ATV Yamaha YFM400 Bigbear ( YFM400FWA(M) ) Complete Factory Service / Repair / Workshop Manual

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🏷️ Basic Information Identification Make: Yamaha Model: YFM400 Big Bear Model Code: YFM400FWA(M) Vehicle Type: All-Terrain Vehicle (ATV) Generation Generation Designation: Fourth Generation Big Bear Codes Chassis Code: YFM400FWA(M) 👋...

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类型: Atv

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标签: Atv Misc Motorcycles Yamaha YFM400 Bigbear YFM400FWA(M)

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Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YFM400 Big Bear

Model Code:

YFM400FWA(M)

Vehicle Type:

All-Terrain Vehicle (ATV)

Generation

Generation Designation:

Fourth Generation Big Bear

Codes

Chassis Code:

YFM400FWA(M)

👋 Introduction

Market Position

Atv Segment:

Utility ATV

Target User:

Recreational riders, hunters, farmers, and those needing a dependable workhorse.

Competitive Analysis

Key Competitors:

Honda Foreman, Kawasaki Prairie, Polaris Sportsman.

Key Features

Model Highlights:

Known for its ruggedness, reliability, selectable 4WD, and comfortable ride.

Manual Value Proposition:

Provides the essential technical knowledge for owners and technicians to maintain and repair the YFM400 Big Bear, ensuring longevity and optimal performance.

📋 Manual Details

Coverage Areas

Manual Title:

ATV Yamaha YFM400 Bigbear (YFM400FWA(M)) Complete Factory Service / Repair / Workshop Manual

Manual Scope:

Complete Factory Service, Repair, and Workshop

Page Count

Estimated Page Count:

Approximately 500+ pages (based on typical factory manuals for this era and complexity)

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Digital Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine overhaul, disassembly, assembly, lubrication, cooling system, ignition system, fuel system (carburetor tuning and maintenance), exhaust system, emissions control.

Transmission Drivetrain:

Automatic transmission (CVT), gearcase, drive shafts, differentials (if applicable), clutches, maintenance, and repair procedures.

Chassis Suspension:

Frame inspection and repair, front and rear suspension (A-arms, shocks, bushings), steering system (handlebar, steering shaft, tie rods).

Braking System:

Front and rear brake calipers, master cylinders, brake lines, hydraulic fluid specifications, bleeding procedures, pad replacement, rotor inspection.

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), lighting system (headlights, taillights, indicators), starting system (starter motor, solenoid), CDI unit, sensors.

Bodywork Plastics:

Fender removal and installation, seat removal, fuel tank and shroud maintenance, handlebar assembly, grip replacement.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, spark plug replacement, lubrication points, chain/belt adjustment (if applicable), brake adjustments.

Troubleshooting:

Diagnostic charts, common problem identification (e.g., starting issues, poor performance, electrical faults), symptom-based troubleshooting guides.

Repair Overhaul:

Detailed step-by-step instructions for component disassembly, inspection, repair, and reassembly of major systems like the engine, transmission, and suspension.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Technical Depth

Diagnostic Capabilities:

Advanced diagnostics for engine performance issues, electrical system faults, and drivetrain problems.

Rebuild Procedures:

Comprehensive guides for full engine rebuilds, transmission overhauls, and suspension component replacement.

Specifications Tolerances:

Precise technical data including torque specifications, clearances, tolerances, fluid capacities, and electrical resistance values.

📊 Manual Specifications

File Format

File Format:

Print Quality

Image Resolution:

High resolution for clear diagrams and text.

Text Searchability:

Searchable text for quick information retrieval.

Binding Type

Binding Type Digital:

N/A (Digital PDF)

Paper Type

Paper Type Digital:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, air-cooled

Displacement:

387 cc

Bore X Stroke:

82.0 mm x 71.5 mm

Compression Ratio:

8.8:1

Valve Clearance Intake Cold:

0.09 - 0.14 mm (0.0035 - 0.0055 in)

Valve Clearance Exhaust Cold:

0.12 - 0.17 mm (0.0047 - 0.0067 in)

Performance

Horsepower Estimated:

Approx. 21 HP @ 5500 RPM (Industry standard, specific Yamaha figures may vary slightly)

Torque Estimated:

Approx. 24 lb-ft @ 4000 RPM (Industry standard, specific Yamaha figures may vary slightly)

Fuel System

Fuel Delivery:

Carburetor

Carburetor Model:

Mikuni BSR33/1

Fuel Type:

Unleaded gasoline

Fuel Octane Rating:

87 AKI (Octane Rating)

Fuel Tank Capacity:

13.5 L (3.57 gal)

Lubrication

Engine Oil Type:

Yamalube 4 (or equivalent SAE 10W-40, API SG or higher)

Engine Oil Capacity W Filter:

2.20 L (2.32 US qt)

Engine Oil Capacity Wo Filter:

2.00 L (2.11 US qt)

Cooling System

Cooling Method:

Air-cooled

Ignition System

Ignition System:

CDI (Capacitor Discharge Ignition)

Spark Plug Type:

NGK CR6HSA / DENSO U20FSR-U

Spark Plug Gap:

0.6 - 0.7 mm (0.024 - 0.028 in)

🔧 Transmission

Standard

Transmission Type:

Automatic Continuously Variable Transmission (CVT)

Drive System:

Shaft drive, Selectable 4WD with 2WD/4WD switch

Features

Gear Reduction Ratio Low:

3.596:1

Gear Reduction Ratio High:

2.888:1

Final Drive:

Bevel gear and drive shaft

Fluid Specifications

Gearcase Oil Type:

Yamalube Gear Oil (or SAE 80 hypoid gear oil)

Fluid Capacities

Gearcase Oil Capacity:

0.42 L (0.44 US qt)

📐 Dimensions

Exterior

Length:

2030 mm (79.9 in)

Width:

1095 mm (43.1 in)

Height:

1170 mm (46.1 in)

Wheelbase:

1280 mm (50.4 in)

Ground Clearance:

250 mm (9.8 in)

Weights

Dry Weight:

262 kg (578 lbs)

Wet Weight Estimated:

274 kg (604 lbs) (Approx. with full fluids)

Cargo

Front Rack Capacity:

20 kg (44 lbs)

Rear Rack Capacity:

40 kg (88 lbs)

Wheels Tires

Front Tire Size:

AT25x8-12

Rear Tire Size:

AT25x10-12

Front Wheel Size:

12 x 7.0 AT

Rear Wheel Size:

12 x 8.0 AT

Bolt Pattern Wheels:

4/110mm

🛡️ Safety Features

Ratings

Safety Certification:

Meets ANSI standards for recreational ATVs (American National Standards Institute).

Active Features

Braking System Type:

Hydraulic disc brakes, front and rear.

Parking Brake:

Handlebar-mounted mechanical parking brake.

Passive Features

Lighting:

Dual 30W Krypton headlights, 8W/23W brake/tail light.

Hand Guards:

Integrated hand guards for rider protection.

💡 Technology Features

Infotainment

Infotainment System:

Basic instrumentation panel (speedometer, odometer, hour meter, fuel gauge, 2WD/4WD indicator).

Driver Assistance

Driver Assistance Features:

Limited; primarily relies on rider input and mechanical capabilities. Selectable 4WD is a key feature.

Connectivity

Connectivity Options:

None (No Bluetooth, USB, or smartphone integration).

🔧 Maintenance

Service Intervals

Initial Service:

First service recommended at 10 hours or 1 month of operation (check oil, tighten fasteners, inspect air filter).

Engine Oil Change:

Every 3,000 km (1,800 miles) or 6 months, whichever comes first.

Air Filter Cleaning:

Every 1,000 km (600 miles) or if conditions are dusty, clean more frequently. Replace as needed.

Spark Plug Inspection:

Inspect every 3,000 km (1,800 miles). Replace if necessary.

Brake Fluid Flush:

Recommended every 2 years or 18,000 miles (11,000 miles).

Fluid Specifications

Coolant Type:

Not applicable (Air-cooled engine)

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

CVT belt wear, suspension bushings, wheel bearings, carburetor jetting issues in varied altitudes.

Potential Problems:

Carburetor flooding/poor idling (requires cleaning/adjustment), drive shaft spline wear under heavy use, rear differential seal leaks.

📚 Vehicle History

Brand Heritage

Manufacturer Heritage:

Yamaha Motor Corporation, established in 1955, is a global leader in powersports vehicles, renowned for innovation, quality, and performance.

Model Evolution

Big Bear Lineage:

The Big Bear line has a long history, evolving from earlier utility ATV models, emphasizing durability and user-friendliness.

Yfm400 Introduction:

The YFM400 Big Bear was introduced in the early 2000s, building upon the success of previous Big Bear models with updated styling and features.

Production

Production Period:

YFM400 Big Bear models were produced roughly between 2000 and 2006.

Manufacturing Location:

Primarily manufactured in Japan by Yamaha.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

Consistently praised in reviews for its durability, reliability, and strong low-end torque, making it a popular choice for work and trail riding.

Ratings

User Satisfaction:

High user satisfaction ratings for its long-term dependability and value.