2003 YAMAHA BIG BEAR PRO 400 oil filter

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
U4SH6A.book Page 2 Thursday, May 30, 2002 1:25 PM

5-15
CAUTION:_

In order to prevent clutch slippage (since
the engine oil also lubricates the clutch),
do not mix any chemical additives. Do not
use oils with a diesel specification of “CD”
or oils of a higher quality than specified. In
addition, do not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign material enters
the crankcase.
_
Oil quantity:
Periodic oil change
(engine oil):
2.4 L
Periodic oil change
(engine oil and transfer gear oil with oil
filter element replacement):
2.8 L
Total amount:
3.7 L
U4SH6A.book Page 15 Thursday, May 30, 2002 1:25 PM

8-7
EBU00262PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*•Check valve clearance.
•Adjust if necessary.Spark plug•Check condition.
•Adjust gap and clean.
•Replace if necessary.Air filter•Clean.
•Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*•Check idle speed/starter operation.
•Adjust if necessary.Crankcase breather
system*•Check breather hose for cracks or damage.
•Replace if necessary.Exhaust system*•Check for leakage.
•Retighten if necessary.
•Replace gasket(s) if necessary.Fuel line*•Check fuel hose for cracks or damage.
•Replace if necessary.Engine oil
•Replace (Warm engine before draining).Transfer gear oil
Engine oil filter
•Replace.Engine oil strainer
•Clean.Final gear oil
•Check oil level/oil leakage.
•Replace every 12 months.Differential gear oil
Front brake*•Check operation/fluid leakage/see NOTE page 8-8.
•Correct if necessary.Rear brake*•Check operation.
•Adjust if necessary.Clutch*•Check operation.
•Adjust if necessary.U4SH6A.book Page 7 Thursday, May 30, 2002 1:25 PM

8-15 1. Clamp
1. Bride
1. Mordaza
1. Drain bolt (engine oil) 2. O-ring
3. Compression spring 4. Oil strainer
1. Boulon de vidange (huile de moteur) 2. Joint torique
3. Ressort de compression 4. Crépine à huile
1. Perno de drenaje (aceite del motor) 2. Junta tórica
3. Muelle de compresión 4. Colador de aceite
Engine oil replacement and oil filter cleaning
1. Place the ATV on a level surface.
2. Warm up the engine for several minutes, and
then stop it.
3. Place a container under the engine to collect
the used oil.
4. Remove the clamp by removing the screw.
5. Remove the engine oil filler cap and drain bolt
to drain the oil.CAUTION:_ When removing the drain bolt, the compres-
sion spring, oil strainer and O-ring will fall out.
Take care not to lose these parts. _
U4SH6A.book Page 15 Thursday, May 30, 2002 1:25 PM

8-17 1. Filter cover bolt (× 3)
2. Oil filter cover
1. Boulon de couvercle de filtre (× 3)
2. Couvercle du filtre à huile
1. Perno de la tapa del filtro (× 3)
2. Tapa del filtro de aceite
1. Oil filter 2. O-ring (× 2)
1. Filtre à huile 2. Joint torique (× 2)
1. Filtro de aceite 2. Junta tórica (× 2)
6. Remove the shift pedal by removing the bolt.
7. Remove the oil filter element cover, and then
the oil filter element.
8. Clean the oil strainer and oil filter element
with solvent.
9. Inspect the O-ring and replace it if damaged.
10. Install the oil filter element, O-ring, oil filter el-
ement cover, compression spring, oil strainer
and drain bolt. Tighten the drain bolt to the
specified torque.CAUTION:_ Before installing the drain bolt, be sure to in-
stall the O-ring, compression spring and oil
strainer. _
Tightening torque
Drain bolt (engine):
32 Nm (3.2 m·kgf)
Oil filter element cover bolt:
10 Nm (1.0 m·kgf)
U4SH6A.book Page 17 Thursday, May 30, 2002 1:25 PM

8-19
11. Fill the engine with oil and install the oil filler
cap.CAUTION:_ Make sure that no foreign material enters the
crankcase. _
Recommended oil:
See page 10-2.
Oil quantity:
Periodic oil change:
2.4 L
With oil filter element replacement:
2.5 L
Total amount:
3.4 L
U4SH6A.book Page 19 Thursday, May 30, 2002 1:25 PM

8-25 1. Drain bolt
1. Boulon de vidange
1. Perno de drenaje
6. Fill the transfer gear case with oil.CAUTION:
Be sure no foreign material enters the transfer
gear case.7. Install the filler bolt and tighten to specifica-
tion.
8. Check for oil leakage. If oil leakage is found,
check for the cause.
9. Reinstall the transfer gear case guard.Recommended oil: See page 10-2
Quantity:
Transfer gear oil and engine oil with
filter replacement:
2.8 L
Tightening torque:
Filler bolt (transfer gear case):
23 Nm (2.3 m·kgf)
U4SH6A.book Page 25 Thursday, May 30, 2002 1:25 PM

8-45 1. Air filter element
1.Élément du filtre à air
1. Elemento filtrante
1. Element plate 2. Air filter element
3. Guide
1. Plaque d’élément 2.Élément du filtre à air
3. Guide
1. Placa del elemento 2. Elemento filtrante
3. Guía
3. Remove the air filter element, and separate it
from the guide.
4. Wash the element gently but thoroughly in
solvent.
WARNING
Always use parts cleaning solvent to clean the
air filter element. Never use low flash point sol-
vents or gasoline to clean the air filter element
because the engine could catch fire or ex-
plode.5. Squeeze the excess solvent out of the filter
and let it dry.CAUTION:
Do not twist the filter element when squeezing
it.6. Inspect the element. If damaged, replace it.
7. Apply SAE10W30 motor oil to the element.NOTE:The element should be wet but not dripping.
U4SH6A.book Page 45 Thursday, May 30, 2002 1:25 PM