2003 YAMAHA BIG BEAR PRO 400 battery

Brake fluid replacement...................... 8-61
Front brake adjustment ...................... 8-63
Rear brake pedal and lever
adjustment........................................ 8-67
Adjusting the rear brake light switch... 8-75
Clutch adjustment............................... 8-77
Cable inspection and lubrication ........ 8-79
Brake and shift pedal/brake lever
lubrication ......................................... 8-79
Wheel removal ................................... 8-81
Wheel installation ............................... 8-81
Battery ................................................ 8-83
Battery maintenance .......................... 8-87
Fuse replacement............................... 8-89
Replacing the headlight bulb .............. 8-91
Headlight beam adjustment................ 8-93
Tail/brake light bulb replacement ....... 8-95
Troubleshooting.................................. 8-97
Troubleshooting chart......................... 8-99
CLEANING AND STORAGE ................... 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................. 10-1
910
HOW TO USE THE CONVERSION
TABLE ................................................... 11-1
11
EE.book Page 3 Monday, June 18, 2001 10:18 AM

4-15
EBU00735
Light switch
Turn the switch to the “” position to switch on
the low beam and the taillight.
Turn the switch to the “” position to switch on
the high beam and the taillight.
Turn the switch to the “OFF” position to switch off
the headlight and the taillight.CAUTION:_ Do not use the headlight with the engine
turned off for more than thirty minutes. The
battery may discharge to the point that the
starter motor will not operate properly. If this
should happen, remove the battery and re-
charge it. _
EBU00059
Horn switch “”
Press the switch to sound the horn.
EE.book Page 15 Monday, June 18, 2001 10:18 AM

4-45
CAUTION:_

Do not use accessories requiring more
than the above maximum capacity. This
may overload the circuit and cause the
fuse to blow.


If accessories are used without the engine
running or with the headlight turned on,
the battery will lose its charge and engine
starting may become difficult.


Do not use an automotive cigarette lighter
or other accessories with a plug that gets
hot because the jack can be damaged.
_
EE.book Page 45 Monday, June 18, 2001 10:18 AM

6-7
NOTE:

If the engine fails to start, release the start
switch, then push the start switch again.
Pause a few seconds before the next attempt.
Each cranking should be as short as possible
to preserve battery energy. Do not crank the
engine more than 10 seconds on each at-
tempt.


If the battery is discharged, pull the recoil
starter to start the engine.
7. If the engine is started with the starter (choke)
in position
1, the starter (choke) should be
returned to position
2 to warm up the engine.
If the engine is started with the starter (choke)
in position
2, keep the starter (choke) in this
position to warm up the engine.
8. Continue warming up the engine until it idles
smoothly and return the starter (choke) to po-
sition
3 before riding.CAUTION:
See the “Engine break-in” section prior to op-
erating engine for the first time.
EE.book Page 7 Monday, June 18, 2001 10:18 AM

8-83 1. Tapered nut
1.Écrou conique
1. Tuerca cónica
1. Tapered wheel nuts are used for both front
and rear wheels. Install the nut with its ta-
pered side towards the wheel.
2. Tighten the wheel nuts to the specified
torque.
EBU00381
Battery
This machine is equipped with a sealed-type bat-
tery. Therefore it is not necessary to check the
electrolyte or add distilled water in the battery. If
the battery seems to have discharged, consult a
Yamaha dealer.CAUTION:
Do not try to remove the sealing caps of the
battery cells. You may damage the battery.Wheel nut torque:
Front: 55 Nm (5.5 m·kgf)
Rear: 55 Nm (5.5 m·kgf)
EE.book Page 83 Monday, June 18, 2001 10:18 AM

8-85
WARNING
Battery electrolyte is poisonous and danger-
ous, causing severe burns, etc. It contains sul-
furic acid. Avoid contact with skin, eyes or
clothing.
Antidote:

EXTERNAL: Flush with water.


INTERNAL: Drink large quantities of water
or milk. Follow with milk of magnesia, beat-
en egg or vegetable oil. Call a physician
immediately.


EYES: Flush with water for 15 minutes and
get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes or other sources of
ignition away. Ventilate when charging or us-
ing in an enclosed space. Always shield your
eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
EE.book Page 85 Monday, June 18, 2001 10:18 AM

8-87
EBU00385
Battery maintenance
1. When the machine is not used for a month or
longer, remove the battery and store it in a
cool, dark place. Completely recharge the
battery before reinstallation.CAUTION:
A special battery charger (constant voltage/
ampere or constant voltage) is required for re-
charging a sealed-type battery. Using a con-
ventional battery charger may shorten the
battery life.2. Always make sure the connections are cor-
rect when putting the battery back in the ma-
chine.
EE.book Page 87 Monday, June 18, 2001 10:18 AM

8-99
EBU00440Troubleshooting chart1. Fuel
Check if there is fuel
in the fuel tank.There is fuel.Turn the fuel
cock to “OFF”.Remove the fuel pipe
from the fuel cock. Fuel cock
clogged.
Clean fuel
cock. Some fuel.Turn the fuel
cock to “RES”.Restart engine.
No fuel.
Supply fuel
2. Compression
Use electric starter
to see if there is
compression.There is compression.
No compression.
3. Ignition
Remove plug and
check electrodes.WetWipe clean with
dry cloth.
DryAttach plug cap and
ground to chassis.Use the
electric starter.Spark good.Ignition system
normal.
Spark weak.
Adjust plug gap
or replace plug. No spark.
Ask a Yamaha dealer to inspect. 4. Battery
Use electric starter.Engine turns over
quickly.Battery good.
Engine turns over
slowly.
Check fuel
flow. Turn the fuel
cock to “ON”.
Compression normal.Ask a Yamaha dealer to inspect.
Recharge, check
connections.
No fuel.
EE.book Page 99 Monday, June 18, 2001 10:18 AM