
Checking the Wheel
439
Checking and Lubricating the Cable
439
Lubricating the Levers, Pedal, Etc
440
Electrical
441
Checking the Batiery
441
Checking the Fuse
446
Adjusting the Headlight Beam
448
Changing the Headlight Bulb
449
Chapter 4. Engine
450
Engine Removal
450
Air Ducts, Muffler and Exhaust Pipe
450
Select Lever Unit and Coolant Reservoir
452
Hoses and Leads
453
Engine Mounting Bolts
454
Installing the Engine
456
Cylinder Head
457
Removing the Cylinder Head
459
Checking the Tappet Cover
460
Checking the Timing Chain Tensioner
460
Checking the Camshaft Sprocket
460
Checking the Cylinder Head
461
Installing the Cylinder Head
462
Camshaft, Rocker Arms and Valves
465
Removing the Camshaft and Rocker Arm
467
Removing the Valve and Valve Spring
467
Checking the Camshaft
468
Checking the Rocker Arm and Camshaft
468
Checking the Valve and Valve Spring
470
Installing the Valve and Valve Spring
474
Installing the Camshaft and Rocker Arm
475
Cylinder and Piston
476
Removing the Piston
477
Checking the Timing Chain Guide
477
Checking the Cylinder and Piston
477
Checking the Piston Ring
479
Checking the Piston Pin
480
Installing the Piston
481
Installing the Cylinder
482
Recoil Starter and A.C. Magneto
483
Magneto
484
Disassembling the Recoil Starter
486
Checking the CDI Magneto
486
Checking the Starter Clutch
487
Checking the Starter Pulley
488
Checking the Recoil Starter
488
Assembling the Recoil Starter
488
Magneto
489
Primary and Secondary Sheaves
491
Primary Sliding Sheave
493
Secondary Sheave
494
Removing the Primary and Secondary Sheaves
495
Disassembling the Secondary Sheave
495
Checking the Primary Sheave
496
Checking the Secondary Sheave
496
Assembling the Primary Sheave
497
Assembling the Secondary Sheave
497
Installing the Primary and Secondary Sheaves
499
Clutch
500
Removing the Clutch
502
Checking the Clutch
502
Installing the Clutch
503
Thermostat
542
Water Pump
544
Assembling the Water Pump
547
Carburetor
549
Disassembling the Carburetor
552
Assembling the Carburetor
554
Universal Joint
562
Differential Gear
563
E Universal Joint
565
Velocity Joint
566
Chapter 10. Troubleshooting
670
Starting Failure/Hard Starting
686
Poor Idle Speed Performance Poor Idle Speed Performance
686
Faulty Drive Train
687
Faul Ty Gear Shifting
688
Hard Shifting
688
Jumps out of Gear
688
Faul Ty Clutch Performance
688
Engine Operates but Machine will Not Move
688
Clutch Slipping
688
Poor Starting Performance
688
Overheating Overheating
689
Faul Ty Brake
689
Shock Absorber Malfunction
690
Unstable Handling
690
Lighting System
690

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Yamaha Kodiak 450 2003 Manuals

Yamaha Kodiak 450 2003 Service Manual (692 pages)

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