2004 YAMAHA BIG BEAR PRO 400 clutch

Front brake lever free play ................. 8-63
Rear brake pedal and
lever adjustment ............................... 8-65
Adjusting the rear brake light switch... 8-73
Clutch adjustment............................... 8-75
Cable inspection and lubrication ........ 8-77
Brake and shift pedal/
brake lever lubrication ...................... 8-77
Wheel removal ................................... 8-79
Wheel installation ............................... 8-79
Battery ................................................ 8-81
Battery maintenance .......................... 8-85
Fuse replacement............................... 8-87
Replacing a 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
CONVERSION TABLE .......................... 11-1
91011U4SH6B.book Page 3 Tuesday, May 27, 2003 4:39 PM

5-13
EBU12351
Engine oil/transfer gear oil
Make sure the engine oil/transfer gear oil is at the
specified level. Add oil as necessary. (See pages
8-13–8-25.)CAUTION:_

In order to prevent clutch slippage (since
the engine oil also lubricates the clutch),
do not mix any chemical additives. Do not
use oils with a diesel specification of “CD”
or oils of a higher quality than specified. In
addition, do not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign material enters
the crankcase.
_
Recommended engine oil classification:
See page 10-2.
Recommended engine oil/transfer gear oil type
and quantity:
See page 10-2.
U4SH6B.book Page 13 Tuesday, May 27, 2003 4:39 PM

6-17 1. Shift pedal N. Neutral position
1. Pédale de sélection N. Point mort
1. Pedal del cambio N. Posición de punto muerto
EBU00202
Shifting
This model is equipped with a dual, 5-speed for-
ward and 1-speed reverse transmission with a
centrifugal clutch. The transmission allows you to
control the amount of power you have available at
a given speed or for starting, accelerating, climb-
ing hills, reverse, etc. To shift into neutral, return
the throttle lever to its original position and repeat-
edly depress the shift pedal until it stops.CAUTION:
Do not coast for long periods with the engine
off, and do not tow the machine a long dis-
tance. Even in neutral position, the transmis-
sion is only properly lubricated when the
engine is running. Inadequate lubrication may
cause damage.
U4SH6B.book Page 17 Tuesday, May 27, 2003 4:39 PM

7-37
With the engine idling, lift the shift pedal to the 1st
gear position and then release the parking brake.
Apply the throttle slowly and smoothly. The centrif-
ugal clutch will engage and you will start to accel-
erate. Once the ATV has attained adequate
speed, release the throttle and lift the shift pedal to
the 2nd gear position. Release the shift pedal and
apply the throttle smoothly. Use this same proce-
dure as you move into the higher gears. Be sure to
coordinate the use of the throttle and shift pedal
properly. If the throttle is applied too abruptly or if
the throttle is not released during shifting, or if the
shift pedal is not released before applying the
throttle, the front wheels may lift off the ground re-
sulting in a loss of directional control. Avoid higher
speeds until you are thoroughly familiar with the
operation of your ATV.CAUTION:_ Do not shift gears without releasing the throt-
tle. Damage to the engine or drive train may oc-
cur. _
U4SH6B.book Page 37 Tuesday, May 27, 2003 4:39 PM

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*Check valve clearance.
Adjust if necessary.Spark plugCheck condition.
Adjust gap and clean.
Replace if necessary.Air filter elementClean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*Check starter (choke) operation.
Adjust engine idling speed.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 element
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.U4SH6B.book Page 7 Tuesday, May 27, 2003 4:39 PM

8-75 1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
EBU00346
Clutch adjustment
1. Loosen the locknut.
2. Slowly turn the adjusting bolt counterclock-
wise until resistance is felt. Then, turn it 1/8
turn clockwise.
3. Tighten the locknut to specification.NOTE:Turn the adjusting bolt counterclockwise to de-
crease the clutch free play and turn it clockwise to
increase the free play.
Tightening torque:
15 Nm (1.5 m·kgf)
U4SH6B.book Page 75 Tuesday, May 27, 2003 4:39 PM

10-2
10
Noise and vibration level:
Noise level (77/311/EEC) 87.1 dB (A)
Vibration on seat (EN1032, ISO5008) Will not exceed 0.5 m/s
2
Vibration on handlebar (EN1032, ISO5008) Will not exceed 2.5 m/s
2
Engine oil/Transfer gear oil:
Type
Recommended engine oil classification: API Service SE, SF, SG type or higherModel YFM400FP/YFM400FW
-20˚ -10˚ 0˚
10˚20˚ 30˚40˚50˚C
10W/30
15W/4020W/4020W/50
10W/40
5W/30
CAUTION:
In order to prevent clutch slippage (since the en-
gine oil also lubricates the clutch), do not mix any
chemical additives. Do not use oils with a diesel
specification of “CD” or oils of a higher quality
than specified. In addition, do not use oils labeled
“ENERGY CONSERVING II” or higher.
U4SH6B.book Page 2 Tuesday, May 27, 2003 4:39 PM

10-4
Fuel:
Type For Europe: Regular unleaded gasoline only with a
research octance number of 91 or higher
For Australia: Unleaded gasoline only
Fuel tank capacity 13.5 L
Fuel reserve amount 1.3 L
Carburetor:
Type / manufacturer BTM32SH/MIKUNI
Spark plug:
Type (Manufacturer) DR8EA (NGK)
Spark plug gap 0.6–0.7 mm
Clutch type: Wet, centrifugal automatic
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 76/24 (3.167)
Secondary reduction system Shaft drive
Secondary reduction ratio 24/18
× 33/09 (4.889)
Transmission type Constant mesh 5-speed
Operation Left foot operationModel YFM400FP/YFM400FW
U4SH6B.book Page 4 Tuesday, May 27, 2003 4:39 PM