2003 YAMAHA BIG BEAR PRO 400 brake

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

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

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

2-13

Never operate an ATV in fast flowing water or
in water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.


Always be sure there are no obstacles or peo-
ple behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly.


Always use the size and type tires specified in
this manual.


Always maintain proper tire pressure as de-
scribed in this manual.


Never modify an ATV through improper instal-
lation or use of accessories.


Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow
instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for brak-
ing.
EE.book Page 13 Monday, June 18, 2001 10:18 AM

3-1
EBU00032
1-DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear carrier
2. Seat
3. Front carrier
4. Rear brake pedal
5. Reverse lock
release wire
6. Headlight
7. Fuel cock
8. Tail/brake light
9. Recoil starter
10. Shift pedal
11. Rear brake lever12. Parking brake
13. Auxiliary DC jack
14. Speedometer
15. Front brake lever
16. Main switch
17. Throttle lever
18. Fuel gauge
19. Drive select lever
20. Horn
21. Starter (choke)
22. Handlebar switchesNOTE:TheThe machine you have purchased may differ
slightly from those shown in the figures of this
manual.
EE.book Page 1 Monday, June 18, 2001 10:18 AM

4-21 1. Front brake lever
1. Levier de frein avant
1. Palanca del freno delantero
EBU00070
Front brake lever
The front brake lever is located on the right handle-
bar. Pull it toward the handlebar to apply the front
brake.
EE.book Page 21 Monday, June 18, 2001 10:18 AM

4-23 1. Rear brake pedal
1. Pédale de frein arrière
1. Pedal del freno trasero
1. Rear brake lever
1. Levier de frein arrière
1. Palanca del freno trasero
EBU00073
Rear brake pedal and lever
The brake pedal is located on the right side of the
machine and the brake lever is located on the left
handlebar. Push down on the pedal or pull the le-
ver toward the handlebar to apply the rear brake.
EE.book Page 23 Monday, June 18, 2001 10:18 AM

4-25 1. Lock plate
1. Verrou de stationnement
1. Placa de bloqueo
EBU00075
Parking brake
Use the parking brake when you have to start the
engine or park the machine, especially on a slope.
Apply the rear brake lever and push down the lock
plate to apply the parking brake. Squeeze the rear
brake lever to release the parking brake.
WARNING


Always set the parking brake before start-
ing the engine. The ATV could start mov-
ing unexpectedly if the parking brake is not
applied. This could cause loss of control or
a collision.


Always be sure you have released the
parking brake before you begin to ride. The
brake could overheat if you ride the ATV
without releasing the parking brake. You
could lose braking performance which
could cause an accident. You could also
wear out the brakes prematurely.
EE.book Page 25 Monday, June 18, 2001 10:18 AM