Yamaha 400 Big Bear 2000 2001 2002 Workshop Service Manual for Repair. Instant Download means there is NO shipping costs. The Official Website of Yamaha Motor Canada - Conquering in the Powersports and Marine industry for Motorcycles & Scooters, ATVs, Side by sides,. Complete Repair and Maintenance Manual for your 2000-2006 YFM400 Big Bear on CD-ROM. 2000-2006 YFM400 Big Bear 400 2WD & 4WD.

1. Yamaha Big Bear Service Manual
2. Yamaha Big Bear 400 Repair Manual
3. Repair Manual 2001 Yamaha Big Bear 400

. READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM40FBW WARNING This ATV should not be ridden by anyone under 16 years of age.

LIT-11626-20-45 4S1-F8199-10. Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting. EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Throttle lever.4-10 EWB00010 WARNING Speed limiter.4-11 Front brake lever.4-12 Indicates a potential hazard that could result in serious injury or death. Brake pedal and rear brake lever.4-12 Parking brake.4-13 Shift pedal.4-14 Reverse knob “REV”.4-14 EBU17420 Recoil starter.4-15 TABLE OF CONTENTS.

Throttle lever.5-4 CROSSING THROUGH SHALLOW Tires.5-5 WATER.7-28 Measuring the tire pressure. 5-6 RIDING OVER ROUGH TERRAIN.7-30 Tire wear limit.5-7 SLIDING AND SKIDDING.7-30 Chassis fasteners.5-7 WHAT TO DO IF.7-31 Instruments, lights and switches.5-7 WHAT TO DO.7-31 OPERATION.8-37 Noise regulation.11-3 Checking and lubricating the brake and Maintenance record.11-4 shift pedals.8-38 YAMAHA MOTOR CORPORATION, Checking the wheel bearings.8-38 U.S.A. ATV LIMITED WARRANTY.11-5 Lubricating the drive shaft universal YAMAHA EXTENDED SERVICE joint. EBU17430 SAFETY INFORMATION EBU17442 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE. Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition.

Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill. speed when climbing a hill. If you stall or roll Always be sure there are no obstacles or people backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly.

EWB00021 HOW TO AVOID THE HAZARD WARNING If you should swallow some gasoline or in- hale a lot of gasoline vapor, or get some gas- POTENTIAL HAZARD oline in your eyes, seek medical help Improper handling of gasoline. If gasoline spills on your skin, WHAT CAN HAPPEN wash with soap and water. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with ad- equate ventilation.

EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS. Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation.

Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer. EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Front shock absorber assembly spring preload adjusting 1. Spark arrester ring 2.

Air filter case 2. Engine oil filler cap 3. Recoil starter 4.

Spark plug 4. Throttle stop screw 5.

EBU17712 NOTE: Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. Rear brake lever 2. Parking brake lock plate 3. Starter (choke) 4. Speedometer 5.

Reverse knob 6. Auxiliary DC jack 7. EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17770 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights, meter lighting and taillight come on 1.

NOTE: Indicator lights and warning light If the indicator light flashes under any other circum- stances or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. EBU17870 Neutral indicator light “NEUTRAL”. On-Command differential gear lock indicator cool. If the warning light stays on when the engine light “ ” is cool, have a Yamaha dealer check the electrical This indicator light and the On-Command four- circuit. Wheel-drive indicator light “ ” come on when the. Fuel gauge 1. Reset knob 2.

Speedometer 3. Odometer NOTE: 4. Math study for 5th grade. Tripmeter If the ATV runs out of fuel, move the fuel cock lever EBU18050 to the “RES” position. Approximately 4.0 L (1.06 Fuel gauge US gal) (0.88 Imp.gal) of fuel will be remaining in The fuel gauge indicates the amount of fuel in the the tank.

EBU18061 EBU18100 Handlebar switches Start switch “ ” Push this switch to crank the engine with the start- ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18160 Light switch “ /OFF” Set this switch to “ ”. EBU28350 EWB00110 Override switch “OVERRIDE” WARNING POTENTIAL HAZARD Riding too fast while the ATV is in four- wheel-drive differential gear lock.

WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the ATV. “4WD” (four-wheel drive): Power is supplied to EWB00120 WARNING the rear and front wheels. To change from two-wheel drive to four-wheel POTENTIAL HAZARD drive, stop the ATV and push the switch in to the Changing from two-wheel drive to four- “4WD”. EBU28360 To lock the differential gear in four-wheel drive, On-Command differential gear lock switch make sure the On-Command four-wheel-drive “4WD”/“LOCK” switch is pushed in to the “4WD” position. This ATV is equipped with a switch allowing you to lock the differential gear when in four-wheel drive.

Select the appropriate switch position according to the terrain and the conditions. WHAT CAN HAPPEN The ATV handles differently in four-wheel drive than in differential gear lock in some circumstances.

Changing from four-wheel drive to differential gear lock or vice-versa while moving may cause the ATV to handle differently unexpectedly. This could distract the operator and increase the risk of losing control and causing an accident. HOW TO AVOID THE HAZARD Regulate the speed of the ATV by varying the Always ride at a slow speed when the ATV is throttle position.

Because the throttle is spring- in differential gear lock, and allow extra time loaded, the ATV will decelerate, and the engine will and distance for maneuvers. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Locknut Yamaha dealer if you can’t find or solve the 2. Adjusting screw problem yourself.

No more than 12 mm (0.47 in) EBU18311 3. WHAT CAN HAPPEN The throttle cable could be damaged. Im- proper throttle operation could result.

You could lose control, have an accident or be in- jured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in).

Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). EBU18450 Parking brake Use the parking brake before starting the engine or parking the ATV, especially on a slope.

Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake.

WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before start- ing the engine. This could cause loss of con- trol or a collision. The brake could overheat if you ride the ATV without releasing the parking brake. Recoil starter 1.

Reverse knob “REV” EWB02361 EBU27371 WARNING Recoil starter POTENTIAL HAZARD Firmly grasp the handle and pull slightly until en- Starting the engine in gear or starting the gagement can be felt. Then pull forcefully, being engine without applying the parking brake. Careful not to pull the rope all the way out.

EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counter- clockwise. Fuel level 2. Fuel tank filler tube Recommended fuel: UNLEADED GASOLINE ONLY 1. Fuel tank cap Fuel tank capacity: EBU18730 15.0 L (3.96 US gal) (3.30 Imp.gal) Fuel Fuel reserve amount: Make sure that there is sufficient fuel in the tank. HOW TO AVOID THE HAZARD Your Yamaha engine has been designed to use Do not overfill the fuel tank. Be careful not to regular unleaded gasoline with a pump octane. Arrow mark positioned over “OFF” 1.

Arrow mark positioned over “ON” With the fuel cock lever in this position, fuel will not With the fuel cock lever in this position, fuel flows flow. Always turn the fuel cock lever to this position to the carburetor. Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. Arrow mark positioned over “RES” This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Seat lock lever 1.

Seat holder 2. Projection To install the seat EBU18901 Insert the projections on the front of the seat into Storage compartment the seat holders and push down on the seat at the ECB00130 rear. CAUTION: NOTE: Do not store metal or sharply edged objects, Make sure that the seat is securely fitted. EBU18970 Rear carrier Do not exceed the load limit of 80.0 kg (176 lb) for the rear carrier. Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV. EBU19130 Adjusting the front and rear shock ab- sorber assemblies The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions.

Spring preload adjusting ring 1. Special wrench 2. Position indicator Spring preload setting: Minimum (soft): NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. Standard: Maximum (hard): 4-22. EWB00350 WARNING POTENTIAL HAZARD Improper shock absorber assembly adjust- ment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorber assem- 1.

If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine start- ing may become difficult. Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged. Before operating this ATV, be sure to check the items listed in the following table. NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer.

Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer. ITEM ROUTINE PAGE. Make sure that operation is smooth. Lubricate cable and lever hous- Throttle lever ing if necessary. 5-4, 8-26. Check cable free play, and adjust if necessary. Control cables.

Make sure that operation is smooth. Lubricate if necessary. Check that there is no free play in the front brake HOW TO AVOID THE HAZARD lever. If there is free play, have a Yamaha dealer Do not overfill the fuel tank. Be careful not to check the brake system.

If a problem cannot be corrected by the adjustment procedures pro- Brake fluid leakage (front brake) vided in this manual, have a Yamaha dealer Check to see if any brake fluid is leaking out of the check for the cause. HOW TO AVOID THE HAZARD Rear: The tires listed below have been approved 25.0 kPa (3.6 psi) (0.250 kgf/cm²) by Yamaha Motor Manufacturing Corpora-. Check and adjust tire pressures when tion of America for this model.

Other tire the tires are cold. Tire pressure below the minimum speci- NOTE: fied could cause the tire to dislodge from The low-pressure tire gauge is included as stan- the rim under severe riding conditions. Dard equipment. Make two measurements of the Minimum tire pressure: tire pressure and use the second reading.

Dust or Front: dirt in the gauge could cause the first reading to be 22.0 kPa (3.2 psi) (0.220 kgf/cm²). Recommended pressure: Front 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: 1. Tire wear limit Front 28.0 kPa (4.1 psi) (0.280 kgf/cm²) EBU19840 Chassis fasteners Rear.

Read the Owner’s Manual carefully. If there is prior to operating the engine for the first time. A control or function you do not understand, ask your Yamaha dealer.

Set the parking brake. Turn the fuel cock to “ON”.

Shift the transmission into neutral. The neutral Ambient temp./starter (choke) position indicator light should come on. If the indicator light does not come on, have a Yamaha deal- er check the electrical circuit. NOTE: The engine can be started under the following con- ditions: The transmission is in neutral. If the battery is discharged, pull the recoil starter EBU20291 Starting a warm engine to start the engine. Follow the same procedure as for starting a cold 7. If the engine is started with the starter (choke) engine, with the exception that the starter (choke) in position (1), the starter (choke) should be is not required when the engine is warm.

If the indicator light does not come on, clutch. The transmission allows you to control the have a Yamaha dealer check the electrical circuit. Amount of power you have available at a given speed or for starting, accelerating, climbing hills, 4. Shift into second gear and release the shift pedal. Open the throttle gradually. Follow the same procedure when shifting to the next higher gear.

EWB00690 WARNING POTENTIAL HAZARD Opening the throttle before releasing the shift pedal. WHAT CAN HAPPEN 1. EWB00650 EBU20672 Engine break-in WARNING POTENTIAL HAZARD NOTE: Engaging a lower gear when the engine For ATVs equipped with an odometer or an hour speed is too high. Meter, follow the figures given in km (mi) or the WHAT CAN HAPPEN figures given in hours. The ATV can now be operated normally. ECB00220 CAUTION: If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV. Parking brake lock plate EBU20721 Parking When parking the ATV, stop the engine, shift into first gear, apply the parking brake, and then turn the fuel cock to “OFF”.

Yamaha accessories. Other accessories plied, apply the parking brake and slowly re- may also be available on the market. However, lease the brake pedal. It is not possible for Yamaha to test all non- Yamaha accessories, nor control over their qual. Choose a genuine Yamaha ac- MAXIMUM LOADING LIMIT cessory, or one that is equivalent in design and ATV loading limit (total weight of rider, cargo, quality.

Accessories, and tongue): Accessories should be rigidly and securely 210.0 kg (463 lb) mounted. Load cargo on the carriers as close to the center EWB00750 WARNING of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, POTENTIAL HAZARD and center it. Overloading this ATV or carrying or towing Tie down cargo securely to the carriers.

EBU21131 RIDING YOUR ATV. EWB00010 ular attention to the safety information on pages WARNING 1-1–1-5. Please also read all caution and warning labels on your ATV. Indicates a potential hazard that could result in serious injury or death. RIDE WITH CARE AND GOOD JUDGEMENT EBU28450 Get training if you are inexperienced.

They should then ry or death of the child. Regularly practice the skills learned in the HOW TO AVOID THE HAZARD course and the operating techniques de- A child under 16 should never operate an scribed in this Owner’s Manual. This ATV is designed to carry operator and car- go only – passengers prohibited. EWB00910 WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV.

Could cause an accident, resulting in harm to you and/or your passen- ger. Apparel HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet EWB00920 WARNING that fits properly. You should also wear: POTENTIAL HAZARD eye protection (goggles or face shield) Operating this ATV without wearing an ap- gloves proved motorcycle helmet, eye protection boots and protective clothing. Do not operate after consuming alcohol or HOW TO AVOID THE HAZARD drugs. Never consume alcohol or drugs before or The operator’s performance capability is reduced while driving this ATV. By the influence of alcohol or drugs. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety.

EWB00950 Do not operate at speeds too fast for your skills WARNING or the conditions. EWB00960 POTENTIAL HAZARD WARNING Operating this ATV with improper tires, or with improper or uneven tire pressure. POTENTIAL HAZARD WHAT CAN HAPPEN Operating this ATV at speeds too fast for Use of improper tires on this ATV, or opera- your skills or the conditions. Speed limiter Loading and accessories For riders less experienced with this model, the Use extra caution when riding the ATV with addi- throttle lever housing is equipped with a speed lim- tional loads, such as accessories or cargo. The speed limiter keeps the throttle from fully ATV’s handling may be adversely affected.

EWB00970 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.

During operation WHAT CAN HAPPEN Always keep your feet on the footboards during op- Removing even one hand or foot can reduce eration, otherwise they may contact the rear your ability to control the ATV or could wheels. Cause you to lose your balance and fall off of the ATV. Never modify this ATV through improper in- stallation or use of accessories.

All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo- nents designed for use on this ATV and should be installed and used according to instructions. Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. EWB01010 WARNING POTENTIAL HAZARD Hot exhaust system.

HOW TO AVOID THE HAZARD EWB01030 WARNING Always avoid paved surfaces, including sidewalks, driveways, parking lots and POTENTIAL HAZARD streets. Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. Know the terrain where you ride.

Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. EWB01040 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain.

EWB01060 WARNING POTENTIAL HAZARD. Do not ride in areas posted “no trespassing”. The shift pedal. Remember that the engine and ex- Do not ride on private property without getting per- haust pipe will be hot when riding and afterwards; mission. Do not allow skin or clothing to come in contact with these components. When slowing down or stopping, release the throt- tle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear.

Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing con- trol and increasing the possibility of an accident. TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off-road Always follow proper procedures for turning in 2WD or 4WD, the two rear wheels turn together as described in this Owner’s Manual. Prac- at the same speed. Furthermore, when riding in tice turning at low speeds before attempting 4WD-LOCK (“DIFF.

Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside. CLIMBING UPHILL EWB01100 WARNING Use proper riding techniques to avoid ATV over- turns on hills.

Be sure that you can maneuver your POTENTIAL HAZARD ATV well on flat ground before attempting any in- Climbing hills improperly. Cline and then practice riding first on gentle slopes. WHAT CAN HAPPEN Try more difficult climbs only after you have devel- Could cause loss of control or cause the. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.

HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. could come off the ground. The ATV could easily tip over backwards.

Apply both the front and rear brakes gradually, or dismount the ATV immediate- ly on the uphill side. EWB02420 WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dis- mounting while climbing a hill.

If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while roll- ing backwards. Apply the front brake. When fully stopped, apply the rear brake as well, and then lock the parking brake.

4WD or 4WD-LOCK: Apply both front and rear brakes gradually. RIDING DOWNHILL Whenever possible, ride your ATV straight down- When riding your ATV downhill, shift your weight hill. Avoid sharp angles which could allow the ATV as far to the rear and uphill side of the ATV as pos- to tip or roll over. Carefully choose your path and sible.

CROSSING A SLOPE HOW TO AVOID THE HAZARD Traversing a sloping surface on your ATV requires Never attempt to turn the ATV around on any you to properly position your weight to maintain hill until you have mastered the turning tech- proper balance. CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Air filter case check hose ECB00240 CAUTION: After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. RIDING OVER ROUGH TERRAIN SLIDING AND SKIDDING Riding over rough terrain should be done with cau- Care should be used when riding on loose or slip- tion.

Look out for obstacles which could cause pery surfaces since the ATV may slide. If unex- damage to the ATV or could lead to an upset or ac- pected and uncorrected, sliding could lead to an cident. WHAT CAN HAPPEN You may lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain.

If your ATV begins to tip while turning: If your ATV encounters shallow water: Lean more into the turn to regain balance. If nec- Ride slowly and carefully through slow moving essary, gradually let off the throttle and/or steer water, watching for obstacles. Be sure to let wa- to the outside of the turn. Safety is an obligation of the owner.

Periodic in- nance unless otherwise specified. Have a spection, adjustment and lubrication will keep your Yamaha dealer perform the service if you are ATV in the safest and best operating condition not familiar with maintenance work. Yamaha ATV dealer. Necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours. Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system. Check for looseness and tighten all screw clamps and joints if necessary. EBU21863 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element.

Clean and replace if necessary. Dusty areas) √. INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Drive shaft univer- √ √ √.

Lubricate with lithium-soap-based grease. Sal joint. Make sure that all nuts, bolts, and screws are √. INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours. Change. √ √ √ Final gear oil. Check ATV for oil leakage, and correct if neces- sary.

Every two years replace the internal components of the brake master cylinder and calipers, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged. EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU23211 Checking the spark plug The spark plug is an important engine component, which is easy to check.

Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- 1. If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. Spark plug gap 2.

Check the spark plug for electrode erosion 2. Install the spark plug with the spark plug 2.

Check the engine oil level on a cold engine. Wrench, and then tighten it to the specified NOTE: torque. If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, Tightening torque: and then wait at least ten minutes until the oil set- Spark plug. To change the engine oil (with or without oil fil- ter element cleaning) 1. Place the ATV on a level surface. Start the engine, warm it up for several min- utes, and then turn it off. Place an oil pan under the engine to collect the used oil.

ECB00310 CAUTION: When removing the engine oil drain bolt, the compression spring, oil strainer and O-ring will fall out. Take care not to lose these parts. NOTE: Skip steps 5–9 if the oil filter element is not being cleaned. Remove the oil filter element cover by remov- ing the bolts, and then remove the oil filter el- 1. Tightening torque: Recommended oil: Oil filter element cover bolt: See page 10-1.

10 Nm (1.0 mkgf, 7.2 ftlbf) Oil quantity: Without oil filter element replacement: 10. Install the oil strainer, compression spring, O- 2.90 L (3.07 US qt) (2.55 Imp.qt) ring and engine oil drain bolt.

Yamaha Big Bear Service Manual

The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart. To change the final gear oil 1. Remove the final gear case guard by remov- ing the bolts.

Final gear oil drain bolt 5. Install the drain bolt, and then tighten it to the specified torque. Final gear case guard 2. Differential gear oil gear case may occur when applying the rear The differential gear case must be checked for oil brake. Leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV.

In addition, the differential gear oil level must be checked and the oil changed as follows at the in- tervals specified in the periodic maintenance and lubrication chart. To check the differential gear oil level 1. Place the ATV on a level surface. NOTE: The differential gear oil level must be checked on a cold engine. To change the differential gear oil 5.

Add the recommended differential gear oil to 1. Place the ATV on a level surface. The brim of the filler hole as shown. Place an oil pan under the differential gear case to collect the used oil. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 mkgf, 17 ftlbf) 7.

Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. EBU23671 Cleaning the air filter element The air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart. Air filter case cover 1. Air filter element assembly 2.

Air filter case cover holder 4. Remove the sponge material from the air filter 3. Pull the air filter element assembly out of the element. Air filter case.

Squeeze the excess water or solvent out of the sponge material and let it dry. ECB00470 CAUTION: Do not twist the sponge material when squeezing it. Do not apply oil to the sponge material. Check the sponge material and replace it if damaged. Pull the sponge material over the air filter ele- ally, operation without the air filter element ment.

Will affect carburetor jetting with subsequent 10. Insert the air filter element assembly into the poor performance and possible engine over- air filter case, and then install the air filter case heating. Therefore, Improperly purging the exhaust system. Most carburetor adjustments should be left to a Hot exhaust system. Yamaha dealer, who has the necessary profes- WHAT CAN HAPPEN sional knowledge and experience.

The adjustment Could injure the eyes. NOTE: NOTE: If the specified idling speed cannot be obtained as The engine is warm when it quickly responds to the described above, have a Yamaha dealer make the throttle. Attach the tachometer to the spark plug lead. The valve clearance changes with use, resulting in bolt in direction (b). Improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart.

The reverse lock release cable stretches with use, aged or if the lining thickness is less than 1.0 mm which can result in improper function. Therefore, (0.04 in), have a Yamaha dealer replace the brake the reverse lock release cable should be checked pads as a set. A low brake fluid level may indicate worn the wear indicator reaches the wear limit mark, brake pads and/or brake system leakage. If the have a Yamaha dealer replace the brake friction brake fluid level is low, be sure to check the brake plates as a set. Water will signifi- free play of zero mm (zero in) as shown.

If the free cantly lower the boiling point of the fluid and may play is incorrect, have a Yamaha dealer check the result in vapor lock. Brake system.

Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge.

These procedures should be performed by a Yamaha dealer. EBU28601 Adjusting the brake pedal and rear brake lever free play. Brake lever free play 1. Brake lever free play adjusting bolt 1. Loosen the locknut at the brake lever and fully 2. Fully loosen the brake lever free play adjust- turn in the brake lever free play adjusting bolt. Ing nut on the brake cable at the final gear case.

Brake lever free play adjusting nut 1. Brake pedal free play adjusting nut 2.

Brake camshaft lever 3. Push the brake camshaft lever in direction (a) 3.

Gap “A” until it stops apply approximately 47 N (10.6 4. Push the brake camshaft lever in direction (a) lbf) (4.8 kgf) of force, and then turn the brake until it stops apply approximately 47 N (10.6 pedal free play adjusting nut on the brake ca. Brake lever free play adjusting nut 1. Brake camshaft lever 2. Brake lever free play adjusting bolt 3. Tighten the locknut at the brake lever. Check the brake lever free play and, if neces- NOTE: sary, adjust it by turning the brake lever free When adjusting the rear brake lever free play.

Make sure the brakes do not drag. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24230 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart. The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. NOTE: The brake light switch is properly adjusted when 1. Brake light switch the brake light comes on just before braking takes 2.

If a cable is damaged or does not move 1. Locknut smoothly, have a Yamaha dealer check or replace 2. Adjusting bolt NOTE: Recommended lubricant. WHAT CAN HAPPEN Front brake lever Corrosion can result when the cable sheaths become damaged, and cables can also be- come frayed or kinked, which could restrict the operation of controls and lead to an acci- dent or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. EBU24970 Lubricating the drive shaft universal.

Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer replace the stabilizer bush- es if necessary.

Grease nipple EBU25050. To charge the battery WHAT CAN HAPPEN Have a Yamaha dealer charge the battery as soon You could be poisoned. You could be se- as possible if it seems to have discharged. Keep in verely burned by the sulfuric acid in battery mind that the battery tends to discharge more electrolyte. If you do not have 2.

Make sure to properly connect the battery access to a constant-voltage battery charg- leads to the battery terminals. Er, have a Yamaha dealer charge your bat- tery. Positive battery terminal 2. Negative battery terminal.

EBU25313 Replacing a fuse 1. Headlight fuse 2. Ignition fuse 1. Auxiliary DC jack fuse 2. Spare main fuse 4. Carburetor warmer fuse 3. Spare fuse 5.

Spare fuse 4. Four-wheel-drive motor fuse The main fuse and the fuse box are located under 5. 30.0 A circuits to check if the devices operate. Headlight fuse: 4.

If the fuse immediately blows again, have a 15.0 A Yamaha dealer check the electrical system. Ignition fuse: 15.0 A EBU28400 Replacing a headlight bulb Four-wheel-drive motor fuse: 10.0 A.

Yamaha Big Bear 400 Repair Manual

Headlight beam adjusting screw 2. Headlight unit screw 3. Remove the headlight unit from the headlight 4. Remove the headlight bulb holder cover by assembly by removing the headlight beam ad- pulling it off. Justing screw and headlight unit screws. Remove the defective bulb by pulling it out.

EWB02180 WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and im- mediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. CAUTION: transparency of the glass, the luminosity of the It is advisable to have a Yamaha dealer make bulb, and the bulb life will be adversely affect- this adjustment. Thoroughly clean off any dirt and finger. Headlight beam adjusting screw 1. Storage compartment 2.

Nut EBU25631 Replacing the tail/brake light bulb 3. Remove the bulb holder (together with the bulb) by turning it counterclockwise. If the tail/brake light bulb burns out, replace it as follows. Tail/brake light bulb holder 1.

Tail/brake light bulb holder 2. Tail/brake light bulb 2. Tail/brake light assembly 5. Insert a new bulb into the bulb holder, push it 4. Remove the defective bulb by pushing it in in, and then turn it clockwise until it stops. And turning it counterclockwise. Tapered nuts are used for both the front and rear wheels.

Install the nuts with their tapered side to- wards the wheel. Elevate the ATV and place a suitable stand under the frame. Remove the nuts from the wheel.

Repair Manual 2001 Yamaha Big Bear 400

The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- 1. Tapered nut rience, and know-how to service the ATV properly. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel sys- tem. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces. Remove the spark plug and check the electrodes.

The engine does not start. Have a Yamaha dealer check the ATV. Check the battery.

Battery The engine turns over The battery is good. EBU25860 CLEANING AND STORAGE EBU25870 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. Only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components. EWB02300 To prevent corrosion, avoid damp cellars, WARNING stables (because of the presence of ammo- nia) and areas where strong chemicals are POTENTIAL HAZARD stored. Operation with wet brakes after washing.

WHAT CAN HAPPEN Wet brakes may have reduced stopping abil- Long-term ity, increasing the chance of an accident. Pour a teaspoonful of engine oil into the sively cold or warm place less than 0 °C (30 spark plug bore.

°F) or more than 30 °C (90 °F). For more in- c. Install the spark plug cap onto the spark formation on storing the battery, see page plug, and then place the spark plug on the 8-40. EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 8.60:1 Overall length: Starting system: 2016 mm (79.4 in) Electric and recoil starter Overall width: Lubrication system: 1116 mm (43.9 in) Wet sump Overall height: Engine oil: 1187 mm (46.7 in) Seat height: Type: 895 mm (35.2 in) YAMALUBE 4, SAE5W30 or SAE10W30 or SAE20W40 Wheelbase.

Available Today: The Full 2000-2001 Yamaha BIG BEAR 400 4×4 Service Manual and ATV Owners Maintenance Manual Set.This is Absolutely The BEST Service Manual for your Yamaha ATV / UTV.The Yamaha BIGBEAR 400 4WD Workshop Repair Manual has: ✔ Detailed Procedures with Pictures ✔ Exploded Parts Diagrams ✔ Troubleshooting and Electrical ✔ Engine Rebuild, Valve jobs, Transmission, Suspension. ✔ Fully covers your ATV / UTV Wheel to Wheel. Every thing!The 2000-2001 Yamaha BIG BEAR 400 4×4 Service Manual is GUARANTEED to match your specific ATV Model and Year. I put in the effort to match, collect, and confirm this Shop Manual Set is Correct for your Yamaha BIGBEAR 400 4WD. All Supplementary Manuals required to cover All Model Years listed are checked for and included in my listings. I also include the matching printable Yamaha BIGBEAR 400 4WD Owner’s Manual, which has:✔ Standard Maintenance Procedures, Adjustments, and Schedules.✔ Control Functions, Specifications, and Operating Instructions.You want this helpful Operators Guide regardless, but if your ATV is older than 1998, you understand it is simply impossible find these Owners manuals, however I include them for you!The printable 2000-2001 Yamaha BIG BEAR 400 4×4 PDF Service Manual is BOOKMARKED and KEYWORD SEARCHABLE.

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