Atv Segment:
Mid-size utility ATV, popular for recreational and light-duty farm/ranch use.
Target Audience:
Owners and technicians performing maintenance, repair, and diagnostics on the 2003 Yamaha Kodiak 400.
Competitors:
Honda Foreman/Rancher, Suzuki King Quad, Polaris Sportsman, Kawasaki Prairie.
Manual Value Proposition:
Provides essential technical data and procedures to maintain and repair the ATV, saving time and money compared to professional service.
Yamaha Kodiak Reputation:
Known for its reliability, robust build, and capable performance in various terrains.
Primary Coverage:
Comprehensive service, repair, and maintenance for the 2003 Yamaha Kodiak YFM400FAR 400 ATV.
Secondary Coverage:
Troubleshooting, diagnostics, specifications, and periodic checks.
Estimated Page Count:
Information not explicitly stated, but typical for this type of manual is 300-600 pages.
Manual Type:
Service Repair Workshop Manual
Digital Format:
PDF Download
Engine:
Engine overhaul, diagnostics, component testing, lubrication system, valve clearance, ignition system, fuel system (carburetion), exhaust system.
Cooling System:
Radiator, fan, coolant, hoses, thermostat, system checks.
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel pump, fuel lines, fuel tank.
Drivetrain:
Transmission (gearbox), clutch, driveshafts, differential, U-joints, maintenance, repair procedures.
Chassis:
Frame, suspension (front and rear), steering system, wheels, tires, brakes (hydraulic system, pads, rotors).
Electrical System:
Wiring diagrams, battery, charging system (stator, rectifier/regulator), ignition system, starter motor, lighting, instrumentation.
Bodywork:
Body panels, seat, fenders, racks, plastic components, removal and installation.
Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain adjustment (if applicable), brake system bleeding, coolant flush.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.
Repair:
Detailed step-by-step instructions for component disassembly, repair, reassembly, and adjustments.
Diagnostics:
Procedures for checking electrical components, engine performance, and mechanical systems.
Depth Level:
Comprehensive: From basic routine maintenance to complete engine and transmission overhauls.
Diagnostic Tools:
Information on using standard hand tools, torque wrenches, and basic electrical testing equipment.
Rebuild Procedures:
Detailed instructions for rebuilding major components like the engine and transmission.
Engine Type:
4-stroke, SOHC, air-cooled with fan assist
Bore X Stroke:
82.0 mm x 72.0 mm
Valve Clearance Intake:
0.10 - 0.20 mm (cold)
Valve Clearance Exhaust:
0.20 - 0.30 mm (cold)
Horsepower:
Approx. 20-22 HP (Estimate, actual may vary by specific configuration and regulations)
Torque:
Information not explicitly stated in product data, but typically around 25-30 lb-ft.
Carburetor Model:
Mikuni BSR33
Fuel Type:
Unleaded gasoline, minimum octane rating 86
Ignition Type:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Air-cooled with forced fan cooling
Oil Type:
Yamalube 4 (or equivalent SAE 10W-30) API SG or higher
Oil Capacity:
1.80 L (1.90 US qt) for oil change, 2.00 L (2.10 US qt) with filter change
Transmission Type:
Automatic (Yamaha Ultramatic®)
Drive System:
Shaft drive with 2WD/4WD selector
Gear Selection:
H, L, N, R, P
Engine Braking:
Integral feature of the Ultramatic® transmission for controlled descents.
Transmission Oil Type:
Yamaha Gear Oil (or equivalent SAE 80 hypoid gear oil)
Final Drive Oil Capacity:
Approx. 0.14 L (0.15 US qt)
Atv Safety Standards:
Meets ANSI/SVIA standards.
Braking System:
Hydraulic disc brakes front and rear.
Parking Brake:
Mechanical drum brake on rear drive shaft.
Lighting:
Dual 30W headlights, 8W taillight/stoplight.
Seatbelt:
N/A (ATVs typically do not have seatbelts)
Roll Over Protection:
N/A (Riding ATVs requires operator caution and protective gear).
Infotainment System:
N/A (Basic utility ATV)
Driver Assistance Features:
N/A (Focus on mechanical operation, not electronic driver aids)
Connectivity Features:
N/A
Instrument Panel:
Speedometer, odometer, trip meter, neutral indicator, reverse indicator, high beam indicator, oil level indicator, 2WD/4WD indicator.
Engine Oil Change:
Every 6 months or 2,000 km (1,200 miles) or 100 hours of operation.
Oil Filter Replacement:
Every 2,000 km (1,200 miles) or 100 hours of operation (with oil change).
Air Filter Cleaning:
Every 6 months or 500 km (300 miles) or 40 hours of operation. Replace if damaged.
Spark Plug Service:
Inspect every 6 months or 500 km (300 miles) or 40 hours. Replace as needed.
Valve Clearance Adjustment:
Every 12 months or 4,000 km (2,400 miles) or 200 hours of operation.
Brake Fluid Flush:
Every 2 years or as needed, depending on usage and environment.
Engine Oil:
Yamalube 4 (or equivalent SAE 10W-30) API SG or higher
Transmission Oil:
Yamaha Gear Oil (or equivalent SAE 80 hypoid gear oil)
Coolant:
Permanent type antifreeze (ethylene glycol based), mixed 50/50 with distilled water. Use Yamaha Super Coolant or equivalent.
Common Wear Items:
Brake pads, wheel bearings, tie rod ends, ball joints, drive shaft U-joints due to off-road usage.
Carburetor Tuning:
Carburetors can become slightly finicky with age or due to fuel quality, requiring occasional cleaning and adjustment.
Electrical Connectors:
Corrosion in electrical connectors can occur in wet environments, potentially causing intermittent issues.
Yamaha Motors Corporation:
Established in 1955, Yamaha is a renowned Japanese manufacturer known for its innovation in motorcycles, marine products, and power sports vehicles.
Kodiak Lineage:
The Kodiak line has a history of offering reliable, go-anywhere utility ATVs. The 400cc models were a popular segment.
Manufacturing Location:
Likely manufactured in Japan or at Yamaha's North American production facilities.
Model Year Significance:
The 2003 model represents a mature iteration of the Kodiak 400 platform, incorporating refinements from earlier years.
