2004 YAMAHA BIG BEAR PRO 400 ignition

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.
U4SH6B.book Page 15 Tuesday, May 27, 2003 4:39 PM

4-13 1. Light switch “//OFF”
2. Engine stop switch “/”
3. Start switch “”
4. Horn switch “”
1. Contacteur d’éclairage “//OFF”
2. Coupe-circuit du moteur “/”
3. Contacteur du démarreur “”
4. Contacteur de l’avertisseur “”
1. Interruptor de luce “//OFF”
2. Interruptor de paro del motor “/”
3. Interruptor de arranque “”
4. Interruptor de la bocina “”
EBU00053
Handlebar switches
EBU12050
Engine stop switch “/”
Make sure that the engine stop switch is set to
“” before starting the engine. The engine stop
switch controls ignition and can be used at all
times to stop the engine, especially in an emer-
gency. The engine will not start or run when the
engine stop switch is set 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.
U4SH6B.book Page 13 Tuesday, May 27, 2003 4:39 PM

8-83
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.
U4SH6B.book Page 83 Tuesday, May 27, 2003 4:39 PM

8-87 1. Main fuse 2. Spare fuse
1. Fusible principal 2. Fusible de rechange
1. Fusible principal 2. Fusible de repuesto
EBU08990
Fuse replacement
1. The main fuse case and the fuse box are lo-
cated under the seat.
2. If a fuse is blown, turn off the main switch and
install a new fuse of the specified amperage.
Then turn on the switches. 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. _
Specified fuses:
Main fuse: 30 A
Headlight fuse: 15 A
Ignition fuse: 10 A
Auxiliary DC jack fuse: 10 A
Signaling system fuse: 10 A
U4SH6B.book Page 87 Tuesday, May 27, 2003 4:39 PM

8-89 1. Headlight fuse 2. Ignition fuse
3. Auxiliary DC jack fuse 4. Signaling system fuse
5. Spare fuse (× 2)
1. Fusible de phare 2. Fusible d’allumage
3. Fusible de prise pour accessoires
4. Fusible du système de signalisation
5. Fusible de rechange (× 2)
1. Fusible del faro 2. Fusible del encendido
3. Fusible de la toma de CC auxiliar
4. Fusible del sistema de señalización
5. Fusible de repuesto (× 2)
CAUTION:_ To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse. _
U4SH6B.book Page 89 Tuesday, May 27, 2003 4:39 PM

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.
U4SH6B.book Page 97 Tuesday, May 27, 2003 4:39 PM

8-99
EBU00440Troubleshooting chart1. Fuel
Check if there is fuel
in the fuel tank.There is fuel.Turn the fuel cock
lever to “OFF”.No fuel.Fuel cock is
clogged.
Clean the
fuel cock. Some fuel.Turn the fuel cock
lever to “RES”.Restart the engine.
No fuel.Supply fuel.
2. Compression
Use the electric
starter to see if
there is compression.There is compression.
Compression normal.
No compression.Ask a Yamaha dealer to
inspect.
3. Ignition
Remove the
spark plug and
check electrodes.WetWipe clean with dry cloth.
DryAttach spark plug cap and
ground to chassis.Use the
electric starter.Spark is good.Ignition system is
normal.
Spark is weak.
Adjust the spark plug gap
or replace the spark plug. No spark.
Ask a Yamaha dealer to
inspect. 4. Battery
Use the electric starter.Engine turns over
quickly.Battery is good.
Engine turns over
slowly.Check the connections.Check the
fuel flow.
Turn the fuel cock
lever to “ON”.
Remove the fuel hose
from the fuel cock.
U4SH6B.book Page 99 Tuesday, May 27, 2003 4:39 PM

10-6
Suspension:
Front suspension Double wishbone
Rear suspension Swingarm (monocross)
Shock absorber:
Front shock absorber Coil spring / oil damper
Rear shock absorber Coil spring / oil damper
Wheel travel:
Front wheel travel 100.0 mm
Rear wheel travel 110.0 mm
Electrical:
Ignition system D.C. C.D.I.
Generator system A.C. magneto
Battery type YTX 20L-BS
Battery voltage, capacity 12 V, 18.0 AH
Headlight type: Krypton bulb
Bulb voltage, wattage
× quantity:
Headlight 12 V, 30.0 W / 30.0 W
× 2
Tail / brake light 12 V, 5.0 W / 21.0 W × 1
Meter light 14 V, 3.0 W
× 1
Indicator light:
Neutral 12 V, 1.7 W
× 1
Reverse 12 V, 1.7 W × 1
Oil temperature 12 V, 1.7 W
× 1 Model YFM400FP/YFM400FW
U4SH6B.book Page 6 Tuesday, May 27, 2003 4:39 PM