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
Accessories.........................................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
67
Crossing a slope ................................. 7-61
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
8
EE.book Page 2 Monday, June 18, 2001 10:18 AM

5-15
CAUTION:
Be sure to use motor oils that do not contain
anti-friction modifiers. Passenger car motor
oils (often labeled “Energy Conserving II”)
contain anti-friction additives which will cause
clutch and/or starter clutch slippage, resulting
in reduced component life and poor engine
performance.Oil quantity:
Periodic oil change
(engine oil):
2.4 L
Periodic oil change
(engine oil and transfer gear oil with oil
filter replacement):
2.8 L
Total amount:
3.7 L
EE.book Page 15 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

8-15 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 machine on a level place.
2. Warm up the engine for several minutes and
stop it.
3. Place a container under the engine to collect
the used oil.
4. Remove the clamp.
5. Remove the 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. _
EE.book Page 15 Monday, June 18, 2001 10:18 AM

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.
7. Remove the oil filter cover and oil filter.
8. Clean the oil strainer and oil filter with solvent.
9. Inspect the O-ring and replace it if damaged.
10. Install the oil filter, O-ring, oil filter cover, com-
pression 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)
Filter cover bolt:
10 Nm (1.0 m·kgf)
EE.book Page 17 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

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)
EE.book Page 25 Monday, June 18, 2001 10:18 AM

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.
EE.book Page 45 Monday, June 18, 2001 10:18 AM