1999-2005 YAMAHA YFM400 BIG BEAR ATV’S SERVICE MANUAL
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1999-2005 YAMAHA YFM400 BIG BEAR ATV’S SERVICE MANUAL
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
MANUAL FORMAT :
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections.
TABLE OF CONTENTS:
1999-2005 YAMAHA YFM400 BIG BEAR ATV’S SERVICE MANUAL
CHAPTER 1
GENERAL INFORMATION
MACHINE IDENTIFICATION 1-1
VEHICLE IDENTIFICATION NUMBER 1-1
MODEL LABEL 1-1
IMPORTANT INFORMATION 1-2
PREPARATION FOR REMOVAL PROCEDURES 1-2
REPLACEMENT PARTS 1-2
GASKETS, OIL SEALS AND O-RINGS 1-2
LOCK WASHERS/PLATES AND COTTER PINS 1-3
BEARINGS AND OIL SEALS 1-3
CIRCLIPS 1-3
SPECIAL TOOLS 1-4
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1
MAINTENANCE SPECIFICATIONS 2-4
ENGINE 2-4
CHASSIS 2-14
ELECTRICAL 2-18
HOW TO USE THE CONVERSION TABLE 2-20
GENERAL TORQUE SPECIFICATIONS 2-20
LUBRICATION POINTS AND LUBRICANT TYPE 2-21
ENGINE 2-21
LUBRICATION DIAGRAMS 2-22
CABLE ROUTING 2-24
CHAPTER 3
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION 3-1
PERIODIC MAINTENANCE/LUBRICATION 3-1
SEAT, CARRIERS, FENDERS AND FUEL TANK 3-3
REMOVAL 3-3
INSTALLATION 3-5
ENGINE 3-8
VALVE CLEARANCE ADJUSTMENT 3-8
TIMING CHAIN ADJUSTMENT 3-10
IDLING SPEED ADJUSTMENT 3-11
THROTTLE LEVER FREE PLAY ADJUSTMENT 3-12
SPEED LIMITER ADJUSTMENT 3-13
STARTER LEVER FREE PLAY ADJUSTMENT 3-14
SPARK PLUG INSPECTION 3-15
IGNITION TIMING CHECK 3-15
COMPRESSION PRESSURE MEASUREMENT 3-16
ENGINE OIL LEVEL INSPECTION 3-18
OIL TEMPERATURE WARNING LIGHT CHECK 3-19
ENGINE OIL REPLACEMENT 3-19
CLUTCH ADJUSTMENT 3-21
AIR FILTER CLEANING 3-22
SPARK ARRESTER CLEANING 3-23
CHASSIS 3-25
REAR BRAKE LEVER AND PEDAL ADJUSTMENT 3-25
FRONT BRAKE FLUID LEVEL INSPECTION 3-27
FRONT BRAKE PAD INSPECTION 3-27
REAR BRAKE SHOE INSPECTION 3-28
BRAKE HOSE INSPECTION 3-28
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 3-28
REVERSE CONTROL CABLE ADJUSTMENT 3-30
SHIFT PEDAL ADJUSTMENT 3-30
FINAL GEAR OIL LEVEL INSPECTION 3-31
FINAL GEAR OIL REPLACEMENT 3-31
DIFFERENTIAL GEAR OIL QUANTITY INSPECTION 3-32
DIFFERENTIAL GEAR OIL REPLACEMENT 3-33
CONSTANT VELOCITY JOINT DUST BOOT INSPECTION 3-34
STEERING SYSTEM INSPECTION 3-35
TOE-IN ADJUSTMENT 3-35
FRONT SHOCK ABSORBER ADJUSTMENT 3-37
REAR SHOCK ABSORBER ADJUSTMENT 3-37
TIRE INSPECTION 3-37
WHEEL INSPECTION 3-40
CABLE INSPECTION AND LUBRICATION 3-40
LEVERS, PEDAL, ETC LUBRICATION 3-40
ELECTRICAL 3-41
BATTERY INSPECTION 3-41
FUSE INSPECTION 3-46
HEADLIGHT BEAM ADJUSTMENT 3-48
HEADLIGHT BULB REPLACEMENT 3-48
CHAPTER 4
ENGINE OVERHAUL
ENGINE REMOVAL 4-1
SEAT, CARRIERS, FENDERS AND FUEL TANK 4-1
ENGINE OIL ; 4-1
CARBURETOR 4-1
EXHAUST PIPE AND MUFFLER 4-2
STARTER MOTOR 4-2
OIL FILTER 4-3
REVERSE CONTROL CABLE 4-3
SHIFT PEDAL AND FOOTREST 4-3
SPARK PLUG 4-4
LEADS 4-4
REAR SHOCK ABSORBER AND SWINGARM 4-5
FRONT DRIVE SHAFT PROTECTOR 4-6
FRONT FENDER BRACKET 4-6
ENGINE REMOVAL 4-6
ENGINE DISASSEMBLY 4-8
RECOIL STARTER 4-8
CYLINDER HEAD AND CYLINDER 4-8
PISTON 4-11
CRANKCASE COVER (LEFT) 4-11
SHIFT SHAFT AND STARTER IDLE GEAR 4-12
COl ROTOR AND TIMING CHAIN 4-13
CRANKCASE COVER (RIGHT) 4-13
CLUTCH 4-14
REVERSE SHIFT BRACKET 4-16
OIL PUMP AND BALANCER DRIVE GEARS 4-16
CRANKCASE (LEFT) , 4-18
BALANCER WEIGHT AND TRANSMISSION 4-18
CRANKSHAFT 4-19
CAMSHAFT, ROCKER ARM AND VALVE 4-20
OIL PUMP 4-22
INSPECTION AND REPAIR 4-23
CYLINDER HEAD 4-23
VALVE SEAT 4-24
VALVE AND VALVE GUIDE 4-26
VALVE SPRING 4-27
CAMSHAFT 4-28
ROCKER ARM AND ROCKER ARM SHAFT 4-29
TIMING CHAIN TENSIONER 4-29
TAPPET COVER AND SIDE COVER (CYLINDER HEAD) 4-30
CYLINDER AND PISTON 4-30
PISTON RING 4-32
PISTON PIN 4-33
CRANKSHAFT 4-34
BALANCER DRIVE GEAR AND DRIVEN GEAR 4-35
PRIMARY GEARS 4-35
PRIMARY CLUTCH 4-35
SECONDARY CLUTCH 4-36
OIL PUMP 4-38
SHIFTER AND TRANSMISSION 4-39
STARTER DRIVES 4-41
STARTER PULLEY AND RECOIL STARTER 4-42
OIL STRAINER, OIL FILTER AND OIL DELIVERY PIPES 4-42
CRANKCASE 4-43
BEARINGS AND OIL SEALS 4-43
CIRCLIPS AND WASHERS , 4-43
MIDDLE GEAR SERVICE 4-44
REMOVAL 4-45
DISASSEMBLY 4-45
INSPECTION 4-49
MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION 4-49
ASSEMBLY 4-52
INSTALLATION 4-56
GEAR LASH MEASUREMENT 4-56
ENGINE ASSEMBLY AND ADJUSTMENT 4-58
OIL PUMP 4-58
VALVE, CAMSHAFT AND ROCKER ARM 4-59
VALVE, ROCKER ARM AND CAMSHAFT 4-60
CRANKSHAFT 4-61
TRANSMISSION AND BALANCER WEIGHT 4-61
CRANKSHAFT AND TRANSMISSION 4-62
CRANKCASE (LEFT) 4-63
BALANCER DRIVE AND DRIVEN GEARS AND OIL PUMP 4-65
BALANCER DRIVE GEARS AND OIL PUMP 4-66
REVERSE SHIFT BRACKET 4-67
CLUTCH 4-68
CLUTCH 4-69
CRANKCASE COVER (RIGHT) 4-71
TIMING CHAIN AND CDI ROTOR 4-72
CDI ROTOR AND STARTER 4-73
SHIFTER 4-74
STARTER IDLE GEAR AND SHIFT SHAFT 4-75
CRANKCASE COVER (LEFT) 4-76
PISTON AND CYLINDER 4-78
PISTON 4-79
CYLINDER AND CYLINDER HEAD 4-79
CYLINDER HEAD 4-81
RECOIL STARTER 4-84
REMOUNTING THE ENGINE 4-85
CHAPTER 5
CARBURETION
CARBURETOR 5-1
REMOVAL 5-2
DISASSEMBLY 5-3
INSPECTION 5-4
ASSEMBLY 5-7
INSTALLATION 5-8
FUEL LEVEL ADJUSTMENT 5-9
CHAPTER 6
DRIVE TRAIN
TROUBLESHOOTING 6-1
DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS 6-4
REMOVAL 6-6
DISASSEMBLY 6-7
INSPECTION 6-10
ASSEMBLY 6-11
MEASUREMENT AND ADJUSTMENT 6-15
INSTALLATION 6-17
DIFFERENTIAL GEAR OPERATION CHECK 6-19
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT 6-20
REMOVAL 6-22
DISASSEMBLY 6-23
INSPECTION 6-25
FINAL DRIVE PINION GEAR AND
RING GEAR SHIM SELECTION 6-27
ASSEMBLY 6-30
FINAL GEAR LASH MEASUREMENT AND ADJUSTMENT 6-34
INSTALLATION 6-37
CHAPTER 7
CHASSIS
FRONT AND REAR WHEELS 7-1
REMOVAL 7-2
INSPECTION 7-4
INSTALLATION 7-4
FRONT BRAKE 7-6
BRAKE PAD REPLACEMENT 7-7
CALIPER DISASSEMBLY 7-9
MASTER CYLINDER DISASSEMBLY 7-10
INSPECTION AND REPAIR 7-11
CALIPER ASSEMBLY 7-14
MASTER CYLINDER ASSEMBLY 7-17
REAR BRAKE 7 -20
REMOVAL 7-21
INSPECTION 7-22
INSTALLATION 7-23
STEERING SYSTEM 7 -26
REMOVAL 7-27
INSPECTION 7-30
INSTALLATION 7-33
FRONT SHOCK ABSORBER AND FRONT ARM 7-37
REMOVAL 7-38
INSPECTION 7-39
INSTALLATION 7-41
REAR SHOCK ABSORBER AND SWINGARM 7 -43
REMOVAL 7-44
INSPECTION 7-46
INSTALLATION 7-47
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS 8-1
CHECKING OF CONNECTIONS 8-2
IGNITION SYSTEM 8-3
CIRCUIT DIAGRAM 8-3
TROUBLESHOOTING 8-4
ELECTRICAL STARTING SYSTEM 8-9
CIRCUIT DIAGRAM 8-9
STARTING CIRCUIT OPERATION 8-10
TROUBLESHOOTING 8-11
STARTER MOTOR 8-16
CHARGING SYSTEM 8-21
CIRCUIT DIAGRAM 8-21
TROUBLESHOOTING 8-22
LIGHTING SYSTEM 8-25
CIRCUIT DIAGRAM 8-25
TROUBLE SHOOTING 8-26
LIGHTING SYSTEM CHECK 8-29
SIGNAL SYSTEM 8-31
CIRCUIT DIAGRAM 8-31
TROUBLE SHOOTING 8-32
SIGNAL SYSTEM CHECK 8-34
COOLING SYSTEM 8-37
CIRCUIT DIAGRAM 8-37
TROUBLE SHOOTING 8-38
CARBURETOR WARMING SySTEM 8-42
CIRCUIT DIAGRAM 8-42
TROUBLE SHOOTING 8-43
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING 9-1
FUEL SYSTEM 9-1
ELECTRICAL SYSTEM 9-1
COMPRESSION SYSTEM 9-2
POOR IDLE SPEED PERFORMANCE 9-2
POOR IDLE SPEED PERFORMANCE 9-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE 9-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE 9-2
FAULTY DRIVE TRAIN 9-3
FAULTY GEAR SHIFTING 9-4
HARD SHIFTING 9-4
SHIFT PEDAL DOES NOT MOVE 9-4
JUMPS-OUT-OF GEAR 9-4
CLUTCH SLIPPING/DRAGGING , 9-4
CLUTCH SLIPPING 9-4
CLUTCH DRAGGING 9-4
OVER HEATING 9-5
OVERHEATING 9-5
FAULTY BRAKE 9-5
POOR BRAKING EFFECT 9-5
SHOCK ABSORBER MALFUNCTION 9-5
MALFUNCTION 9-5
UNSTABLE HANDLING 9-6
UNSTABLE HANDLING 9-6
LIGHTING SySTEM 9-6
HEADLIGHT DARK 9-6
BULB BURNT OUT 9-6
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]