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Yamaha BIG BEAR 400 YFM400 FWNP YFM400FWNM YFM400NM Shop Manual 2000-2006

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Basic Information Identification Make: Yamaha Model: Big Bear 400 Model Codes: YFM400FWNP, YFM400FWNM, YFM400NM Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006 Introduction Market Position Quad Type: Utility ATV Target User: Recreational riders, farm use, trail riding. Competitive Analysis Competitors: Honda FourTrax, Suzuki King Quad, Arctic Cat (competitors in the utility ATV segment during that era). Key Features Engine Type: Reliable 4-stroke, liquid-cooled engine. Drivetrain Type: Selectable 4WD (Four-Wheel Drive) with a 2WD option for different terrains. Transmission: Automatic transmission (V-belt, CVT type) with high/low range and reverse. Suspension Type: Independent front suspension for improved ride comfort and handling. Braking System: Robust disc brake system for effective stopping power. Manual Details Coverage Areas Manual Type: Shop Manual / Service & Repair Manual Language: English Format: PDF Download Device Compatibility: PC, MAC, Tablets, Smartphones Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, including cylinder head, pistons, crankshaft, camshaft, valve train, and lubrication system. Engine Electrical: Ignition system (CDI, spark plug), starting system (starter motor, starter clutch), charging system (stator, regulator/rectifier), and wiring diagrams. Fuel System: Carburetor (Mikuni BSR33) specifications, cleaning, adjustment, fuel pump, fuel tank, and fuel lines. Transmission Drivetrain: 5-speed constant mesh transmission, automatic centrifugal clutch, final drive (shaft drive), differential, and driveshaft. Suspension: Front independent double-wishbone suspension, rear swingarm suspension, shock absorbers, and related components. Brakes: Front and rear hydraulic disc brakes, brake caliper service, brake lines, master cylinders, and brake fluid. Steering: Handlebar steering mechanism, tie rods, steering knuckle, and wheel alignment. Electrical System Components: Headlight, taillight, brake lights, indicators, battery, fuses, switches, and control units. Frame Chassis: Frame inspection, welds, and related chassis components. Bodywork Trim: Fender removal and installation, seat, fuel tank cover, and plastic trim components. Procedures Included Maintenance Schedules: Detailed recommended maintenance intervals for oil changes, filter replacement, valve adjustments, and more. Troubleshooting: Comprehensive diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts. Repair Procedures: Step-by-step instructions for all major component repairs and replacements. Rebuild Instructions: Detailed procedures for engine and transmission rebuilds. Wiring Diagrams: Complete and clear electrical wiring schematics for easy diagnosis and repair. Torque Specifications: Essential torque values for all critical fasteners and bolts. Special Tool Requirements: Identification of any specialized tools needed for specific procedures. Technical Depth Depth Level: Professional and in-depth, suitable for both novice mechanics and experienced technicians. Diagnostic Capability: Enables advanced diagnostics and systematic troubleshooting. Component Level Detail: Covers repair and overhaul down to individual component level. Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Searchable text for quick information retrieval. Print Quality Resolution: High-resolution for clear diagrams and text. Scalability: Scalable for viewing on various screen sizes. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Engine Specifications Primary Engine Engine Type: SOHC (Single Overhead Cam), 4-stroke, 5-valve, liquid-cooled, single-cylinder Engine Displacement: 386 cc (cubic centimeters) Bore X Stroke: 84.0 mm x 70.0 mm (approximate) Performance Horsepower: Estimated 21-23 HP (Horsepower) at around 5500 RPM (exact figures may vary by year and tuning). Torque: Estimated 23-25 lb-ft (pound-feet) at around 4500 RPM (exact figures may vary). Fuel System Fuel Delivery: Carburetor (Mikuni BSR33) Fuel Type: Unleaded gasoline Lubrication Oil Type: Yamalube 4 (or equivalent SAE 10W-40 API SG or higher) motorcycle oil. Oil Capacity: Approximately 2.2 liters (2.3 US qt) with filter change (refer to manual for exact capacity). Ignition Ignition System: CDI (Capacitor Discharge Ignition) Spark Plug: NGK CR7E (or equivalent - always verify with manual) Transmission Standard Transmission Type: Automatic (V-belt, CVT - Continuously Variable Transmission) Optional Gear Selection: High range (H), Low range (L), Neutral (N), Reverse (R). Features Clutch Type: Automatic centrifugal clutch Final Drive: Shaft drive with differential Transmission Fluid Type: Yamaha Genuine Gear Oil API GL-4 SAE 80W (or equivalent). Capacity approximately 0.13 L (0.14 US qt). Dimensions Exterior Overall Length: Approximately 77.2 inches (1960 mm) Overall Width: Approximately 43.1 inches (1095 mm) Overall Height: Approximately 45.5 inches (1155 mm) Wheelbase: Approximately 49.2 inches (1250 mm) Weights Dry Weight: Approximately 570 lbs (259 kg) - curb weight will be higher. Curb Weight: Typically around 590-600 lbs (268-272 kg) with all necessary fluids. Cargo Front Rack Capacity: Approximately 45 kg (99 lbs) Rear Rack Capacity: Approximately 85 kg (187 lbs) Tires Front Tire Size: AT25x8-12 Rear Tire Size: AT25x10-12 Wheels Wheel Bolt Pattern: Not applicable (hub-centric wheel mounting) Safety Features Ratings Atv Safety: Riders should always wear appropriate safety gear, including a helmet, goggles, gloves, and sturdy footwear. Follow all operational guidelines and terrain recommendations. Active Features Braking System: Hydraulic disc brakes on all wheels for reliable stopping power. Drivetrain Selection: Selectable 2WD/4WD for adapting to various traction conditions. Passive Features Handlebars: Ergonomically designed handlebars for control and comfort. Lighting: Dual 30W headlights, 30/30W brakelight/taillight for visibility. Technology Features Infotainment Infotainment System: Basic utility ATV, no integrated infotainment system. Driver Assistance...
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Yamaha BIG BEAR 400 YFM400 FWNP YFM400FWNM YFM400NM Shop Manual 2000-2006
Basic Information
Identification
Make: Yamaha
Model: Big Bear 400
Model Codes: YFM400FWNP, YFM400FWNM, YFM400NM
Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006
Introduction
Market Position
Quad Type: Utility ATV
Target User: Recreational riders, farm use, trail riding.
Competitive Analysis
Competitors: Honda FourTrax, Suzuki King Quad, Arctic Cat (competitors in the utility ATV segment during that era).
Key Features
Engine Type: Reliable 4-stroke, liquid-cooled engine.
Drivetrain Type: Selectable 4WD (Four-Wheel Drive) with a 2WD option for different terrains.
Transmission: Automatic transmission (V-belt, CVT type) with high/low range and reverse.
Suspension Type: Independent front suspension for improved ride comfort and handling.
Braking System: Robust disc brake system for effective stopping power.
Manual Details
Coverage Areas
Manual Type: Shop Manual / Service & Repair Manual
Language: English
Format: PDF Download
Device Compatibility: PC, MAC, Tablets, Smartphones
Manual Coverage
Systems Covered
Engine Mechanical: Complete engine overhaul, including cylinder head, pistons, crankshaft, camshaft, valve train, and lubrication system.
Engine Electrical: Ignition system (CDI, spark plug), starting system (starter motor, starter clutch), charging system (stator, regulator/rectifier), and wiring diagrams.
Fuel System: Carburetor (Mikuni BSR33) specifications, cleaning, adjustment, fuel pump, fuel tank, and fuel lines.
Transmission Drivetrain: 5-speed constant mesh transmission, automatic centrifugal clutch, final drive (shaft drive), differential, and driveshaft.
Suspension: Front independent double-wishbone suspension, rear swingarm suspension, shock absorbers, and related components.
Brakes: Front and rear hydraulic disc brakes, brake caliper service, brake lines, master cylinders, and brake fluid.
Steering: Handlebar steering mechanism, tie rods, steering knuckle, and wheel alignment.
Electrical System Components: Headlight, taillight, brake lights, indicators, battery, fuses, switches, and control units.
Frame Chassis: Frame inspection, welds, and related chassis components.
Bodywork Trim: Fender removal and installation, seat, fuel tank cover, and plastic trim components.
Procedures Included
Maintenance Schedules: Detailed recommended maintenance intervals for oil changes, filter replacement, valve adjustments, and more.
Troubleshooting: Comprehensive diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts.
Repair Procedures: Step-by-step instructions for all major component repairs and replacements.
Rebuild Instructions: Detailed procedures for engine and transmission rebuilds.
Wiring Diagrams: Complete and clear electrical wiring schematics for easy diagnosis and repair.
Torque Specifications: Essential torque values for all critical fasteners and bolts.
Special Tool Requirements: Identification of any specialized tools needed for specific procedures.
Technical Depth
Depth Level: Professional and in-depth, suitable for both novice mechanics and experienced technicians.
Diagnostic Capability: Enables advanced diagnostics and systematic troubleshooting.
Component Level Detail: Covers repair and overhaul down to individual component level.
Manual Specifications
File Format
File Type: PDF (Portable Document Format)
Searchability: Searchable text for quick information retrieval.
Print Quality
Resolution: High-resolution for clear diagrams and text.
Scalability: Scalable for viewing on various screen sizes.
Binding Type
Binding: N/A (Digital Download)
Paper Type
Paper: N/A (Digital Download)
Engine Specifications
Primary Engine
Engine Type: SOHC (Single Overhead Cam), 4-stroke, 5-valve, liquid-cooled, single-cylinder
Engine Displacement: 386 cc (cubic centimeters)
Bore X Stroke: 84.0 mm x 70.0 mm (approximate)
Performance
Horsepower: Estimated 21-23 HP (Horsepower) at around 5500 RPM (exact figures may vary by year and tuning).
Torque: Estimated 23-25 lb-ft (pound-feet) at around 4500 RPM (exact figures may vary).
Fuel System
Fuel Delivery: Carburetor (Mikuni BSR33)
Fuel Type: Unleaded gasoline
Lubrication
Oil Type: Yamalube 4 (or equivalent SAE 10W-40 API SG or higher) motorcycle oil.
Oil Capacity: Approximately 2.2 liters (2.3 US qt) with filter change (refer to manual for exact capacity).
Ignition
Ignition System: CDI (Capacitor Discharge Ignition)
Spark Plug: NGK CR7E (or equivalent - always verify with manual)
Transmission
Standard
Transmission Type: Automatic (V-belt, CVT - Continuously Variable Transmission)
Optional
Gear Selection: High range (H), Low range (L), Neutral (N), Reverse (R).
Features
Clutch Type: Automatic centrifugal clutch
Final Drive: Shaft drive with differential
Transmission Fluid Type: Yamaha Genuine Gear Oil API GL-4 SAE 80W (or equivalent). Capacity approximately 0.13 L (0.14 US qt).
Dimensions
Exterior
Overall Length: Approximately 77.2 inches (1960 mm)
Overall Width: Approximately 43.1 inches (1095 mm)
Overall Height: Approximately 45.5 inches (1155 mm)
Wheelbase: Approximately 49.2 inches (1250 mm)
Weights
Dry Weight: Approximately 570 lbs (259 kg) - curb weight will be higher.
Curb Weight: Typically around 590-600 lbs (268-272 kg) with all necessary fluids.
Cargo
Front Rack Capacity: Approximately 45 kg (99 lbs)
Rear Rack Capacity: Approximately 85 kg (187 lbs)
Tires
Front Tire Size: AT25x8-12
Rear Tire Size: AT25x10-12
Wheels
Wheel Bolt Pattern: Not applicable (hub-centric wheel mounting)
Safety Features
Ratings
Atv Safety: Riders should always wear appropriate safety gear, including a helmet, goggles, gloves, and sturdy footwear. Follow all operational guidelines and terrain recommendations.
Active Features
Braking System: Hydraulic disc brakes on all wheels for reliable stopping power.
Drivetrain Selection: Selectable 2WD/4WD for adapting to various traction conditions.
Passive Features
Handlebars: Ergonomically designed handlebars for control and comfort.
Lighting: Dual 30W headlights, 30/30W brakelight/taillight for visibility.
Technology Features
Infotainment
Infotainment System: Basic utility ATV, no integrated infotainment system.
Driver Assistance
Traction Control: No electronic traction control; relies on selectable 2WD/4WD and tire tread.
Connectivity
Connectivity Features: None
Maintenance
Service Intervals
Engine Oil Change: Every 1000 km (600 miles) or 6 months, whichever comes first. Shorter intervals recommended for severe usage.
Oil Filter Replacement: Replace at every engine oil change.
Air Filter Cleaning: Inspect every 500 km (300 miles) or 3 months. Clean or replace as needed.
Spark Plug Cleaning Gap: Inspect and adjust gap every 1000 km (600 miles) or 6 months. Replace as needed.
Valve Clearance Check: Every 2000 km (1200 miles) or 12 months.
Fluid Specifications
Engine Oil: Yamalube 4 (or SAE 10W-40 API SG or higher)
Gear Oil: Yamaha Genuine Gear Oil API GL-4 SAE 80W
Coolant: Permanent type anti-freeze coolant (50% mixture with distilled water)
Brake Fluid: DOT 3 or DOT 4 brake fluid
Known Issues
Carburetor Performance: Potential for carburetor gumming if fuel sits for extended periods; regular use or fuel stabilizer recommended. Jetting may need adjustment based on altitude or modifications.
Cv Belt Wear: As with all CVTs, belt wear is a maintenance item. Check for cracks, fraying, or excessive wear at prescribed intervals or if slippage is noticed.
Suspension Bushings: Wear in control arm bushings can lead to play and affect steering and suspension performance over time.
Cooling System: Regular checks of coolant level and condition are important to prevent overheating, especially under heavy load.
Vehicle History
Brand Heritage
Yamaha Motorsports: Yamaha has a long-standing reputation for producing high-quality, reliable, and performance-oriented powersports vehicles, including ATVs.
Model Evolution
Big Bear Lineage: The Big Bear nameplate has been a staple in Yamaha's utility ATV lineup, known for its durability and off-road capability. The 400cc model succeeded earlier Big Bear versions.
Production
Manufacturing Location: Primarily manufactured in Japan by Yamaha Motor Corporation.
Production Period: The Big Bear 400 was produced for a significant period, with this manual covering the 2000-2006 model years, indicating continuous updates and variations within this timeframe.
Awards & Recognition
Recognitions
Atv Awards: While specific awards for this exact model are not widely publicized, the Big Bear line has historically been recognized for its value, reliability, and all-around utility in the powersports media.
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