2003 YAMAHA BIG BEAR PRO 400 brake

8-8 * It is recommended that these items be serviced by a Yamaha dealer.
NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
Drive select lever
safety system*•Check operation.
•Adjust if necessary.Wheels*•Check balance/damage/runout.
•Repair if necessary.Wheel bearing*•Check bearing assemblies for looseness/damage.
•Replace if damaged.Steering system*•Check operation.
•Replace if damaged.
•Check toe-in.
•Adjust if necessary.Axle boots*•Check condition.
•Replace if damaged.Fittings and Fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U4SH6A.book Page 8 Thursday, May 30, 2002 1:25 PM

8-55 1. Adjusting bolt 2. Locknut a. Free play
1. Bouchon de réglage 2. Contre-écrou a. Jeu
1. Perno de ajuste 2. Contratuerca a. Juego libre
1. Brake pad a. Wear limit: 1 mm
1. Plaquette de frein a. Limite d’usure: 1 mm
1. Pastillas del freno a. Límite de desgaste: 1 mm
EBU00307
Throttle lever adjustmentNOTE:Adjust the engine idling speed before adjusting the
throttle lever free play.1. Loosen the locknut.
2. Turn the adjusting bolt until the throttle lever
free play is 3–5 mm.
3. Tighten the locknut.
EBU00312
Front brake pad inspection
Inspect the brake pads for damage and wear. If
the thickness is less than the specified value, have
a Yamaha dealer replace the pads.NOTE:The wheels need to be removed to inspect the
brake pads. See page 8-81 for removal proce-
dures.
U4SH6A.book Page 55 Thursday, May 30, 2002 1:25 PM

8-57 1. Wear indicator 2. Wear limit
1. Indicateur d’usure 2. Limite d’usure
1. Indicador de desgaste 2. Límite de desgaste
1. Minimum level mark “LOWER”
1. Repère de niveau minimum “LOWER”
1. Marca de nivel mínimo “LOWER”
EBU00313
Rear brake shoe inspection
A wear indicator is provided on the rear brake.
This indicator allows checking of brake shoe wear
without disassembling the brake.
Apply the rear brake and check the position of the
indicator. If the indicator reaches the wear limit
line, ask a Yamaha dealer to replace shoes as a
set.
EBU00755
Brake fluid level inspection
Insufficient brake fluid may let air enter the brake
system, possibly causing the brakes to become in-
effective.
Before riding, check that the brake fluid is above
the lower level and replenish when necessary.
Observe these precautions:
1. When checking the fluid level, make sure the
top of the master cylinder is level by turning
the handlebars.
2. Use only the designated quality brake fluid.
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake perfor-
mance.
U4SH6A.book Page 57 Thursday, May 30, 2002 1:25 PM

8-59
3. Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reac-
tion and lead to poor brake performance.
4. Be careful that water does not enter the mas-
ter cylinder when refilling. Water will signifi-
cantly lower the boiling point of the fluid and
may result in vapor lock.
5. Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
6. Have a Yamaha dealer check the cause if the
brake fluid level goes down. Recommended brake fluid: DOT 4
U4SH6A.book Page 59 Thursday, May 30, 2002 1:25 PM

8-61
EBU01118
Brake fluid replacement
1. Complete fluid replacement should be done
only by trained Yamaha service personnel.
2. Have a Yamaha dealer replace the following
components during periodic maintenance or
when they are damaged or leaking.

Replace all rubber seals every two years.


Replace all hoses every four years.
U4SH6A.book Page 61 Thursday, May 30, 2002 1:25 PM

8-63 a. Free play
a. Jeu
a. Juego libre
EBU00951
Front brake adjustment
The front brake lever should have a free play of
zero mm (zero in) at the lever end. If not, ask a
Yamaha dealer to adjust it.
WARNING
_ Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability
which could lead to an accident. _After servicing:

Make sure the brakes operate smoothly and
that the free play is correct.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All air
must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
U4SH6A.book Page 63 Thursday, May 30, 2002 1:25 PM

8-65
WARNING
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly
and that the free play is correct.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
U4SH6A.book Page 65 Thursday, May 30, 2002 1:25 PM

8-67 1. Locknut 2. Adjusting bolt a. 5 mm
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
EBU00334*
Rear brake pedal and lever adjustment
Pedal height adjustment
1. Loosen the locknut.
2. Turn the adjusting bolt so that the top of the
brake pedal is positioned 5 mm below the top
of the footrest.
3. Tighten the locknut.
U4SH6A.book Page 67 Thursday, May 30, 2002 1:25 PM