2003 YAMAHA BIG BEAR PRO 400 torque

5-19
EBU00152
Fittings and Fasteners
Always check the tightness of chassis fittings and
fasteners before a ride. Take the machine to a
Yamaha dealer or refer to the Service Manual for
correct tightening torque.
EBU01003
Lights
Check the headlights and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU01082
Switches
Check the operation of all switches. Repair as nec-
essary for proper operation.
U4SH6A.book Page 19 Thursday, May 30, 2002 1:25 PM

8-3 1. Owner’s manual
2. Low-pressure tire gauge
1. Manuel du propriétaire
2. Manomètre basse pression pour pneus
1. Manual del propietario
2. Manómetro de baja presión
1. Owner’s tool kit
1. Trousse à outils
1. Equipo de herramientas
EBU00256
Owner’s manual and tool kit
You are recommended to put this owner’s manual
and low-pressure tire gauge in the vinyl bag and
always carry them in the storage box. Put the own-
er’s tool kit in the space under the seat. The ser-
vice information included in this manual is
intended to provide you, the owner, with the nec-
essary information for completing your own pre-
ventive maintenance and minor repairs. The tools
provided in the Owner’s tool kit are sufficient for
this purpose, except that a torque wrench is also
necessary to properly tighten nuts and bolts.NOTE:If you do not have a torque wrench available dur-
ing a service operation requiring one, take your
machine to a Yamaha dealer to check the torque
settings and adjust them as necessary.
U4SH6A.book Page 3 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

8-23 1. Bolt (× 3)
1. Boulon (× 3)
1. Perno (× 3)
1. Oil filler bolt
1. Boulon de l’orifice de remplissage
1. Perno del orificio de llenado
EBU00462
Transfer gear oil replacementNOTE:When replacing the transfer gear oil, replace the
engine oil also.1. Remove the transfer gear case guard.
2. Place the machine on a level place.
3. Place a container under the transfer gear
case.
4. Remove the oil filler bolt and drain bolt to
drain the oil.
5. Install the drain bolt and tighten to specifica-
tion.
Tightening torque:
Drain bolt (transfer gear case):
20 Nm (2.0 m·kgf)
U4SH6A.book Page 23 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

8-27 1. Final gear oil 2. Correct oil level
3. Filler bolt
1. Huile de transmission finale 2. Niveau d’huile correct
3. Boulon de l’orifice de remplissage
1. Aceite de la transmisión final 2. Nivel de aceite correcto
3. Perno de llenado
1. Bolt (× 3)
1. Boulon (× 3)
1. Perno (× 3)
EBU00825
Final gear oil
Final gear oil measurement
1. Place the machine on a level place.
2. Remove the oil filler bolt and check the oil lev-
el. It should be up to the brim of the hole. If
the level is low, add oil to raise it to the proper
level.CAUTION:_ Be sure no foreign material enters the final
gear case. _3. Install the oil filler bolt and tighten it to the
specified torque.
Final gear oil replacement
1. Remove the final gear case cover.
2. Place the machine on a level place.
3. Place a container under the final gear case to
collect the used oil. Tightening torque:
Oil filler bolt:
23 Nm (2.3 m·kgf)
U4SH6A.book Page 27 Thursday, May 30, 2002 1:25 PM

8-29 1. Drain bolt
1. Boulon de vidange
1. Perno de drenaje
4. Remove the oil filler bolt and the drain bolt to
drain the oil.
5. Install the drain bolt and tighten it to the spec-
ified torque.
6. Fill the final gear case with oil.CAUTION:_ Be sure no foreign material enters the final
gear case. _
Tightening torque:
Drain bolt (final gear case):
23 Nm (2.3 m·kgf)
Recommended oil:
See page 10-3.
Oil quantity:
Periodic oil change:
0.19 L
Total amount:
0.25 L
U4SH6A.book Page 29 Thursday, May 30, 2002 1:25 PM

8-31 1. Filler bolt
1. Boulon de l’orifice de remplissage
1. Perno de llenado
7. Install the filler bolt and tighten to the speci-
fied torque.
8. Check for oil leakage. If oil leakage is found,
check for the cause.
9. Install the final gear case cover.
EBU00826
Differential gear oil replacement
1. Place the machine on a level place.
2. Place a container under the differential gear
case to collect the used oil.
3. Remove the filler bolt and drain bolts to drain
the oil. Tightening torque:
Filler bolt (final gear case):
23 Nm (2.3 m·kgf)
U4SH6A.book Page 31 Thursday, May 30, 2002 1:25 PM