2003 YAMAHA BIG BEAR PRO 400 fuel cap

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
U4SH6A.book Page 1 Thursday, May 30, 2002 1:25 PM

4-29 1. Recoil starter
1. Lanceur à réenroulement
1. Arranque por tracción de cable
1. Fuel tank cap
1. Bouchon de réservoir de carburant
1. Tapón del depósito de combustible
EBU00591
Recoil starter
Firmly grasp the handle and pull slightly until en-
gagement can be felt. Then pull forcefully, being
careful not to pull the rope all the way out.
WARNING
Put the transmission in neutral and set the
parking brake before starting the engine or the
ATV could start to move unexpectedly, which
could cause an accident.
EBU00092
Fuel tank cap
Remove the fuel tank cap by turning it counter-
clockwise.
U4SH6A.book Page 29 Thursday, May 30, 2002 1:25 PM

5-9
EBU00998
Fuel
Make sure there is sufficient gasoline in the tank.NOTE:_ (for Europe only)
If knocking or pinging occurs, use a different brand
of gasoline or higher octane grade. _
Recommended fuel:
For Europe:
Regular unleaded gasoline only with a
research octane number of 91 or higher.
For Australia:
Unleaded gasoline only
Fuel tank capacity:
Total:
13.5 L
Reserve:
1.3 L
U4SH6A.book Page 9 Thursday, May 30, 2002 1:25 PM

5-11 1. Fuel level 2. Filler tube
1. Niveau de carburant 2. Tube de remplissage
1. Nivel de combustible 2. Tubo del relleno
CAUTION:_ Use only unleaded gasoline. The use of leaded
gasoline will cause severe damage to internal
engine parts, such as the valves and piston
rings, as well as to the exhaust system. _
WARNING
_

Do not overfill the fuel tank. Fuel expands
when it heats up. If the fuel tank is over-
filled, fuel could spill out due to heat from
the engine or the sun.


Be careful not to spill fuel, especially on
the engine or exhaust pipe which can
cause a fire and severe injury. Wipe up any
spilled fuel immediately.


Do not refuel right after the engine has
been running and is still very hot.


Be sure the fuel tank cap is closed secure-
ly.
_
U4SH6A.book Page 11 Thursday, May 30, 2002 1:25 PM

8-99
EBU00440Troubleshooting chart1. Fuel
Check if there is fuel
in the fuel tank.There is fuel.Turn the fuel
cock to “OFF”.Remove the fuel pipe
from the fuel cock. Fuel cock
clogged.
Clean fuel
cock. Some fuel.Turn the fuel
cock to “RES”.Restart engine.
No fuel.
Supply fuel
2. Compression
Use electric starter
to see if there is
compression.There is compression.
No compression.
3. Ignition
Remove plug and
check electrodes.WetWipe clean with
dry cloth.
DryAttach plug cap and
ground to chassis.Use the
electric starter.Spark good.Ignition system
normal.
Spark weak.
Adjust plug gap
or replace plug. No spark.
Ask a Yamaha dealer to inspect. 4. Battery
Use electric starter.Engine turns over
quickly.Battery good.
Engine turns over
slowly.
Check fuel
flow. Turn the fuel
cock to “ON”.
Compression normal.Ask a Yamaha dealer to inspect.
Recharge, check
connections.
No fuel.
U4SH6A.book Page 99 Thursday, May 30, 2002 1:25 PM

10-4
Fuel:
Type For Europe: Regular unleaded gasoline only with a
research octance number of 91 or higher
For Australia: Unleaded gasoline only
Fuel tank capacity 13.5 L
Fuel reserve amount 1.3 L
Carburetor:
Type / manufacturer BTM32SH/MIKUNI
Spark plug:
Type (Manufacturer) DR8EA (NGK)
Spark plug gap 0.6–0.7 mm
Clutch type: Wet, centrifugal automatic
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 76/24 (3.167)
Secondary reduction system Shaft drive
Secondary reduction ratio 24/18
× 33/09 (4.889)
Transmission type Constant mesh 5-speed
Operation Left foot operation, Left hand operationModel YFM400FP/YFM400FW
U4SH6A.book Page 4 Thursday, May 30, 2002 1:25 PM