2003 YAMAHA BIG BEAR PRO 400 lock

7-17 1. Locknut 2. Adjuster
1. Contre-écrou 2. Vis de réglage
1. Contratuerca 2. Ajuste
Speed limiter
For riders inexperienced with this model, this mod-
el is equipped with a speed limiter in the throttle le-
ver housing. The speed limiter limits the power
and top speed of the machine. Turning the screw
in decreases top speed, and turning it out increas-
es top speed.
Loading and accessories
Use extra caution when riding the machine with
additional loads, such as accessories or cargo.
The machine’s handling may be adversely affect-
ed. Reduce your speed when adding additional
loads.
EE.book Page 17 Monday, June 18, 2001 10:18 AM

7-55
WARNING
Use proper gear and maintain steady speed
when climbing a hill.
If you lose all forward speed:

Keep weight uphill.


Apply the brakes.


Lock parking brake, after you are stopped.
If you begin rolling backwards:


Keep weight uphill.


Never apply the rear brake while rolling
backwards. Apply the front brake.
When fully stopped, apply rear brake as
well, and then lock parking brake.
Dismount on uphill side or to a side if pointed
straight uphill. Turn the ATV around and re-
mount, following the procedure described in
the Owner’s Manual.
EE.book Page 55 Monday, June 18, 2001 10:18 AM

8-53 1. Locknut 2. Adjuster
1. Contre-écrou 2. Dispositif de réglage
1. Contratuerca 2. Ajustador
EBU00303
Valve clearance adjustment
The correct valve clearance changes with use, re-
sulting in improper fuel/air supply or engine noise.
To prevent this, the valve clearance must be ad-
justed regularly. This adjustment however, should
be left to a professional Yamaha service techni-
cian.
EBU00305
Select lever safety system cable adjustment
The select lever safety system cable stretches
with use, resulting in improper function.
To prevent this, the cable must be adjusted regu-
larly. This adjustment, however, should be left to a
Yamaha dealer.
EE.book Page 53 Monday, June 18, 2001 10:18 AM

8-55 1. Adjusting bolt 2. Locknut a. 3 ~ 5 mm
1. Bouchon de réglage 2. Contre-écrou
1. Perno de ajuste 2. Contratuerca
1. Brake pad a. Wear limit: 1 mm
1. Plaquette de frein a. Limite d’usure: 1 mm
1. Pastillas del freno a. Límite de desgaste: 1 mm
EBU00307
Throttle lever adjustmentNOTE:Adjust the engine idling speed before adjusting the
throttle lever free play.1. Loosen the locknut.
2. Turn the adjusting bolt until the throttle lever
free play is 3 ~ 5 mm.
3. Tighten the locknut.
EBU00312
Front brake pad inspection
Inspect the brake pads for damage and wear. If
the thickness is less than the specified value, have
a Yamaha dealer replace the pads.NOTE:The wheels need to be removed to inspect the
brake pads. See page 8-81 for removal proce-
dures.
EE.book Page 55 Monday, June 18, 2001 10:18 AM

8-59
3. Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reac-
tion and lead to poor brake performance.
4. Be careful that water does not enter the mas-
ter cylinder when refilling. Water will signifi-
cantly lower the boiling point of the fluid and
may result in vapor lock.
5. Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
6. Have a Yamaha dealer check the cause if the
brake fluid level goes down. Recommended brake fluid:DOT 4
EE.book Page 59 Monday, June 18, 2001 10:18 AM

8-67 1. Locknut 2. Adjusting bolt a. 5 mm
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
EBU00334*
Rear brake pedal and lever adjustment
Pedal height adjustment
1. Loosen the locknut.
2. Turn the adjusting bolt so that the top of the
brake pedal is positioned 5 mm below the top
of the footrest.
3. Tighten the locknut.
EE.book Page 67 Monday, June 18, 2001 10:18 AM

8-71 1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
1. Adjusting nut (brake cable) a. 0 ~ 1 mm
1.Écrou de réglage (câble de frein)
1. Tuerca de ajuste (cable de freno)
Brake lever free play adjustment
1. Loosen the locknut and fully turn in the ad-
justing bolt at the brake lever.
2. Screw in the adjusting nut on brake cable to
provide a gap of 0 ~ 1 mm between the lever
and the pin.
EE.book Page 71 Monday, June 18, 2001 10:18 AM

8-73 1. Locknut 2. Adjusting bolt a. 4 ~ 7 mm
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
3. Turn the adjusting bolt until free play at the
brake lever pivot is 4 ~ 7 mm.
4. Tighten the locknut.
WARNING
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly
and that the free play is correct.


Make sure the brakes do not drag.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
EE.book Page 73 Monday, June 18, 2001 10:18 AM