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2004-2008 Yamaha YFM400 Kodiak YFM350 Bruin ATV Repair Manual

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This manual provides comprehensive service information for the 2004-2008 utility ATVs and the 2004-2008 utility ATVs. These robust utility ATVs, known for their reliability and off-road capability, are designed for...
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Taper: Atv
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2004-2008 Yamaha YFM400 Kodiak YFM350 Bruin ATV Repair Manual2004-2008 Yamaha YFM400 Kodiak YFM350 Bruin ATV Repair Manual2004-2008 Yamaha YFM400 Kodiak YFM350 Bruin ATV Repair Manual2004-2008 Yamaha YFM400 Kodiak YFM350 Bruin ATV Repair Manual
This manual provides comprehensive service information for the 2004-2008 utility ATVs and the 2004-2008 utility ATVs. These robust utility ATVs, known for their reliability and off-road capability, are designed for a variety of tasks, from work to recreation. The model, featuring a 348 cc engine and rear-wheel drive, offers agile performance, while the model, equipped with a 386 cc engine and selectable 4WD, delivers enhanced traction and power for more demanding conditions. Both models benefit from engineering quality, ensuring dependable operation across different terrains and uses. This extensive manual covers all essential aspects of maintaining and repairing your ATV. It includes detailed procedures for engine service, drivetrain maintenance, chassis and suspension adjustments, and electrical system diagnostics. You will find step-by-step instructions for routine maintenance, troubleshooting common issues, and performing component rebuilds. Technical specifications, fluid recommendations, and safety guidelines are also thoroughly documented, making this an indispensable resource for owners and technicians alike to ensure optimal performance and longevity of the models.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
YFM400 Kodiak
Generation
Model Years Covered:
2004, 2005, 2006, 2007, 2008
Codes
Chassis Codes Bruin:
YFM350FW, YFM350FX (indicative, specific VIN decoding recommended)
Chassis Codes Kodiak:
YFM400FHW, YFM400FHX (indicative, specific VIN decoding recommended)
👋 Introduction
Market Position
Target Audience:
Yamaha ATV owners and independent repair shops seeking detailed service information
Competitive Analysis
Manual Provider:
GearHead Manuals
Key Features
Convenience:
Instant downloadable PDF, usable on smartphones for trailside repairs
Content Scope:
Covers all aspects of repair, maintenance, and troubleshooting for specified models
📋 Manual Details
Coverage Areas
Applicable Models:
2004-2008 Yamaha YFM350 Bruin 4x2 ATV, 2004-2008 Yamaha YFM400 Kodiak 4x4 ATV
Page Count
Estimated Page Count:
Comprehensive (exact number not specified, but implies full workshop coverage)
Manual Type
Type:
Repair Manual / Service Manual / Workshop Manual / Owner's Manual / Parts Catalog (multi-faceted)
Language
Language:
English (presumed, based on common industry practice for manuals sold in English-speaking markets)
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine removal/installation, engine specifications, lubrication, cooling, fuel system, intake/exhaust
Drivetrain:
Transmission, drive chain, sprockets, differential (Kodiak 4x4)
Chassis And Suspension:
Steering system, shocks, suspension components
Electrical:
Electrical system diagnostics, wiring diagrams (likely), components
Bodywork And Cosmetics:
Body panels, plastics, general appearance maintenance
Procedures Included
Maintenance:
Routine maintenance, service intervals, fluid changes, filter replacements
Troubleshooting:
Advanced troubleshooting guides, diagnostic procedures, common issues
Repair:
Detailed step-by-step repair instructions for various components
Rebuilds:
Engine rebuild, transmission rebuild, differential rebuild (likely)
Technical Depth
Depth:
Comprehensive, covering basic to advanced repair and diagnostics
📊 Manual Specifications
File Format
File Type:
PDF
Accessibility:
Instant download, no zip files, plain simple easy to use
Print Quality
Printability:
Printable pages for on-site use
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Quality:
N/A (Digital PDF)
Policy
Loss Or Damage Policy:
Lifetime Protection Policy for replacements if lost or damaged
⚙️ Engine Specifications
Primary Engine
Engine Type Bruin:
Air-cooled, 4-stroke, SOHC, 2-valve, single-cylinder
Engine Type Kodiak:
Air-cooled, 4-stroke, SOHC, 4-valve, single-cylinder
Displacement Bruin:
348 cc (21.2 cu. in.)
Displacement Kodiak:
386 cc (23.5 cu. in.)
Performance
Horsepower Kodiak Approx:
Estimated 22-25 hp (specific dyno data varies)
Torque Kodiak Approx:
Estimated 23-26 lb-ft (specific dyno data varies)
Fuel System
Fuel Delivery Bruin:
Carburetor (Mikuni BSR33, likely)
Fuel Delivery Kodiak:
Carburetor (likely Mikuni BSR33 or similar)
Fuel Type:
Unleaded gasoline
Lubrication
Oil Type Recommendation:
Yamalube 4T SAE 20W-40 or SAE 10W-30 API SG or higher (refer to manual for precise specification)
Cooling
Cooling System:
Air-cooled
🔧 Transmission
Standard
Transmission Type:
Automatic (Yamaha Ultramatic®)
Drive System Bruin:
2WD (Rear Wheel Drive)
Drive System Kodiak:
4WD (Selectable 4WD with 2WD option)
Optional
Gear Selection:
High, Low, Neutral, Reverse, Park
Features
Final Drive:
Shaft drive (Kodiak 4x4), Chain drive (Bruin likely as well, manual will specify)
Belt Type:
V-belt, centrifugal clutch
📐 Dimensions
Exterior
Length Approx:
Kodiak: ~81.1 inches, Bruin: ~76.4 inches (specifics vary, consult manual)
Width Approx:
Kodiak: ~45.3 inches, Bruin: ~42.5 inches (specifics vary, consult manual)
Height Approx:
Kodiak: ~45.7 inches, Bruin: ~44.1 inches (specifics vary, consult manual)
Weights
Dry Weight Bruin:
Approx. 507 lbs (230 kg)
Dry Weight Kodiak:
Approx. 569 lbs (258 kg)
Towing Capacity:
1,102 lbs (500 kg) (verify specific model, consult manual)
Front Rack Capacity:
55 lbs (25 kg)
Rear Rack Capacity:
198 lbs (90 kg)
🛡️ Safety Features
Ratings
Rollover Protection:
N/A (ATVs do not have roll cages or seatbelts as standard safety features; safe operating practices are paramount)
Active Features
Braking System:
Hydraulic disc brakes, front and rear (specific configuration detailed in manual)
Passive Features
Lighting:
Headlights, taillight/stoplight
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic utility ATV, no integrated infotainment)
Driver Assistance
Driver Assistance Features:
N/A
Connectivity
Connectivity Options:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 1,000 km (600 mi) or 6 months (refer to manual for exact schedule)
Air Filter Cleaning:
As needed based on operating conditions, typically every 100-200 hours or 500-1000 miles
Spark Plug Replacement:
Refer to manual, typically every 2,000-3,000 miles or 1-2 years
Fluid Specifications
Engine Oil Capacity:
Approx. 1.7 L (1.8 US qt) with filter change (consult manual for exact capacity)
Gear Oil Specification:
Yamaha"'s internal gear oil or equivalent GL-4 SAE 80 hypoid gear oil (confirm with manual)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (confirm with manual)
Known Issues
Carburetor Cleaning:
Common need for periodic carburetor cleaning/rebuilding due to ethanol fuels and sediment
Drive Belt Wear:
V-belt wear and tear is a maintenance item requiring inspection and eventual replacement
Cooling Fins Blockage:
Air-cooled engines require keeping cooling fins clean of mud and debris to prevent overheating
Cvt Cover Sealing:
Ensuring proper sealing of the CVT cover to prevent water and debris ingress
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Corporation, Japan
Model Evolution
Bruin Lineage:
Successor to models like the Big Bear, emphasizing comfort and utility
Kodiak Lineage:
Known for its robust 4x4 system and utility, building on the Kodiak legacy
Production
Manufacturing Location:
Likely manufactured in Japan or North America (specific plant not detailed)
🏆 Awards & Recognition
Recognitions
Model Specific Awards:
Not typically awarded in the same manner as automotive vehicles; focus is on utility and reliability
Ratings
Consumer Reliability:
Generally good reputation for Yamaha's utility ATV platforms
Certifications
Emissions Standards:
Compliant with relevant emissions standards for model year production (details in manual)
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