2003 YAMAHA BIG BEAR PRO 400 brakes

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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2-13

Never operate an ATV in fast flowing water or
in water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.


Always be sure there are no obstacles or peo-
ple behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly.


Always use the size and type tires specified in
this manual.


Always maintain proper tire pressure as de-
scribed in this manual.


Never modify an ATV through improper instal-
lation or use of accessories.


Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow
instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for brak-
ing.
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4-25 1. Lock plate
1. Verrou de stationnement
1. Placa de bloqueo
EBU00075
Parking brake
Use the parking brake when you have to start the
engine or park the machine, especially on a slope.
Apply the rear brake lever and push down the lock
plate to apply the parking brake. Squeeze the rear
brake lever to release the parking brake.
WARNING


Always set the parking brake before start-
ing the engine. The ATV could start mov-
ing unexpectedly if the parking brake is not
applied. This could cause loss of control or
a collision.


Always be sure you have released the
parking brake before you begin to ride. The
brake could overheat if you ride the ATV
without releasing the parking brake. You
could lose braking performance which
could cause an accident. You could also
wear out the brakes prematurely.
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5-5
EBU01091
Front and rear brakes
Brake levers and brake pedal
Check for correct free play in the brake levers and
brake pedal. If the free play is incorrect, adjust it.
(See pages 8-63–8-73.)
Check operation of the levers and pedal. They
should move smoothly and there should be a firm
feeling when the brake is applied. If not, have a
Yamaha dealer inspect the brake system.
Brake fluid level (front brake)
Check the brake fluid level. Add fluid if necessary.
(See pages 8-57–8-59.)
Recommended brake fluid: DOT 4
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5-7
Brake fluid leakage (front brake)
Check to see if any brake fluid is leaking out of the
hose, joint or brake fluid reservoir of the front
brake. Apply the brake firmly for one minute. If the
lever moves slowly inward, there may be a leak in
the brake system. If there is any leakage, the
brake system should be inspected by a Yamaha
dealer.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, in-
spect the brakes for wear. (See pages 8-55–8-57.)
WARNING
_ Always check the brakes at the start of every
ride. Do not ride the ATV if you find any prob-
lem with the brakes or you could lose braking
ability, which could lead to an accident. If a
problem cannot be corrected by the adjust-
ment procedures provided in this manual,
have a Yamaha dealer check for the cause. _
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6-21
EBU00208
To decelerate:
When slowing down or stopping, release the throt-
tle and apply the brakes smoothly and evenly. As
you slow down, shift to a lower gear. Be sure that
the engine has sufficiently slowed before engaging
a lower gear. Improper use of the brakes or shift-
ing can cause the tires to lose traction, reducing
control and increasing the possibility of an acci-
dent.
WARNING
Make sure the engine has sufficiently slowed
before shifting to a lower gear. Engaging a low-
er gear when the engine speed is too high
could make the wheels stop rotating. This
could cause loss of control, an accident and
injury. It could also cause engine or drive train
damage.
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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.
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7-35
Select a large, flat area off-road to become familiar
with your ATV. Make sure that this area is free of
obstacles and other riders. You should practice
control of the throttle, brakes, shifting procedures,
and turning techniques in this area before trying
more difficult terrain. Always avoid riding on paved
surfaces: the ATV is designed for off-road use
only, and handling maneuvers are more difficult to
perform on pavement.
Set the parking brake and follow the instruction on
page 6-3 to start the engine. Once it has warmed
up you are ready to begin riding your ATV. As you
get on the ATV, be sure not to accidentally move
the shift pedal. Remember that the engine and ex-
haust pipe will be hot when riding and afterwards;
do not allow skin or clothing to come in contact
with these components.
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