2000-2003 Yamaha YFM400NM NMC Big Bear ATV Service Manual

Description

This Official 2000 2001 2002 2003 Yamaha YFM400NM NMC Big Bear ATV Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2000-2003 Yamaha YFM400NM/NMC Big Bear 2WD and YFM400FWNM/MC Big Bear 4WD and Buckmaster utility All Terrain Vehicles. This is the same manual used by the service department at your local Yamaha dealer. It has everything in it you need to know in order to repair and service your Yamaha utility ATV.

CONTENTS

CHAPTER 1.
GENERAL INFORMATION:
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
MODEL LABEL
IMPORTANT INFORMATION:
PREPARATION FOR REMOVAL PROCEDURES
REPLACEMENT PARTS
GASKETS, OIL SEALS AND O-RINGS
LOCK WASHERS/PLATES AND COTTER PINS
BEARINGS AND OIL SEALS
CIRCLIPS
SPECIAL TOOLS

CHAPTER 2.
SPECIFICATIONS:
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
CHASSIS
ELECTRICAL
HOW TO USE THE CONVERSION TABLE
GENERAL TORQUE SPECIFICATIONS
LUBRICATION POINTS AND LUBRICANT TYPE
ENGINE
LUBRICATION DIAGRAMS
CABLE ROUTING

CHAPTER 3.
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
PERIODIC MAINTENANCE/LUBRICATION
SEAT, CARRIERS, FENDERS AND FUEL TANK
REMOVAL
INSTALLATION
ENGINE
VALVE CLEARANCE ADJUSTMENT
TIMING CHAIN ADJUSTMENT
IDLING SPEED ADJUSTMENT
THROTTLE LEVER FREE PLAY ADJUSTMENT
SPEED LIMITER ADJUSTMENT
STARTER LEVER FREE PLAY ADJUSTMENT
SPARK PLUG INSPECTION
IGNITION TIMING CHECK
COMPRESSION PRESSURE MEASUREMENT
ENGINE OIL LEVEL INSPECTION
OIL TEMPERATURE WARNING LIGHT CHECK
ENGINE OIL REPLACEMENT
CLUTCH ADJUSTMENT
AIR FILTER CLEANING
SPARK ARRESTER CLEANING
CHASSIS
REAR BRAKE LEVER AND PEDAL ADJUSTMENT
FRONT BRAKE FLUID LEVEL INSPECTION
FRONT BRAKE PAD INSPECTION
REAR BRAKE SHOE INSPECTION
BRAKE HOSE INSPECTION
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
REVERSE CONTROL CABLE ADJUSTMENT
SHIFT PEDAL ADJUSTMENT
FINAL GEAR OIL LEVEL INSPECTION
FINAL GEAR OIL REPLACEMENT
DIFFERENTIAL GEAR OIL QUANTITY INSPECTION
DIFFERENTIAL GEAR OIL REPLACEMENT
CONSTANT VELOCITY JOINT DUST BOOT INSPECTION
STEERING SYSTEM INSPECTION
TOE-IN ADJUSTMENT
FRONT SHOCK ABSORBER ADJUSTMENT
REAR SHOCK ABSORBER ADJUSTMENT
TIRE INSPECTION
WHEEL INSPECTION

CABLE INSPECTION AND LUBRICATION
LEVERS, PEDAL, ETC. LUBRICATION
ELECTRICAL
BATTERY INSPECTION
FUSE INSPECTION
HEADLIGHT BEAM ADJUSTMENT
HEADLIGHT BULB REPLACEMENT

CHAPTER 4.
ENGINE OVERHAUL
ENGINE REMOVAL
SEAT, CARRIERS, FENDERS AND FUEL TANK
ENGINE OIL
CARBURETOR
EXHAUST PIPE AND MUFFLER
STARTER MOTOR
OIL FILTER
REVERSE CONTROL CABLE
SHIFT PEDAL AND FOOTREST
SPARK PLUG
LEADS
REAR SHOCK ABSORBER AND SWINGARM
FRONT DRIVE SHAFT PROTECTOR
FRONT FENDER BRACKET
ENGINE REMOVAL
ENGINE DISASSEMBLY
RECOIL STARTER
CYLINDER HEAD AND CYLINDER
PISTON
CRANKCASE COVER (LEFT)
SHIFT SHAFT AND STARTER IDLE GEAR
CDI ROTOR AND TIMING CHAIN
CRANKCASE COVER (RIGHT)
CLUTCH
REVERSE SHIFT BRACKET
OIL PUMP AND BALANCER DRIVE GEARS
CRANKCASE (LEFT)
BALANCER WEIGHT AND TRANSMISSION
CRANKSHAFT
CAMSHAFT, ROCKER ARM AND VALVE
OIL PUMP
INSPECTION AND REPAIR
CYLINDER HEAD
VALVE SEAT
VALVE AND VALVE GUIDE
VALVE SPRING
CAMSHAFT
ROCKER ARM AND ROCKER ARM SHAFT
TIMING CHAIN TENSIONER
TAPPET COVER AND SIDE COVER (CYLINDER HEAD)
CYLINDER AND PISTON
PISTON RING
PISTON PIN
CRANKSHAFT
BALANCER DRIVE GEAR AND DRIVEN GEAR
PRIMARY GEARS
PRIMARY CLUTCH
SECONDARY CLUTCH
OIL PUMP
SHIFTER AND TRANSMISSION
STARTER DRIVES
STARTER PULLEY AND RECOIL STARTER
OIL STRAINER, OIL FILTER AND OIL DELIVERY PIPES
CRAN KCASE
BEARINGS AND OIL SEALS
CIRCLIPS AND WASHERS
MIDDLE GEAR SERVICE
REMOVAL
DISASSEMBLY
INSPECTION
MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION
ASSEMBLY
INSTALLATIO
GEAR LASH MEASUREMENT
ENGINE ASSEMBLY AND ADJUSTMENT
OIL PUMP
VALVE, CAMSHAFT AND ROCKER ARM
VALVE, ROCKER ARM AND CAMSHAFT
CRANKSHAFT
TRANSMISSION AND BALANCER WEIGHT
CRANKSHAFT AND TRANSMISSION
CRANKCASE (LEFT)
BALANCER DRIVE AND DRIVEN GEARS AND OIL PUMP
BALANCER DRIVE GEARS AND OIL PUMP
REVERSE SHIFT BRACKET
CLUTCH

CLUTCH
CRANKCASE COVER (RIGHT)
TIMING CHAIN AND CDI ROTOR
CDI ROTOR AND STARTER
SHIFTER
STARTER IDLE GEAR AND SHIFT SHAFT
CRANKCASE COVER (LEFT)
PISTON AND CYLINDER
PISTON
CYLINDER AND CYLINDER HEAD
CYLINDER HEAD
RECOIL STARTER
REMOUNTING THE ENGINE

CHAPTER 5.
CARBURETION
CARBURETOR .
REMOVAL
DISASSEMBLY
INSPECTION
ASSEMBLY
INSTALLATION
FUEL LEVEL ADJUSTMENT

CHAPTER 6.
DRIVE TRAIN
TROUBLESHOOTING
DIFFERENTIAL GEAR AND CONSTANT VELOCITY JOINTS
REMOVAL
DISASSEMBLY
I“ INSPECTION
ASSEMBLY
MEASUREMENT AND ADJUSTMENT
INSTALLATION
DIFFERENTIAL GEAR OPERATION CHECK
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT
REMOVAL
DISASSEMBLY
INSPECTION
FINAL DRIVE PINION GEAR AND
RING GEAR SHIM SELECTION
ASSEMBLY
FINAL GEAR LASH MEASUREMENT AND ADJUSTMENT
INSTALLATION

CHAPTER 7.
CHASSIS
FRONT AND REAR WHEELS
REMOVAL
INSPECTION
INSTALLATION
FRONT BRAKE
BRAKE PAD REPLACEMENT
CALIPER DISASSEMBLY
MASTER CYLINDER DISASSEMBLY
INSPECTION AND REPAIR
CALIPER ASSEMBLY
MASTER CYLINDER ASSEMBLY
REAR BRAKE
REMOVAL
INSPECTION
INSTALLATION
STEERING SYSTEM .
REMOVAL
INSPECTION
INSTALLATION
FRONT SHOCK ABSORBER AND FRONT ARM
REMOVAL
INSPECTION
INSTALLATION
REAR SHOCK ABSORBER AND SWINGARM
REMOVAL
INSPECTION
INSTALLATION

CHAPTER 8.
ELECTRICAL
ELECTRICAL COMPONENTS
CHECKING OF CONNECTIONS
IGNITION SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
ELECTRICAL STARTING SYSTEM
CIRCUIT DIAGRAM
STARTING CIRCUIT OPERATION
TROUBLESHOOTING
STARTER MOTOR
CHARGING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
LIGHTING SYSTEM
CIRCUIT DIAGRAM
TROUBLE SHOOTING
LIGHTING SYSTEM CHECK
SIGNAL SYSTEM
CIRCUIT DIAGRAM
TROUBLE SHOOTING
SIGNAL SYSTEM CHECK
COOLING SYSTEM
CIRCUIT DIAGRAM
TROUBLE SHOOTING
CARBURETOR WARMING SYSTEM
CIRCUIT DIAGRAM
TROUBLE SHOOTING

CHAPTER 9.
TROUBLESHOOTING
STARTING FAILUREIHARD STARTING
FUEL SYSTEM
ELECTRICAL SYSTEM
COMPRESSION SYSTEM
POOR IDLE SPEED PERFORMANCE
POOR IDLE SPEED PERFORMANCE
POOR MEDIUM AND HIGH SPEED PERFORMANCE
POOR MEDIUM AND HIGH SPEED PERFORMANCE
FAULTY DRIVE TRAIN
FAULTY GEAR SHIFTING
HARD SHIFTING
SHIFT PEDAL DOES NOT MOVE
JUMPS-OUT-OF GEAR
CLUTCH SLIPPING
CLUTCH DRAGGING
OVE R HEATI N G
FAULTY BRAKE
POOR BRAKING EFFECT
SHOCK ABSORBER MALFUNCTION
MALFUNCTION
UNSTABLE HANDLING
UNSTABLE HANDLING
LIGHTING SYSTEM
HEADLIGHT DARK
BULB BURNT OUT