2003 YAMAHA BIG BEAR PRO 400 lights

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

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.
EE.book Page 15 Monday, June 18, 2001 10:18 AM

4-1
EBU00040
1-CONTROL FUNCTIONS
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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.
EE.book Page 1 Monday, June 18, 2001 10:18 AM

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 “”
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Indicator and warning lights
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Reverse indicator light “REVERSE”
This indicator light comes on when the transmis-
sion is in reverse.
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Neutral indicator light “NEUTRAL”
This indicator light comes on when the transmis-
sion is in neutral.
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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.
_
EE.book Page 3 Monday, June 18, 2001 10:18 AM

4-13 1. Lights switch “LIGHTS”
2. Engine stop switch “”/“”
3. Start switch “”
4. Horn switch “”
1. Contacteur d’éclairage “LIGHTS”
2. Coupe-circuit du moteur “”/“”
3. Contacteur du démarreur “”
4. Contacteur de l’avertisseur “”
1. Interruptor de luces “LIGHTS”
2. Interruptor de paro del motor “”/“”
3. Interruptor de arranque “”
4. Interruptor de la bocina “”
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Handlebar switches
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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.
EE.book Page 13 Monday, June 18, 2001 10:18 AM

4-43 1. Auxiliary DC jack 2. Cap
1. Connecteur pour accessoires 2. Capuchon
1. Toma de CC auxiliar 2. Tapa
EBU00748
Auxiliary DC jack
The auxiliary DC jack is located at the front right
side of the ATV. The auxiliary DC jack can be used
for suitable work lights, radios, etc. The auxiliary
DC jack can only be used when the main switch is
in the “ON” position.
1. Turn the headlight switch to the “OFF” posi-
tion.
2. Start the engine. (See pages 6-3 ~ 6-7.)
3. Open the auxiliary DC jack cap and insert the
accessory power plug into the jack.
4. When the auxiliary DC jack is not being used,
cover it with the cap. Maximum rated capacity for the auxiliary
DC jack:
DC 12 V, 120 W (10 A)
EE.book Page 43 Monday, June 18, 2001 10:18 AM

5-1
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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

5-19
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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.
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Lights
Check the headlight and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU00912
Switches
Check the operation of the light switch, engine
stop switch and any other switches. Repair as nec-
essary for proper operation.
EE.book Page 19 Monday, June 18, 2001 10:18 AM