Description

Yamaha Kodiak 400 Engine Rebuild (2003–2006) – 2WD & 4WD

If your 2003–2006 Yamaha Kodiak 400 engine has lost compression, developed internal noise, or started consuming oil, we rebuild your original engine to restore dependable performance. This is a build core required listing, which means we must receive your engine before rebuild work begins.

Because we complete machining and assembly in-house, we control every tolerance and inspection step from teardown to final torque.

Warranty Coverage

Every rebuilt Kodiak 400 engine includes a standard 1-year no-fault warranty. In addition, you may upgrade to a 2-year no-fault, no-questions-asked warranty for $450.

For full coverage details, review our engine warranty page.

What Your Complete Engine Rebuild Includes

• Complete teardown, cleaning, and inspection of all components
• Crankshaft rebuilt, inspected, and verified within OEM specifications
• All bearings inspected and cleaned
• Cylinders inspected for wear and damage
• Worn cylinders bored to next oversize and honed or replaced
• New piston and piston rings
• Cylinder head cleaned, decked, and rebuilt to manufacturer specifications
• Valve guides inspected and replaced as needed
• Valves and seats recut and verified with vacuum testing
• Camshaft lobes and journals cleaned and polished, replaced if required
• Timing chain inspected and replaced as needed
• Refurbished oil pump assembly
• Engine cases fully inspected and machined
• All gaskets and seals replaced
• Final assembly torqued to manufacturer specifications

Note: This rebuild outline is standardized. Specific components may vary depending on engine condition and model configuration.

Our Commitment to Quality

We rebuild hundreds of engines each month, and every engine passes a strict quality control inspea ction before shipment. First, a technician completes the rebuild and verifies measurements. Next, the engine undergoes final inspection to ensure proper specifications.

Core Exchange Process

• Place Your Order: Secure your rebuild slot.
• Prep Your Core: Remove exhaust, electrical, and fueling components using our simple tear-down instructions.
• Scheduled Pickup: Once packaged, we arrange carrier pickup directly from your location.
• Expert Rebuild & Return: After passing inspection, your rebuilt engine ships back ready for installation.

Your rebuild begins only after we receive your engine core. Once it arrives, the typical turnaround time is approximately two weeks.

Shipping Instructions

Before sending your engine, review our core shipping instructions for packaging and freight details.

Need Assistance?

If you have questions about fitment, 2WD vs 4WD compatibility, or lead times, visit our help center or contact our team through our support page.

Send in your core and rebuild your Yamaha Kodiak 400 the right way.