Yamaha Big Bear 400 2000-2004 Workshop Service Repair Manual

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The Big Bear 400, produced from 2000 to 2004, is a robust and dependable all-terrain vehicle designed for both demanding work and recreational trail riding. Known for its comfortable ride...

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Typ: Atv

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Art.-Nr: 69578

Stichworte: 2000 2001 2002 2003 2004 ATV Big Bear 400 Big Bear Models Powersports Yamaha

Produktvarianten

Beschreibung

The Big Bear 400, produced from 2000 to 2004, is a robust and dependable all-terrain vehicle designed for both demanding work and recreational trail riding. Known for its comfortable ride and capable performance, this model features independent front suspension, an automatic transmission, and a reliable air-cooled engine. Its durable construction, coupled with significant towing and carrying capacity, makes it a practical choice for various utility tasks. The Big Bear 400 (YFM400F for 4x4 and YFM400 for 4x2 chassis codes) embodies a commitment to building high-quality, user-friendly powersports equipment. This comprehensive workshop service repair manual provides extensive guidance for the Big Bear 400. It covers all essential aspects of maintenance, repair, troubleshooting, and diagnostics, including detailed procedures for the engine, transmission, chassis, brakes, and electrical systems. With factory-level detail, torque specifications, and step-by-step instructions, this manual is an indispensable resource for owners, mechanics, and technicians seeking to maintain the optimal performance and longevity of their vehicle. The manual includes wiring diagrams, exploded views, and assembly/disassembly procedures to facilitate efficient and accurate servicing.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

Big Bear 400

Model Years Covered:

2000, 2001, 2002, 2003, 2004

Codes

Chassis Codes:

YFM400F (4x4), YFM400 (4x2)

👋 Introduction

Market Position

Positioning:

The Yamaha Big Bear 400 was positioned as a rugged, reliable utility ATV for work and recreational trail riding, known for its comfort and capability.

Competitive Analysis

Competitors:

Competed with models like the Honda Foreman 400/450, Suzuki Vinson 500, and Kawasaki Prairie 360/400.

Key Features

Features:

Independent front suspension (IFS), automatic transmission, reliable single-cylinder engine, durable build quality, excellent towing and carrying capacity.

Value Proposition

Manual Value:

This workshop manual provides essential information for maintaining the longevity and performance of the Yamaha Big Bear 400, covering all critical repair and service procedures.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service, Repair, Maintenance, Troubleshooting, Diagnostics

Secondary Coverage:

Wiring Diagrams, Specifications, Exploded Views, Assembly/Disassembly Procedures

Page Count

Estimated Page Count:

Hundreds of pages (specific count not provided, but indicative of comprehensive coverage)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, inspection, tuning, carburetor, cooling system, lubrication

Transmission:

Clutch, gearbox, final drive, drive shafts, differential (where applicable)

Chassis:

Frame, suspension (front and rear), steering, wheels, tires

Brakes:

Hydraulic system, calipers, master cylinder, brake lines, parking brake

Electrical:

Ignition system, lighting, starting system, charging system, battery, wiring diagrams

Bodywork:

Body panels, fenders, racks, seat, plastics

Procedures Included

Maintenance:

Oil changes, filter replacements, spark plug service, valve adjustments, lubrication points

Repair:

Engine rebuilds, transmission repairs, suspension component replacement, brake system overhaul

Troubleshooting:

Diagnostic flowcharts, fault finding for engine, electrical, and mechanical issues

Diagnostics:

Component testing, electrical system diagnosis, performance checks

Technical Depth

Depth:

Comprehensive factory-level detail, suitable for professional technicians and advanced DIY users

Detail Level:

Includes step-by-step instructions, torque specifications, clearances, and special tool requirements

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable within the PDF

Print Quality

Printability:

Designed for printing individual pages or sections as needed

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, air-cooled

Displacement:

386cc

Bore X Stroke:

83 mm x 71 mm

Compression Ratio:

8.6:1

Performance

Horsepower:

Approx. 20-22 HP (at crankshaft, estimated)

Torque:

Approx. 22-24 lb-ft (at crankshaft, estimated)

Fuel System

Fuel Delivery:

Carburetor (Mikuni BSR33)

Fuel Type:

Unleaded gasoline, 87 octane minimum

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

Lubrication

Oil Type:

Yamalube 4 (or equivalent API SE, SF, SG, SH, SJ or higher, SAE 10W-40 or 20W-50)

Oil Capacity W Filter:

2.20 Liters (2.32 US qt)

Cooling System

Cooling Method:

Air-cooled with oil cooler

🔧 Transmission

Standard

Type:

Automatic (Yamaha Ultramatic®)

Drive System:

Shaft drive (2WD/4WD selectable)

Features

Gear Selection:

High, Low, Neutral, Reverse, Park

Fluid Specifications

Transmission Fluid:

Yamalube SAE 10W-30 API SF (or equivalent)

Transmission Fluid Capacity:

0.70 Liters (0.74 US qt)

📐 Dimensions

Exterior

Length:

2000mm (78.7 in)

Width:

1120mm (44.1 in)

Height:

1150mm (45.3 in)

Wheelbase:

1260mm (49.6 in)

Ground Clearance:

235mm (9.3 in)

Weights

Dry Weight:

253 kg (558 lbs) for 4x4

Curb Weight:

277 kg (611 lbs) for 4x4 (approx.)

Cargo

Front Rack Capacity:

90 kg (200 lbs)

Rear Rack Capacity:

180 kg (400 lbs)

Towing Capacity:

500 kg (1102 lbs)

Wheels And Tires

Front Tire Size:

AT25x8-12

Rear Tire Size:

AT25x10-12

Wheel Bolt Pattern:

4-stud, 110mm PCD (typical for Yamaha ATVs)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Designed and manufactured to meet current ANSI/SVIA safety standards.

Active Features

Selectable 4Wd:

Provides enhanced traction for challenging terrain.

Engine Braking:

Ultramatic transmission provides inherent engine braking for descents.

Passive Features

Lighting:

Dual 30W halogen headlights, 15W taillight/stoplight.

Ergonomics:

Comfortable seat and handlebar positioning for rider control.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Utility ATV)

Driver Assistance

Driver Assistance:

N/A (Utility ATV)

Connectivity

Connectivity:

N/A (Utility ATV)

Instrumentation

Dashboard Features:

Speedometer, odometer, trip meter, neutral indicator, reverse indicator, 2WD/4WD indicator, high/low gear indicator.

🔧 Maintenance

Service Intervals

Initial Service:

First service typically recommended at 1000 km (600 miles) or 6 months, whichever comes first.

Engine Oil Change:

Every 1000 km (600 miles) or 6 months.

Air Filter Cleaning:

Every 1000 km (600 miles) or annually, more frequently in dusty conditions.

Spark Plug Replacement:

Check every 2000 km (1200 miles) or annually; replace as needed (NGK CR7E or equivalent).

Valve Clearance Check:

Check every 4000 km (2400 miles) or 2 years.

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid.

Coolant Type:

N/A (Air-cooled engine)

Known Issues

Common Wear Items:

CV joint boots, brake pads, wheel bearings, carburetor jets (can clog).

Carburetor Tuning:

Carburetors can sometimes require adjustment or cleaning due to fuel variability or age.

Suspension Bushings:

Rubber suspension bushings can degrade over time and require replacement for optimal handling.

📚 Vehicle History

Brand Heritage

Heritage:

Yamaha has a long-standing reputation for building reliable and high-performance motorcycles and powersports vehicles, carrying this expertise into their ATV lineup.

Model Evolution

Evolution:

The Big Bear 400 succeeded earlier Big Bear models, incorporating improvements like independent front suspension for enhanced ride comfort and handling. It was a staple in Yamaha's utility ATV range.

Production

Production Period:

The Big Bear 400 was produced for a significant period, with the 2000-2004 generation representing a key iteration.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

While specific awards for this generation are not widely publicized, the Big Bear line has consistently been recognized for its durability and utility in its class.