Yamaha Moto-4, Big Bear Repair Manual 1987-2004

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Item # M490-3  ISBN: 0892879300




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This repair manual covers Yamaha YFM350 2-WD 1987-1999, YFM350FW 4-WD 1987-1999, YFM400 2-WD 2000-2004, and YFM400 FW 4-WD 2000-2004.

Table of Contents

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 solution | Periodic lubrication | Non-schedule lubrication | Periodic maintenance | Non-schedule maintenance | Engine tune-up | Storage

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
Servicing engine in frame | Middle driven gear (1987-1998 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 drive) | 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 replacements | 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 (models 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 drum (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 | Guards and racks | Front fender | Rear fender | Footguards

WIRING DIAGRAMS

Clymer ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Yamaha Moto-4, Big Bear Repair Manual 1987-2004