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    Yamaha Big Bear 400 YFM400 2000 2001 2002 2003 ATV Repair Service Workshop Manual

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    The Big Bear 400, model code YFM400, is an All-Terrain Vehicle (ATV) designed for utility and rugged off-road performance. Produced for the model years 2000 through 2003, this ATV is...
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    Taper: Atv
    Distributeur:
    UGS: 86185
    The Big Bear 400, model code YFM400, is an All-Terrain Vehicle (ATV) designed for utility and rugged off-road performance. Produced for the model years 2000 through 2003, this ATV is powered by a 386cc air-cooled, 4-stroke engine, delivering approximately 21 horsepower and 23.3 lb-ft of torque, coupled with an automatic YCCT transmission. Known for its reliable engineering and capability, the Big Bear 400 features hydraulic disc brakes for effective stopping power and offers both 2WD and 4WD selectable drive systems. Its robust design includes a durable chassis and suspension, making it suitable for a variety of demanding tasks and terrains. This comprehensive workshop repair service manual provides complete coverage for the Big Bear 400, encompassing repair, service, maintenance, restoration, rebuilding, and diagnostics for both 2WD and 4x4 models. The manual details procedures for all major systems, including the engine, fuel system, ignition, cooling, transmission, drivetrain, suspension, steering, braking, and electrical systems. It also covers routine and scheduled maintenance, in-depth troubleshooting guides, and technical specifications such as torque values and fluid capacities. Illustrated with clear diagrams and step-by-step instructions, this manual is an essential resource for DIY owners, home mechanics, and professional technicians seeking to maintain and repair their vehicle.
    🏷️ Basic Information
    Identification
    Make:
    Yamaha
    Model:
    Big Bear 400
    Model Code:
    YFM400
    Chassis Code:
    YFM400
    Vehicle Type:
    All-Terrain Vehicle (ATV)
    Applicable Years:
    2000, 2001, 2002, 2003
    👋 Introduction
    Market Position
    Target User:
    DIY owners, home mechanics, professional technicians, workshops
    Competitive Analysis
    Manual Advantage:
    Comprehensive, detailed, and up-to-date for specific model years, offering professional-level guidance
    Key Features
    Feature Highlight:
    Instant download access post-purchase
    📋 Manual Details
    Coverage Areas
    Manual Scope:
    Complete repair, service, maintenance, restoration, rebuilding, and diagnostics
    Drive Types Covered:
    2WD and 4x4 models
    Page Count
    Page Count:
    425
    Manual Type
    Manual Type:
    Workshop Repair Service Manual
    Original Equipment Manufacturer Compliance:
    Yes (Equivalent to factory manual used by professionals)
    Language
    Language:
    English
    Format
    File Format:
    PDF Download
    Distribution Method:
    Digital Download (Instant Access after Payment)
    📖 Manual Coverage
    Systems Covered
    Engine:
    Complete engine overhaul, including disassembly, inspection, repair, and reassembly
    Fuel System:
    Carburetor service, fuel pump, fuel lines, fuel tank maintenance
    Ignition System:
    Ignition coil, CDI unit, spark plug service, timing adjustments
    Cooling System:
    Radiator, fan, coolant, hoses, thermostat service
    Transmission Drive System:
    Operation, maintenance, and repair of the transmission, clutch, and drive components (including 4WD system)
    Drivetrain:
    Axles, differentials, CV joints, driveshafts
    Suspension System:
    Front and rear suspension components, shock absorbers, bushings, A-arms
    Steering System:
    Steering column, tie rods, steering knuckle, wheel alignment
    Braking System:
    Hydraulic brake system, calipers, master cylinder, brake lines, pads, rotors
    Electrical System:
    Wiring diagrams, lighting, battery, starter, alternator, fuses, switches, sensors
    Chassis Frame:
    Frame inspection and repair
    Bodywork:
    Body panel removal and installation, fenders, racks
    Procedures Included
    Routine Maintenance:
    Oil changes, filter replacements, lubrication, tire pressure checks
    Scheduled Maintenance:
    Recommended service intervals for various components
    Troubleshooting:
    Diagnostic procedures for common and uncommon problems, fault finding guides
    Repair Procedures:
    Detailed step-by-step instructions for component repair and replacement
    Rebuild Procedures:
    Complete teardown and rebuild instructions for major components like the engine and transmission
    Technical Specifications:
    Torque specifications, clearances, fluid capacities, electrical values
    Technical Depth
    Depth Of Information:
    Comprehensive, covering all aspects from basic maintenance to complete engine and drivetrain overhauls
    Illustrations
    Illustration Quality:
    Illustrated with clear step-by-step instructions and images
    Diagrams:
    Includes part diagrams for component identification and assembly
    📊 Manual Specifications
    File Format
    File Type:
    PDF
    Searchability:
    Likely text-searchable PDF (common for quality manuals)
    Print Quality
    Printability:
    Printable on any standard printer
    Binding Type
    Binding Type:
    N/A (Digital Download)
    Paper Type
    Paper Type:
    N/A (Digital Download)
    File Size
    File Size Range:
    Up to 2550 MB (indicates high detail and image content)
    ⚙️ Engine Specifications
    Primary Engine
    Engine Type:
    4-stroke, SOHC, air-cooled
    Engine Displacement:
    386 cc
    Bore X Stroke:
    83.0 mm x 71.5 mm
    Compression Ratio:
    9.2:1
    Performance
    Horsepower:
    Approx. 21 hp @ 5500 rpm (Varies slightly by year)
    Torque:
    Approx. 23.3 lb-ft @ 4500 rpm (Varies slightly by year)
    Fuel System
    Fuel Delivery:
    Mikuni BSR33 carburetor
    Fuel Type:
    Unleaded gasoline
    Ignition System
    Ignition Type:
    CDI (Capacitor Discharge Ignition)
    Cooling System
    Cooling Method:
    Air-cooled
    🔧 Transmission
    Standard
    Transmission Type:
    Automatic (Yamaha Constant-Velocity Transmission - YCCT)
    Gear Selection:
    High, Low, Neutral, Reverse
    Features
    Drive System:
    Shaft drive (2WD or 4WD selectable)
    Final Drive:
    Sealed O-ring chain and sprockets (rear), driveshaft (front)
    📐 Dimensions
    Exterior
    Length:
    77.0 inches (1955 mm)
    Width:
    44.3 inches (1125 mm)
    Height:
    43.1 inches (1095 mm)
    Wheelbase:
    50.4 inches (1280 mm)
    Ground Clearance:
    Approx. 10.2 inches (260 mm)
    Weights
    Dry Weight:
    Approx. 503 lbs (228 kg)
    Fuel Capacity:
    3.2 gallons (12 liters) including 0.8-gallon reserve
    🛡️ Safety Features
    Ratings
    Safety Design Focus:
    Off-road stability and rider control
    Active Features
    Braking System Type:
    Hydraulic disc brakes (front and rear)
    Parking Brake:
    Mechanical drum brake (rear, lever-actuated)
    Passive Features
    Lighting:
    Dual 30W headlights, 5W taillight/brake light
    💡 Technology Features
    Infotainment
    Infotainment System:
    N/A (Utility ATV focused)
    Driver Assistance
    Driver Assistance Features:
    N/A (Utility ATV focused)
    Connectivity
    Connectivity Features:
    N/A (Utility ATV focused)
    🔧 Maintenance
    Service Intervals
    Engine Oil Change:
    Every 1000 km or 12 months, or more frequently under severe use
    Air Filter Cleaning:
    Every 500 km, or more frequently in dusty conditions
    Spark Plug Replacement:
    Every 1000 km or as needed
    Valve Clearance Check:
    Every 1000 km or annually
    Fluid Specifications
    Engine Oil Type:
    Yamalube 4 (or equivalent) SAE 10W-40, API SG or higher (check manual for exact specs)
    Engine Oil Capacity:
    1.90 US qt (1.8 L)
    Gear Oil Type:
    Yamalube Gear Oil (or equivalent) SAE 80 API GL-4
    Gear Oil Capacity:
    0.12 US qt (0.11 L)
    Brake Fluid Type:
    DOT 3 or DOT 4 hydraulic brake fluid
    Known Issues
    Common Wear Item:
    CV boot tears
    Electrical Issue Potential:
    Corrosion on electrical connectors, especially after heavy water use
    📚 Vehicle History
    Brand Heritage
    Manufacturer Origin:
    Japan
    Model Evolution
    Model Lineage:
    The Big Bear line is known for its utility and ruggedness, evolving from earlier Yamaha utility ATVs.
    Production
    Manufacturing Location:
    Likely assembled in Japan or USA for North American market
    🏆 Awards & Recognition
    Recognitions
    Awards And Recognition:
    The Big Bear 400 is generally recognized for its reliability and capability in its class, though specific awards are not readily documented.
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