Moto-4 Big Bear Yamaha ATV Repair Manual 1987-2004 Clymer

Description

This Clymer Yamaha Moto-4 & Big Bear 1987-2004 Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for Yamaha YFM350 2-WD,YFM350FW 4-WD 1987-1999 and the YFM400 2-WD, YFM400FW 4-WD 2000-2004 ATVs.

1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004

This service manual includes everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, ignition system, steering and suspension, wheels, brakes and tires, electrical system, frame and body. Features complete wiring diagrams and 574 illustrated pages.

QUICK REFERENCE DATA

CHAPTER ONE, GENERAL INFORMATION

Manual organization, Notes, cautions and warnings, Safety first, Service hints, Washing the vehicle, Torque specifications, Special tips, Fasteners, Lubricants, Threadlocking compound, Expendable supplies, Warning labels, Basic hand tools, Precision measuring tools, Special tools/ Fabricating tools, Mechanic’s tips, Ball bearing replacement, Oil seals, Riding safety, Off the road rules, Storage

CHAPTER TWO, TROUBLESHOOTING

Operating requirements, Troubleshooting instruments, Starting the engine, Starting difficulties, Engine starting troubles, Engine is difficult to start, Poor idle speed performance, Poor medium and high speed performance, Engine starting system, Charging system, Ignition system, Fuel system, Engine overheating (1987-1998 2-wheel drive and 1987-1997 4-wheel drive), Engine, Engine noises, Engine leak down test, Clutch, Transmission, Drive train noise, Handling, Frame noise, Brakes

CHAPTER THREE, LUBRICATION, MAINTENANCE AND TUNE-UP

Pre-ride check list, Maintenance schedule, Tires and wheels, Battery, Lubricants, Cleaning solvent, Periodic lubrication, Non-schedule lubrication, Periodic maintenance, Non-scheduled maintenance, Engine tune-up

CHAPTER FOUR, ENGINE TOP END

Engine principles, Cylinder head, Decompression camshaft (1987-1988 models), Camshaft and rocker arms, Camshaft chain, Chain guides, Valves and valve components, Cylinder block, Piston and piston rings

CHAPTER FIVE, ENGINE BOTTOM END

Service engine in frame, Middle drive gear (1987-1988 2-wheel drive), Transfer gear assembly (1987-1997 4-wheel drive), Middle drive gear, Balancer gear and oil pump drive gear assembly, Oil pump, Internal oil pipe, External oil pipe, Oil cooler, Magneto stator and stator housing (1987-1998 2-wheel drive and 1987-1997 4-wheel drive), Magneto rotor and starter clutch, Crankcase and crankshaft, Recoil starter, Break-in procedure

CHAPTER SIX, CLUTCH AND EXTERNAL SHIFT MECHANISM

Clutch cover, Clutch release lever mechanism, Clutch assemblies (1987-1998 2-wheel drive and 1987-1997 4-wheel), One-way clutch check, External shift mechanism

CHAPTER SEVEN, TRANSMISSION, SELECT LEVER AND INTERNAL SHIFT MECHANISM

Transmission/reverse system identification, Transmission troubleshooting, Transmission overhaul, Middle drive shaft, Reverse gear and shaft (1987-1998 2-wheel drive and 1987-1997 4-wheel drive), High/low combination gear assembly (1987-1998 2-wheel drive and 1987-1997 4-wheel drive), Internal shift mechanism, Transmission range select lever

CHAPTER EIGHT, FUEL AND EXHAUST SYSTEMS

Carburetor operation, Carburetor, Carburetor adjustments, Throttle cable replacement, Throttle lever housing, Fuel tank, Fuel shutoff valve, Air filter air box, Exhaust system

CHAPTER NINE, ELECTRICAL SYSTEM

Charging system, Stator charging coil, Voltage regulator/rectifier, Capacitor discharge ignition, Ignition coil, CDI magneto (stator source and pickup coils), Starting system, Starter relay, Lighting system, Indicator light system, Meter, Switches, Relays, Fuse, Circuit breaker (so equipped), Wiring diagrams

CHAPTER TEN, FRONT SUSPENSION AND STEERING

Front wheel, Front hub brake drum inspection (all models), Front hub/brake drum (1987-1998 2-wheel drive), Front hub/brake drum (4-wheel drive and 1996-on 2-wheel drive), Front spindle (1996-on 2-wheel drive), Front suspension, Shock absorber, Steering knuckle (1987-1995 2-wheel drive), Steering knuckle (1996-on 2-wheel drive and all 4-wheel drive), Control arm (1987-1995 2-wheel drive), Control arms (1996-on 2-wheel and all 4-wheel drive), Handlebar, Tie rods, Steering shaft, Tires and wheels

CHAPTER ELEVEN, FRONT DRIVE MECHANISM FOUR-WHEEL DRIVE

Front axle, Front differential gearcase, Front drive shaft

CHAPTER TWELVE, REAR SUSPENSION

Rear wheels, Rear hub inspection (all models), Rear hub (1987-1995 both sides and 1996-on left-hand side), Rear hub/brake drum (1996-on right-hand side), Rear axle (1987-1995 models), Rear axle (1996-on models), Final drive unit and short drive shaft Tire changing and tire repairs, Shock absorber, Swing arm

CHAPTER THIRTEEN, BRAKES

Front brake (1987-1998 models), Front drum brake 2-wheel drive (cable actuated-1987-1995), Front drum brake 1996-1998 2-wheel drive and 1987-1998 4-wheel drive (hydraulically actuated), Front master cylinder 1996-1998 2-wheel drive and all 4-wheel drive (hydraulically actuated), Rear brake disc (1987-1995 2-wheel drive), Rear drum brake/hub (all 1996-on models), Front brake hose replacement, Rear brake pedal, Brake bleeding

CHAPTER FOURTEEN, BODY

Seat, Front guard, Front bumper, Front carrier/rack, Rear carrier/rack, Rear guard, Fuel tank cover assembly (1996-1998 2-wheel drive and 1987-1999 4-wheel drive), Front fender, Rear fender (all models), Foot rests

SUPPLEMENT, 1999-ON 2-WHEEL DRIVE, 1998-ON 4-WHEEL DRIVE MODEL SERVICE INFORMATION

Engine starting system, Engine overheating, 2-wheel drive/4-wheel drive selecting system, Brakes, Battery, Periodic lubrication, Periodic maintenance, Brakes/ Rear brake light/engagement switch adjustment, Front brake pad and disc inspection, Servicing the engine in the frame, Engine removal, Engine installation, External oil pipe, Oil pump, Right internal oil pipe, Left internal oil pipe, Oil cooler, Stator and left engine case cover, Magneto stator testing, Magneto stator, Left side engine cover oil seal and bearing replacement, Left engine case cover installation, Magneto rotor and starter clutch, Crankcase disassembly, Crankcase, Clutch release and shift lever mechanism, Right crankcase cover, Primary clutch, Secondary clutch, Reverse shift shaft, Transmission/reverse system identification, Transmission overhaul /Main axle, Drive axle /Reverse gear and shaft, Internal shift mechanism, Carburetor, Carburetor warmer thermo switch, Fuel tank /Exhaust system, Charging system, Stator charging coil, Voltage regulator/rectifier, Capacitor discharge ignition, Starter system, Starter relay, Meter, Switches, Relays, Oil cooler fan, Oil temperature warning light, Oil cooler fan switch /Auxiliary DC jack, Fuse box, Push button 4-wheel drive selection mechanism, Disc brake fundamentals, Front brake pads /Front brake caliper, Front master cylinder, Seat, Guard and racks, Front fender, Rear fender /Footguards

INDEX

WIRING DIAGRAMS