1987–1997 Yamaha Big Bear 350 4WD YFM350FW Service Manual (P/N LIT-11616-FM-37)

This 144-page official Yamaha OEM PDF publication (P/N LIT-11616-FM-37) covers the 1987–1997 Big Bear 350 4WD. It documents comprehensive engine, chassis, electrical, and drivetrain specifications for the entire production series, ranging from YFM350FWT through YFM350FWJ.

• Covers all 1987–1997 Yamaha Big Bear 350 4WD variants, including YFM350FWT, YFM350FWW, YFM350FWA, YFM350FWB, YFM350FWF, YFM350FWH, and YFM350FWJ.
• Features 12 detailed wiring diagrams and 5 major exploded-view schematics for drivetrain and chassis assemblies.
• Includes multiple supplementary manuals essential for model-year-specific configuration differences spanning the ten-year production run.
• Details step-by-step procedures to avoid expensive dealership visits, covering carburetor rebuilds, valve clearance adjustments, top-end tear downs, stator testing, brake system bleeding, clutch replacements, and front differential rebuilds.
• Outlines essential servicing methods for fuel system tuning, recoil starter maintenance, oil pump inspection, ignition timing verification, suspension linkage lubrication, steering knuckle alignment, and exhaust assembly routing.

Factory Service and Maintenance Documentation

This manual breaks down maintenance and assembly procedures across the entire Big Bear series. A distinct advantage of this factory documentation is the inclusion of OEM diagnostic flowcharts and baseline readings, which eliminate trial-and-error parts swapping and drastically reduce diagnostic time on the bench. The documentation provides exact fluid capacities for the differential alongside major sections detailing engine upkeep, electrical system specs, chassis adjustments, and drivetrain repairs. The documentation segments cover machine identification, physical dimensions, and oil requirements. You'll also find clearly defined maintenance intervals for critical components—like valves, air filters, and spark plugs—to keep the machine running strong.

Specifications and Technical References

This reference includes precise torque values for wheel hubs, rear axle nuts, and brake components to ensure proper assembly. Engine internal tolerances—such as piston-to-cylinder clearance and camshaft dimensions—are fully documented to speed up mechanical inspections. Having these exact specifications prevents catastrophic engine failure. For electrical diagnostics, the guide lists magneto resistance values for CDI systems and charging outputs, making ignition troubleshooting straightforward. Finally, the chassis section outlines exact brake pedal and lever adjustments for proper linkage operation.

Important note for shop safety: This page serves as a contents overview of the manual to help you find the right reference material, not a step-by-step repair guide. Always rely on the specific procedures outlined within the manual itself and use proper, well-maintained shop equipment when performing any mechanical work.