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2004-2008 Yamaha YFM400 Kodiak YFM350 Bruin ATV Repair Manual

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🏷️ 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...
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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
🏷️ 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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