2003 YAMAHA BIG BEAR PRO 400 %27

EBU00015
1-CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ....................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION AND
MACHINE IDENTIFICATION ................... 3-1
Identification number records ............... 3-3
Key identification number ..................... 3-5
Vehicle identification number ............... 3-7
Model label ........................................... 3-9
CONTROL FUNCTIONS ......................... 4-1
Main switch........................................... 4-1
Indicator and warning lights.................. 4-3
Oil temperature warning light
checking method ................................ 4-5
Speedometer ........................................ 4-9
Fuel gauge ......................................... 4-11
Handlebar switches ............................ 4-13
Throttle lever ...................................... 4-17
Speed limiter ...................................... 4-19
Front brake lever ................................ 4-21
Rear brake pedal and lever ................ 4-23
1234
Parking brake ..................................... 4-25
Shift pedal .......................................... 4-27
Drive select lever ............................... 4-27
Recoil starter ...................................... 4-29
Fuel tank cap ..................................... 4-29
Fuel cock............................................ 4-31
Starter (choke) ................................... 4-33
Seat.................................................... 4-35
Storage box........................................ 4-37
Front carrier ....................................... 4-37
Rear carrier ........................................ 4-37
Front shock absorber adjustment ...... 4-39
Rear shock absorber adjustment ....... 4-41
Auxiliary DC jack ................................ 4-43
PRE-OPERATION CHECKS ................... 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil/transfer gear oil ................. 5-13
Final gear oil/Differential gear oil ....... 5-17
Throttle lever ...................................... 5-17
Fittings and Fasteners ....................... 5-19
Lights ................................................. 5-19
Switches............................................. 5-19
5
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Tires ....................................................5-21
How to measure tire pressure .............5-25
Tire wear limit......................................5-27
OPERATION ............................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine .........................6-9
Warming up...........................................6-9
Drive select lever operation and
reverse driving ..................................6-11
Reverse lock release wire ...................6-15
Shifting ................................................6-17
To start out and accelerate: ................6-19
To decelerate: .....................................6-21
Engine break-in ...................................6-23
Parking ................................................6-27
Parking on a slope ..............................6-27
Accessories and loading .....................6-29
RIDING YOUR ATV..................................7-1
Getting to know your ATV .....................7-3
Ride with care and good judgement .....7-5
Be careful where you ride ...................7-27
Turning your ATV ................................7-41
Climbing uphill.....................................7-47
Riding downhill ....................................7-57
Crossing a slope .................................7-61
67
Crossing through shallow water ......... 7-65
Riding over rough terrain .................... 7-69
Sliding and skidding............................ 7-71
What to do if ... ................................... 7-75
What to do ... ...................................... 7-75
PERIODIC MAINTENANCE AND
ADJUSTMENT ......................................... 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication.......... 8-7
Engine oil ............................................ 8-13
Transfer gear oil replacement............. 8-23
Final gear oil ....................................... 8-27
Differential gear oil replacement ......... 8-31
Axle boots ........................................... 8-35
Spark plug inspection ......................... 8-37
Air filter cleaning ................................. 8-43
Carburetor adjustment ........................ 8-49
Idle speed adjustment ........................ 8-51
Valve clearance adjustment ............... 8-53
Select lever safety system
cable adjustment .............................. 8-53
Throttle lever adjustment .................... 8-55
Front brake pad inspection ................. 8-55
Rear brake shoe inspection ................ 8-57
Brake fluid level inspection ................. 8-57
Brake fluid replacement ...................... 8-61
8
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1-6
5For Oceania
Pour l’Océanie
Para Oceanía
5For Europe
Pour l’Europa
Para Europa
5FK-2151H-00
6
7
8For Europe
9For Europe
Pour l’Europa Pour l’Europa
Para Europa Para Europa
85 kg {187 lbs}
4WV-24877-A0
LOAD LIMITPULLING LOAD:
TONGUE WEIGHT:4018 N (410 kgf)
903 lbf
147 N ( 15 kgf)
33 lbf
4SH-2151K-00
MAXIMUM LOADING LIMIT
4SH-2156A-00
MODEL
POWER
:
DRY WHEIGHT:17.7 kW
273 kg YFM400FW
E-1.fm Page 6 Friday, May 31, 2002 10:32 AM

4-27 1. Shift pedal N. Neutral position
1. Pédale de sélection N. Point mort
1. Pedal de cambio N. Posición de punto muerto
1. Drive select lever
1. Levier de présélection
1. Palanca de selección de gama
EBU00083
Shift pedal
This machine is equipped with a constant-mesh
5-speed transmission. The shift pedal is located
on the left side of the engine. Neutral is at the bot-
tom position.
EBU00086
Drive select lever
The drive select lever is used to shift your machine
into high, low or reverse. Refer to page 6-11–6-15
for the drive select lever operation.
U4SH6A.book Page 27 Thursday, May 30, 2002 1:25 PM

5-1
EBU00113
1-PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-55–8-75
Rear brakeCheck operation, pedal height and free play.
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oil/
Transfer gear oilCheck oil level.
Fill with oil if necessary.5-13–5-15,
8-13–8-25
Final gear oil/
Differential gear oilCheck for leakage. 5-17, 8-27–8-35
ThrottleCheck for proper throttle cable operation. 5-17, 8-55
Wheels and tiresCheck tire pressure, wear and damage.5-21–5-27,
8-81–8-83
Fittings and FastenersCheck all fittings and fasteners. 5-19
LightsCheck for proper operation. 5-19, 8-91–8-95
Axle bootsCheck operation. 8-35
U4SH6A.book Page 1 Thursday, May 30, 2002 1:25 PM

5-17
EBU00495
Final gear oil/Differential gear oil
Make sure the final gear oil/differential gear oil is at
the specified level. Add oil as necessary. (See
pages 8-27–8-35.)
If desired, an SAE 80W90 hypoid gear oil may be
used for all conditions.NOTE:_ GL-4 is a quality and additive rating. GL-5 or GL-6
rated hypoid gear oils may also be used. _
EBU01083
Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
the idle position when released. Have a Yamaha
dealer repair as necessary for proper operation.Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
U4SH6A.book Page 17 Thursday, May 30, 2002 1:25 PM

5-27 a. 3 mm
EBU00160
Tire wear limit
When the tire groove decreases to 3 mm due to
wear, replace the tire.
U4SH6A.book Page 27 Thursday, May 30, 2002 1:25 PM

6-27 1. Lock plate
1. Verrou de stationnement
1. Placa de bloqueo
EBU00211
Parking
When parking, stop the engine and shift into neu-
tral. Turn the fuel cock to “OFF” and apply the
parking brake.
EBU00220
Parking on a slope
WARNING
Avoid parking on hills or other inclines. Park-
ing on a hill or other incline could cause the
ATV to roll out of control, increasing the
chance of an accident. If you must park on an
incline, put the machine in low gear, apply the
parking brake, and block the front and rear
wheels with rocks or other objects.
Do not park the ATV at all on hills that are so
steep you could not walk up them easily.1. Bring the machine to a stop by applying the
brakes in low gear.
2. Stop the engine.
3. With the rear brake lever and pedal applied,
apply the parking brake and slowly release
the rear brake pedal.
U4SH6A.book Page 27 Thursday, May 30, 2002 1:25 PM