2007-2010 Yamaha Big Bear 400, YFM40FB 4x4 service manual

Product Information

Table of Contents

GENERAL INFORMATION

1. VEHICLE IDENTIFICATION
   • VEHICLE IDENTIFICATION NUMBER
   • MODEL LABEL
2. FEATURES
   • WET MULTIPLE DISC BRAKE
3. IMPORTANT INFORMATION
   • PREPARATION FOR REMOVAL AND DISASSEMBLY
   • REPLACEMENT PARTS
   • GASKETS, OIL SEALS AND O-RINGS
   • LOCK WASHERS/PLATES AND COTTER PINS
   • BEARINGS AND OIL SEALS
   • CIRCLIPS
   • CHECKING THE CONNECTIONS
4. SPECIAL TOOLS

SPECIFICATIONS

1. GENERAL SPECIFICATIONS
2. ENGINE SPECIFICATIONS
3. CHASSIS SPECIFICATIONS
4. ELECTRICAL SPECIFICATIONS
5. TIGHTENING TORQUES
   • ENGINE TIGHTENING TORQUES
   • CHASSIS TIGHTENING TORQUES
6. HOW TO USE THE CONVERSION TABLE
   • GENERAL TIGHTENING TORQUE SPECIFICATIONS
7. LUBRICATION POINTS AND LUBRICANT TYPES
   • ENGINE
8. LUBRICATION DIAGRAMS
9. CABLE ROUTING

PERIODIC CHECKS AND ADJUSTMENTS

1. INTRODUCTION
2. PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
3. GENERAL MAINTENANCE AND LUBRICATION CHART
4. SEAT, CARRIERS, FENDERS, FUEL TANK AND AIR FILTER
   • SEAT
   • FRONT CARRIER, FRONT GUARD AND FRONT FENDER
   • REAR CARRIER AND REAR FENDER
   • FUEL TANK AND AIR FILTER CASE
5. FOOTREST BOARDS
   • INSTALLING THE REAR SKID PLATE
6. ENGINE
   • ADJUSTING THE VALVE CLEARANCE
   • ADJUSTING THE IDLING SPEED
   • ADJUSTING THE THROTTLE LEVER FREE PLAY
   • ADJUSTING THE SPEED LIMITER
   • ADJUSTING THE STARTER CABLE
   • CHECKING THE SPARK PLUG
   • CHECKING THE IGNITION TIMING
   • MEASURING THE COMPRESSION PRESSURE
   • CHECKING THE ENGINE OIL LEVEL
   • OIL TEMPERATURE WARNING LIGHT CHECK
   • CHANGING THE ENGINE OIL
   • ADJUSTING THE CLUTCH RELEASE
   • CLEANING THE AIR FILTER ELEMENT
   • CHECKING THE CARBURETOR JOINT
   • CHECKING THE FUEL HOSE
   • CHECKING THE CYLINDER HEAD BREATHER HOSE
   • CHECKING THE EXHAUST SYSTEM
   • CLEANING THE SPARK ARRESTER
7. CHASSIS
   • ADJUSTING THE FRONT BRAKE
   • ADJUSTING THE REAR BRAKE
   • CHECKING THE BRAKE FLUID LEVEL
   • CHECKING THE FRONT BRAKE PADS
   • CHECKING THE REAR BRAKE PLATES
   • ADJUSTING THE REAR BRAKE LIGHT SWITCH
   • CHECKING THE BRAKE HOSES
   • BLEEDING THE HYDRAULIC BRAKE SYSTEM
   • REVERSE CONTROL CABLE ADJUSTMENT
   • ADJUSTING THE SHIFT PEDAL
   • CHECKING THE FINAL GEAR OIL LEVEL
   • CHANGING THE FINAL GEAR OIL
   • CHECKING THE DIFFERENTIAL GEAR OIL
   • CHANGING THE DIFFERENTIAL GEAR OIL
   • CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS
   • CHECKING THE STEERING SYSTEM
   • ADJUSTING THE TOE-IN
   • CHECKING THE FRONT AND REAR SHOCK ABSORBERS
   • ADJUSTING THE FRONT SHOCK ABSORBER
   • ADJUSTING THE REAR SHOCK ABSORBERS
   • CHECKING THE TIRES
   • CHECKING THE WHEELS
   • CHECKING AND LUBRICATING THE CABLES
   • LUBRICATING THE LEVERS AND PEDALS
8. ELECTRICAL SYSTEM
   • CHECKING AND CHARGING THE BATTERY
   • CHECKING THE FUSES
   • ADJUSTING THE HEADLIGHT BEAMS
   • REPLACING A HEADLIGHT BULB

ENGINE

1. ENGINE REMOVAL
   • MUFFLER AND EXHAUST PIPE
   • LEADS, CABLES AND HOSES
   • ENGINE MOUNTING BOLTS
2. OIL COOLER
3. CYLINDER HEAD
   • REMOVING THE CYLINDER HEAD
   • CHECKING THE TAPPET COVERS
   • CHECKING THE TIMING CHAIN TENSIONER
   • CHECKING THE CAMSHAFT SPROCKET
   • CHECKING THE CYLINDER HEAD
   • INSTALLING THE CYLINDER HEAD
4. CAMSHAFT, ROCKER ARMS AND VALVES
   • REMOVING THE ROCKER ARMS AND CAMSHAFT
   • REMOVING THE VALVES AND VALVE SPRINGS
   • CHECKING THE CAMSHAFT
   • CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS
   • CHECKING THE VALVES AND VALVE SPRINGS
   • INSTALLING THE VALVES AND VALVE SPRINGS
   • INSTALLING THE CAMSHAFT AND ROCKER ARMS
5. CYLINDER AND PISTON
   • REMOVING THE PISTON
   • CHECKING THE CYLINDER AND PISTON
   • CHECKING THE PISTON RINGS
   • CHECKING THE PISTON PIN
   • INSTALLING THE PISTON AND CYLINDER
6. RECOIL STARTER AND AC MAGNETO ROTOR
   • REMOVING THE AC MAGNETO ROTOR
   • DISASSEMBLING THE RECOIL STARTER
   • CHECKING THE STATOR COIL AND PICKUP COIL
   • CHECKING THE STARTER CLUTCH
   • CHECKING THE STARTER PULLEY
   • CHECKING THE RECOIL STARTER
   • ASSEMBLING THE RECOIL STARTER
   • INSTALLING THE AC MAGNETO ROTOR
7. SHIFT SHAFT
   • CHECKING THE SHIFT SHAFT
   • CHECKING THE STOPPER LEVER
   • CHECKING THE SHIFT GUIDES
   • CHECKING THE SHIFT DRUM SEGMENT
   • INSTALLING THE SHIFT SHAFT
8. CLUTCH
   • REMOVING THE CLUTCH
   • CHECKING THE PRIMARY CLUTCH
   • CHECKING THE SECONDARY CLUTCH
   • CHECKING THE PUSH RODS
   • CHECKING THE FRICTION PLATES
   • CHECKING THE CLUTCH PLATES
   • CHECKING THE CLUTCH SPRINGS
   • INSTALLING THE CLUTCH
9. BALANCER GEARS AND OIL PUMP
   • OIL PUMP
   • REMOVING THE BALANCER DRIVEN GEAR
   • REMOVING THE OIL PUMP DRIVE GEAR AND BALANCER DRIVE GEAR
   • CHECKING THE OIL PUMP
   • CHECKING THE OIL PUMP DRIVE GEAR AND OIL PUMP DRIVEN GEAR
   • CHECKING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR
   • INSTALLING THE BALANCER DRIVE GEARS AND OIL PUMP
10. CRANKCASE
    • CRANKCASE BEARINGS
    • SEPARATING THE CRANKCASE
    • CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE
    • CHECKING THE TIMING CHAIN AND GUIDE
    • CHECKING THE BEARINGS AND OIL SEALS
    • CHECKING THE CRANKCASE
    • ASSEMBLING THE CRANKCASE
11. CRANKSHAFT
    • CRANKSHAFT AND BALANCER
    • REMOVING THE CRANKSHAFT
    • CHECKING THE CRANKSHAFT
    • INSTALLING THE CRANKSHAFT
12. TRANSMISSION
    • CHECKING THE SHIFT FORKS
    • CHECKING THE SHIFT DRUM ASSEMBLY
    • CHECKING THE TRANSMISSION
    • ASSEMBLING THE MAIN AXLE AND DRIVE AXLE
    • INSTALLING THE TRANSMISSION
13. MIDDLE GEAR
    • MIDDLE DRIVE PINION GEAR SHAFT
    • MIDDLE DRIVEN SHAFT
    • REMOVING THE MIDDLE DRIVE PINION GEAR SHAFT
    • REMOVING THE MIDDLE DRIVEN SHAFT
    • CHECKING THE PINION GEARS
    • SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS
    • INSTALLING THE MIDDLE DRIVEN SHAFT
    • INSTALLING THE MIDDLE DRIVE PINION GEAR SHAFT
    • MEASURING THE MIDDLE GEAR BACKLASH

CARBURETOR

1. CARBURETOR
   • DISASSEMBLING THE CARBURETOR
   • CHECKING THE CARBURETOR
   • ASSEMBLING THE CARBURETOR
   • ADJUSTING THE FUEL LEVEL

DRIVE TRAIN

1. TROUBLESHOOTING
   • CHECKING NOISES
   • TROUBLESHOOTING CHART
2. FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR
   • DISASSEMBLING THE UNIVERSAL JOINT
   • REMOVING THE FRONT CONSTANT VELOCITY JOINTS
   • REMOVING THE DIFFERENTIAL GEARS
   • CHECKING THE FRONT CONSTANT VELOCITY JOINTS
   • CHECKING THE DIFFERENTIAL GEARS
   • CHECKING THE DIFFERENTIAL GEAR MOTOR
   • ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS
   • ASSEMBLING THE DIFFERENTIAL GEAR
   • MEASURING THE DIFFERENTIAL GEAR LASH
   • ADJUSTING THE DIFFERENTIAL GEAR LASH
   • ASSEMBLING THE UNIVERSAL JOINT
   • CHECKING THE DIFFERENTIAL GEAR OPERATION
3. REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR
   • REMOVING THE REAR CONSTANT VELOCITY JOINTS
   • ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS
   • DISASSEMBLING THE FINAL DRIVE GEAR
   • CHECKING THE DRIVE SHAFT/UNIVERSAL JOINT YOKE
   • CHECKING THE FINAL DRIVE GEAR
   • DISASSEMBLING THE FINAL DRIVE PINION GEAR AND BEARING
   • INSTALLING THE FINAL DRIVE PINION GEAR AND BEARING
   • POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR
   • MEASURING THE RING GEAR THRUST CLEARANCE
   • MEASUREMENT THE FINAL GEAR LASH
   • ADJUSTING THE FINAL GEAR LASH
   • ASSEMBLING THE FINAL DRIVE GEAR
   • INSTALLING THE FINAL GEAR CASE

CHASSIS

1. FRONT AND REAR WHEELS
   • FRONT WHEELS
   • REAR WHEELS
   • CHECKING THE WHEELS
   • CHECKING THE WHEEL HUBS
   • CHECKING THE BRAKE DISCS
   • INSTALLING THE BRAKE DISCS
   • INSTALLING THE WHEEL HUBS
   • INSTALLING THE WHEELS
2. FRONT BRAKE
   • FRONT BRAKE PADS
   • REPLACING THE FRONT BRAKE PADS
   • FRONT BRAKE MASTER CYLINDER
   • CHECKING THE MASTER CYLINDER
   • ASSEMBLING THE FRONT BRAKE MASTER CYLINDER
   • INSTALLING THE FRONT BRAKE MASTER CYLINDER
   • FRONT BRAKE CALIPERS
   • DISASSEMBLING THE FRONT BRAKE CALIPERS
   • CHECKING THE FRONT BRAKE CALIPERS
   • ASSEMBLING THE FRONT BRAKE CALIPERS
   • INSTALLING THE FRONT BRAKE CALIPERS
3. REAR BRAKE
   • REAR BRAKE LEVER
   • BRAKE PEDAL
   • FINAL GEAR CASE (REAR BRAKE)
   • CHECKING THE FRICTION PLATES
   • CHECKING THE REAR BRAKE PLATES
   • CHECKING THE REAR BRAKE SPRINGS
   • CHECKING THE PRESSURE PLATE
   • CHECKING THE RING GEAR
4. STEERING SYSTEM
   • HANDLEBAR
   • REMOVING THE FRONT BRAKE LIGHT SWITCH AND REAR BRAKE LEVER LIGHT SWITCH
   • REMOVING THE HANDLEBAR GRIPS
   • CHECKING THE HANDLEBAR
   • INSTALLING THE HANDLEBAR
   • INSTALLING THE HANDLEBAR GRIPS
   • INSTALLING THE REAR BRAKE LEVER
   • INSTALLING THE BRAKE MASTER CYLINDER ASSEMBLY
   • STEERING STEM
   • REMOVING THE BEARING RETAINER
   • CHECKING THE STEERING STEM
   • INSTALLING THE BEARING RETAINER
   • INSTALLING THE CABLE GUIDE
   • TIE RODS AND STEERING KNUCKLES
   • REMOVING THE STEERING KNUCKLES
   • CHECKING THE TIE RODS
   • CHECKING THE STEERING KNUCKLES
   • INSTALLING THE TIE RODS
5. FRONT ARMS AND FRONT SHOCK ABSORBERS
   • REMOVING THE FRONT ARMS
   • CHECKING THE FRONT ARMS
   • CHECKING THE FRONT SHOCK ABSORBERS
   • INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBERS
6. REAR KNUCKLES AND STABILIZER
   • CHECKING THE REAR KNUCKLES
   • CHECKING THE STABILIZER
7. REAR ARMS AND REAR SHOCK ABSORBERS
   • CHECKING THE REAR ARMS
   • CHECKING THE REAR SHOCK ABSORBERS
   • INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBERS

ELECTRICAL

1. ELECTRICAL COMPONENTS
   • CHECKING SWITCH CONTINUITY
   • CHECKING THE SWITCHES
   • CHECKING THE BULBS AND BULB SOCKETS
   • TYPES OF BULBS
   • CHECKING THE CONDITION OF THE BULBS
   • CHECKING THE CONDITION OF THE BULB SOCKETS
2. IGNITION SYSTEM
   • CIRCUIT DIAGRAM
   • TROUBLESHOOTING
3. ELECTRIC STARTING SYSTEM
   • CIRCUIT DIAGRAM
   • STARTING CIRCUIT OPERATION
   • TROUBLESHOOTING
4. STARTER MOTOR
   • CHECKING THE STARTER MOTOR
   • ASSEMBLING THE STARTER MOTOR
5. CHARGING SYSTEM
   • CIRCUIT DIAGRAM
   • TROUBLESHOOTING
6. LIGHTING SYSTEM
   • CIRCUIT DIAGRAM
   • TROUBLESHOOTING
   • CHECKING THE LIGHTING SYSTEM
7. SIGNALING SYSTEM
   • CIRCUIT DIAGRAM
   • TROUBLESHOOTING
   • CHECKING THE SIGNALING SYSTEM
8. COOLING SYSTEM
   • CIRCUIT DIAGRAM
   • TROUBLESHOOTING
9. 2WD/4WD SELECTING SYSTEM
   • CIRCUIT DIAGRAM
   • TROUBLESHOOTING
10. CARBURETOR WARMING SYSTEM
    • CIRCUIT DIAGRAM
    • TROUBLESHOOTING

TROUBLESHOOTING

1. STARTING FAILURE/HARD STARTING
   • FUEL SYSTEM
   • ELECTRICAL SYSTEM
   • COMPRESSION SYSTEM
2. POOR IDLE SPEED PERFORMANCE
   • POOR IDLE SPEED PERFORMANCE
3. POOR MEDIUM AND HIGH-SPEED PERFORMANCE
   • POOR MEDIUM AND HIGH-SPEED PERFORMANCE
4. FAULTY DRIVE TRAIN
5. FAULTY GEAR SHIFTING
   • HARD SHIFTING
   • SHIFT LEVER DOES NOT MOVE
   • JUMPS OUT OF GEAR
6. FAULTY CLUTCH PERFORMANCE
   • ENGINE OPERATES BUT VEHICLE WILL NOT MOVE
   • CLUTCH SLIPPING
   • POOR STARTING PERFORMANCE
7. OVERHEATING
   • OVERHEATING
8. FAULTY BRAKE
   • POOR BRAKING EFFECT
9. SHOCK ABSORBER MALFUNCTION
   • MALFUNCTION
10. UNSTABLE HANDLING
    • UNSTABLE HANDLING
11. LIGHTING SYSTEM
    • HEADLIGHT DOES NOT COME ON
    • BULB BURNT OUT
    • TAIL/BRAKE LIGHT DOES NOT LIGHT
    • TAIL/BRAKE LIGHT BULB BURNT OUT

How to Download Your Manual - Delivery Policy