Yamaha YFM 400 Bigbear Kodiak ATV
SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
Engine
Electrical
CABLE ROUTING
- Rear brake switch
- Rear brake cable
- Front brake hose
- On command four-wheel drive switch
- Throttle cable
- Home switch
- On command four-wheel drive switch lead
- Front brake hose
- Throttle cable
- Rear brake cable
- Rear brake switch lead
- Handlebar switch
- Starter cable
- Coolant reservoir breather hose
- Sub-wire harness 1 (to fan motor coupler)
- Sub-wire harness 1 (to gear motor and four-wheel drive switch)
- Differential gear case breather hose
- Fan motor breather hose
- Front brake light switch lead
- Headlight coupler
- Circuit breaker
- Terminal
- Terminal coupler
- Engine temperature warning light
- Four-wheel drive indicator light
- Neutral indicator light
- Reverse indicator light
- Parking indicator light
- Coolant reservoir breather hose
- Differential gear case breather hose
- Indicator light coupler
- Main switch coupler
- Ignition coil lead
- A. Connect the headlight lead of the circuit breaker to the headlight on the right side.
- Thermo switch
- Fuel tank breather hose
- Carburetor drain hose
- Speedometer cable
- Coolant reservoir breather
- Coolant reservoir hose
- Sub-wire harness I
- To hole on the front fender.
- Insert the fuel tank into the hole in the handlebar cover
- 10 mm (0.4 in)
- Neutral switch lead
- Starter motor lead
- Negative battery lead
- Water pump breather hose
- Speed sensor
- Carburetor drain hose
- Wire harness
- Sub-wire harness 2
- Ground lead
- AC magneto lead
- Final drive gear case breather hose
- Speed sensor
- Rectifier/ regulator
- Fasten the AC magneto lead Starter With a band.
- TO hole on the rear
- 120 mm (4.72 in)
- Spark plug lead
- Rear brake cable
- Select the lever control cable
- Rear brake roster wire hose
- Rear brake light switch lead
- A. Fasten the radiator inlet hose and fan motor breather hose with a plastic band.
- B.Pass the rear brake cable through the cable guide
- Pass the rear brake reservoir hose, select the lever control cable, and rear brake light switch lead through the cable guide
- Fan motor breather hose
- Cylinder head breather hose
- Air filter case breather hose
- Rear brake hose
- Final drive gear case breather hose
- Fan motor breather hose
- Wire harness
- Positive battery lead
- Taibbrake light
- Main fuse
- Starter relay
- CDI unit
- Fuse box
- Negative battery lead
- Final drive gear case breather hose
- 30 mm(1.18 in)
- Fan motor breather hose
- Front brake hose
- Wire harness
- Cylinder head breather hose
- Throttle cable
- Final drive gear case breather hose
- Air vent hose
- Starter cable
- Rear brake cable
- A. 70 mm (2.76 in)
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all the information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CYLINDER HEAD
CYLINDER HEAD INSTALLATION
- install:
- Cylinder head
- Bolt (MIO)
- Bolt (M6)
- Install:
- Camshaft sprocket
Installing steps
- Rotate the camshaft to align the camshaft pin 1 with the cylinder head match mark 2.
- Turn the crankshaft counterclockwise with a wrench.
- Align the ‘T” mark O on the rotor with the stationary pointer @ on the crankcase cover. When the “T” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (T.D.C.).
- Force the camshaft clockwise and counter-clockwise to remove the timing chain slack.
- Insert a screwdriver into the timing chain tensioner hole and push the timing chain guide inward.
- While pushing the timing chain guide, ensure the camshaft sprocket punch mark 5 is aligned with the cylinder head match mark 2.
- If the marks are aligned, tighten the camshaft sprocket bolt. If the marks are not aligned, change the meshing position Of the camshaft sprocket and timing chain.
Install
- Timing chain tensioner
Installation steps
- Remove the tensioner cap bolt 1, washer 2, and spring 3.
- Release the timing chain tensioner one-way cam 4 and push the tensioner rod 5 throughout ln.
- Install the tensioner 6 with a new gasket into the cylinder.
Tighten
- Camshaft sprocket bolt 1
RECOIL STARTER AND CDI MAGNETO
TRANSMISSION
TROUBLESHOOTING
TROUBLESHOOTINGIF THE STARTER MOTOR FAILS TO OPERATE
Check
- Fuse (main, ignition)
- Battery
- Starter motor
- Starter relay
- Main switch
- switch
- Neutral switch
- Rear brake switch
- Park switch
- Start switch
- Wiring connection (the entire system)
- CDI magneto
- Rectifier/regulator
- Main switch
- Battery
- Main fuse
- Starter relay
- Starter motor
- Speed
- CDI unit
- Rear brake switch
- Ignition coil
- Spark plug
- Reverse switch
- Neutral switch
- Circuit breaker (fan motor)
- Thermo switch
- Fan motor
- Four-wheel drive indÉator light
- Coolant temperature indÉator light
- Park switch
- Thermo switch
- Four-wheel drive fuse
- On command four-wheel drive select switch
- Gear motor
- Four-wheel drive switch
- Auxiliary DC jack fuse
- Auxiliary DC jack
- Diode
- Ignition fuse
- Headlight fuse
- switch (left)
- Lights switch
- Engine stop switch
- Start switch
- Headlight
- Signal luse
- Front brake light switch
- Tail and brake light
- Speedometer light
- Rear brake light switch
- Neutral indicator light
- Reverse indicator light
- Park indicator light
- Hour meter (optional)
- Horn switch
- Horn
- For Europe Oceania
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Yamaha YFM 400 Bigbear Kodiak ATV-FAQs
What type of engine oil should I use for the Yamaha YFM 400 Big Bear Kodiak?
Use 4-stroke engine oil with a viscosity of 10W-40 that meets or exceeds JASO MA or API SG standards. Always check the manual for additional recommendations based on your environment.
How often should I change the oil on my Yamaha YFM 400?
The oil should typically be changed every 20 hours of operation or after 200 miles, whichever comes first. Regular maintenance intervals are provided in the service manual.
What is the recommended tire pressure for the Yamaha YFM 400?
Front tire pressure should be set between 4.4-6.6 psi and rear tire pressure between 3.6-4.4 psi. Always refer to the manual for precise recommendations for your model.
How do I clean the air filter?
Remove the air filter, wash it with a non-flammable solvent, let it dry, and apply air filter oil before reinstalling. Regular cleaning is essential to maintain engine performance.
What type of fuel should I use in the Yamaha YFM 400?
Use unleaded gasoline with a minimum octane rating of 87. Avoid fuels with ethanol content higher than 10%.
How do I check and adjust the valve clearance?
To check the valve clearance, remove the valve covers and use a feeler gauge to measure the gap. Adjustments can be made using the tappet adjuster. Refer to the manual for specific clearances.
What is the correct spark plug for the Yamaha YFM 400?
Use an NGK DPR8EA-9 spark plug or equivalent. Ensure the gap is set to 0.8-0.9 mm before installation.
How do I troubleshoot electrical issues on my ATV?
Begin by checking the battery voltage, fuses, and wiring connections. The service manual provides detailed wiring diagrams and diagnostic steps for troubleshooting.
What is the proper coolant for the Yamaha YFM 400?
Use a high-quality ethylene glycol-based coolant designed for aluminum engines. Ensure the coolant is mixed with distilled water as per the recommended ratio in the manual.
How do I store my Yamaha YFM 400 for long periods?
Clean the ATV thoroughly, drain the fuel tank or add a stabilizer, disconnect the battery, and store the vehicle in a cool, dry place. Follow the manual’s guidelines for long-term storage.