2003 YAMAHA BIG BEAR PRO 400 check oil

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
EE.book Page 1 Monday, June 18, 2001 10:18 AM

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.
EE.book Page 5 Monday, June 18, 2001 10:18 AM

5-1
EBU00113
1-PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5 ~ 5-7,
8-55 ~ 8-73
Rear brakeCheck operation, pedal height and free play.
FuelCheck fuel level.
Fill with fuel if necessary.5-9 ~ 5-11
Engine oil/
Transfer gear oilCheck oil level.
Fill with oil if necessary.5-13 ~ 5-15,
8-13 ~ 8-25
Final gear oil/
Differential gear oilCheck for leakage. 5-17, 8-27 ~ 8-35
ThrottleCheck for proper throttle cable operation. 5-17, 8-55
Wheels and tiresCheck tire pressure, wear and damage.5-21 ~ 5-27,
8-79 ~ 8-83
Fittings and FastenersCheck all fittings and fasteners. 5-19
LightsCheck for proper operation. 5-19, 8-91 ~ 8-95
Axle bootsCheck operation. 8-35
EE.book Page 1 Monday, June 18, 2001 10:18 AM

5-17
EBU00495*
Final gear oil/Differential gear oil
Make sure the final gear oil/differential gear oil is at
the specified level. Add oil as necessary. (See
pages 8-27 ~ 8-35.)
If desired, an SAE 80W90 hypoid gear oil may be
used for all conditions.NOTE:GL-4 is a quality and additive rating. GL-5 or GL-6
rated hypoid gear oils may also be used.
EBU00151
Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
idle position when released. Repair as necessary
for proper operation.Recommended oil:
See page 10-3.
EE.book Page 17 Monday, June 18, 2001 10:18 AM

8-7
EBL00262PERIODIC 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.EE.book Page 7 Monday, June 18, 2001 10:18 AM

8-8 * It is recommended that these items be serviced by a Yamaha dealer.
NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
Drive select lever
safety system*•Check operation.
•Adjust if necessary.Wheels*•Check balance/damage/runout.
•Repair if necessary.Wheel bearing*•Check bearing assemblies for looseness/damage.
•Replace if damaged.Steering system*•Check operation.
•Replace if damaged.
•Check toe-in.
•Adjust if necessary.Axle boots*•Check condition.
•Replace if damaged.Fittings and Fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
EE.book Page 8 Monday, June 18, 2001 10:18 AM

8-13 1. Oil filler cap
1. Bouchon de remplissage d’huile
1. Tapa del orificio de llenado de aceite
1. Dipstick 2. Maximum level mark
3. Minimum level mark
1. Jauge 2. Repère de niveau maximum
3. Repère de niveau minimum
1. Varilla 2. Marca de nivel máximo
3. Marca de nivel minimo
EBU00824
Engine oil
Engine oil level measurement
1. Place the machine on a level place.
2. Warm up the engine for several minutes and
stop it.
3. Remove the oil filler cap and wipe the dipstick
off with a clean rag. Insert the dipstick in the
filler hole without screwing it in.NOTE:_ Wait a few minutes until the oil level settles before
checking. _4. Remove the dipstick and inspect the oil level.
5. The oil level should be between the maxi-
mum and minimum marks. If the level is low,
add oil to raise it to the proper level.CAUTION:_ Be sure no foreign material enters the crank-
case. _
EE.book Page 13 Monday, June 18, 2001 10:18 AM

8-19
11. Fill the engine with oil and install the oil filler
cap.CAUTION:_ Be sure no foreign material enters the crank-
case. _12. Warm up the engine for several minutes at
idle speed. Check for oil leakage while warm-
ing up.CAUTION:_ If oil leakage is found, stop the engine immedi-
ately and check for the cause. _
Recommended oil: See page 10-2.
Oil quantity:
Periodic oil change:
2.4 L
With oil filter replacement:
2.5 L
Total amount:
3.4 L
EE.book Page 19 Monday, June 18, 2001 10:18 AM