2003 YAMAHA BIG BEAR PRO 400 warning light

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

4-3 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 “”
EBU00802
Indicator and warning lights
EBU00044
Reverse indicator light “REVERSE”
This indicator light comes on when the transmis-
sion is in reverse.
EBU00045
Neutral indicator light “NEUTRAL”
This indicator light comes on when the transmis-
sion is in neutral.
EBU00732
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

4-5
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

4-29 1. Recoil starter
1. Lanceur à réenroulement
1. Arranque por tracción de cable
1. Fuel tank cap
1. Bouchon de réservoir de carburant
1. Tapón del depósito de combustible
EBU00591
Recoil starter
Firmly grasp the handle and pull slightly until en-
gagement can be felt. Then pull forcefully, being
careful not to pull the rope all the way out.
WARNING
Put the transmission in neutral and set the
parking brake before starting the engine or the
ATV could start to move unexpectedly, which
could cause an accident.
EBU00092
Fuel tank cap
Remove the fuel tank cap by turning it counter-
clockwise.
EE.book Page 29 Monday, June 18, 2001 10:18 AM

8-89 1. Main fuse 2. Spare fuse
1. Fusible principal 2. Fusible de rechange
1. Fusible principal 2. Fusible de repuesto
1. Headlight fuse 2. Ignition fuse
3. Auxiliary DC jack fuse 4. Signal fuse
5. Spare fuse
1. Fusible de phare 2. Fusible d’allumage
3. Fusible de connecteur 4. Fusible de signalisation
pour accessoires
5. Fusible de rechange
1. Fusible del faro 2. Fusible del sistema de encendido
3. Fusible de la toma 4. Fusible señalización
auxiliar de CC
5. Fusible de repuesto
EBU00745*
Fuse replacement
1. The fuse cases are under the seat.
2. If a fuse is blown, turn off the main switch and
the switch of the circuit in question. Then, in-
stall a new fuse of the specified amperage.
Turn on the main switch. If the fuse immedi-
ately blows again, consult a Yamaha dealer.
WARNING
_ Always use a fuse of the specified rating. Nev-
er use any type of material or object in place of
the proper fuse. An improper fuse can cause
damage to the electrical system which could
lead to a fire. _CAUTION:_ To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse. _
Specified fuses:
Main fuse: 30 A
Headlight fuse: 15 A
Ignition fuse: 10 A
Auxiliary DC jack fuse: 10 A
Signal fuse: 10 A
EE.book Page 89 Monday, June 18, 2001 10:18 AM

8-91 1. Cover
1. Cache
1. Cubierta
1. Bulb holder
1. Douille d’ampoule
1. Portalámparas
EBU00402
Replacing the headlight bulb
If the headlight bulb burns out, replace the bulb as
follows:
1. Remove the cover.
2. Turn the bulb holder counterclockwise and
remove the defective bulb.
WARNING
The headlight bulb is hot when it is on and im-
mediately after it is turned off. Wait for the bulb
to cool before touching or removing it. You can
be burned, or a fire could start if the bulb
touches something flammable.3. Put a new bulb into position and secure it in
place with the bulb holder.
4. Reinstall the cover. Adjust the headlight
beam if necessary.
EE.book Page 91 Monday, June 18, 2001 10:18 AM

8-97
EBU00413
Troubleshooting
Although Yamaha machines receive a rigid in-
spection before shipment from the factory, trouble
may occur during operation.
Any problem in the fuel, compression, or ignition
systems can cause poor starting and loss of pow-
er. The troubleshooting chart describes a quick,
easy procedure for making checks. If your ma-
chine requires any repair, take it to a Yamaha
dealer.
The skilled technicians at a Yamaha dealership
have the tools, experience, and know-how to prop-
erly service your machine. Use only genuine
Yamaha parts on your machine. Imitation parts
may look like Yamaha parts, but they are often in-
ferior. Consequently, they have a shorter service
life and can lead to expensive repair bills.
WARNING
Do not smoke when checking the fuel system.
Fuel can ignite or explode, causing severe in-
jury or property damage. Make sure there are
no open flames or sparks in the area, including
pilot lights from water heaters or furnaces.
EE.book Page 97 Monday, June 18, 2001 10:18 AM