2003 YAMAHA BIG BEAR PRO 400 light

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

Front brake adjustment ...................... 8-63
Rear brake pedal and
lever adjustment ............................... 8-67
Adjusting the rear brake light switch... 8-75
Clutch adjustment............................... 8-77
Cable inspection and lubrication ........ 8-79
Brake and shift pedal/
brake lever lubrication ...................... 8-79
Wheel removal ................................... 8-81
Wheel installation ............................... 8-81
Battery ................................................ 8-83
Battery maintenance .......................... 8-87
Fuse replacement............................... 8-89
Replacing a headlight bulb ................. 8-91
Headlight beam adjustment................ 8-93
Tail/brake light bulb replacement ....... 8-95
Troubleshooting.................................. 8-97
Troubleshooting chart......................... 8-99
CLEANING AND STORAGE ................... 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
9
SPECIFICATIONS................................. 10-1
CONVERSION TABLE .......................... 11-1
1011
U4SH6A.book Page 3 Thursday, May 30, 2002 1:25 PM

2-15
WARNING


Always turn off the engine when refueling.


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


Do not spill gasoline on the engine or ex-
haust pipe/muffler when refueling. Never
refuel while smoking, or while in the vicini-
ty of sparks, open flames, or other sources
of ignition such as the pilot lights of water
heaters and clothes dryers. Gasoline can
catch fire and you could be burned.


When transporting the machine in another
vehicle, be sure it is kept upright and that
the fuel cock is in the “OFF” position. Oth-
erwise, fuel may leak out of the carburetor
or fuel tank.


Gasoline is poisonous. If you should swal-
low some gasoline or inhale a lot of gaso-
line vapor, or get some gasoline in your
eyes, see your doctor immediately. If gaso-
line spills on your skin, wash with soap
and water. If gasoline spills on your cloth-
ing, change your clothes.
U4SH6A.book Page 15 Thursday, May 30, 2002 1:25 PM

3-1
EBU00032
1-DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear carrier
2. Seat
3. Front carrier
4. Rear brake pedal
5. Reverse lock
release wire
6. Headlight
7. Fuel cock
8. Tail/brake light
9. Recoil starter
10. Shift pedal
11. Rear brake lever12. Parking brake
13. Auxiliary DC jack
14. Speedometer
15. Front brake lever
16. Main switch
17. Throttle lever
18. Fuel gauge
19. Drive select lever
20. Horn
21. Starter (choke)
22. Handlebar switchesNOTE:TheThe machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U4SH6A.book Page 1 Thursday, May 30, 2002 1:25 PM

4-1
EBU00040
1-CONTROL FUNCTIONS
EBU00942
Main switch
Functions of the respective switch positions are as
follows:
ON:
The engine can be started only at this position and
the headlights and taillight come on when the light
switch is on.
OFF:
All electrical circuits are switched off. The key can
be removed in this position.
U4SH6A.book Page 1 Thursday, May 30, 2002 1:25 PM

4-3 1. Reverse indicator light “REVERSE”
2. Neutral indicator light “NEUTRAL”
3. Oil temperature indicator light “”
1. Témoin de marche arrière “REVERSE”
2. Témoin de point mort “NEUTRAL”
3. Témoin de température d’huile “”
1. Luz de control de marcha atrás “REVERSE”
2. Luz de control de punto muerto “NEUTRAL”
3. Luz de control de la temperatura del aceite “”
EBU00802
Indicator and warning lights
EBU00044
Reverse indicator light “REVERSE”
This indicator light comes on when the transmis-
sion is in reverse.
EBU00045
Neutral indicator light “NEUTRAL”
This indicator light comes on when the transmis-
sion is in neutral.
EBU00732
Oil temperature warning light “”
When the oil temperature reaches a specified lev-
el, this light comes on to warn that the engine oil
temperature is too hot. If the warning light comes
on during operation, stop the engine as soon as it
is safe to do so and allow the engine to cool down
for about 10 minutes.CAUTION:_

The engine may overheat if the ATV is
overloaded. If this happens, reduce the
load to specification.


Restart after making sure that the warning
light is out. Continuous use while the
warning light is on may cause damage to
the engine.
_
U4SH6A.book Page 3 Thursday, May 30, 2002 1:25 PM

4-5
EBU00733
Oil temperature warning light checking method
ACB-10E
Turn the main switch to “ON” and the
engine stop switch to “”.
Oil temperature warning
light does not come on.
Oil temperature warning
light comes on.
Check engine oil temperature.
Oil temperature warning
light does not come on.
Engine oil temperature and
electrical circuit are OK. Go
ahead with riding.
Push start switch with the
transmission in neutral.
Ask a Yamaha dealer to
inspect the electrical circuit.
Oil tempera-
ture is low.
Allow to cool.
Oil tempera-
ture is high.
Oil temperature
warning light comes
on momentarily.
U4SH6A.book Page 5 Thursday, May 30, 2002 1:25 PM

4-13 1. Lights switch “//OFF”
2. Engine stop switch “”/“”
3. Start switch “”
4. Horn switch “”
1. Contacteur d’éclairage “//OFF”
2. Coupe-circuit du moteur “”/“”
3. Contacteur du démarreur “”
4. Contacteur de l’avertisseur “”
1. Interruptor de luces “//OFF”
2. Interruptor de paro del motor “”/“”
3. Interruptor de arranque “”
4. Interruptor de la bocina “”
EBU00053
Handlebar switches
EBU00849
Engine stop switch “”/“”
Make sure that the engine stop switch is in the
“” position. The engine stop switch controls ig-
nition and can be used at all times to stop the en-
gine, especially in an emergency. The engine will
not start or run when the engine stop switch is
turned to “”.
EBU00607
Start switch “”
The starter motor cranks the engine when this
switch is pushed.CAUTION:
See starting instructions prior to starting the
engine on page 6-3.
U4SH6A.book Page 13 Thursday, May 30, 2002 1:25 PM