2005 YAMAHA BIG BEAR PRO 400 boot

Tire wear limit......................................5-25
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
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
Crossing a slope .................................7-61
Crossing through shallow water ..........7-65
Riding over rough terrain ....................7-69
67
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 and oil filter element........... 8-17
Transfer gear oil replacement............. 8-29
Final gear oil ....................................... 8-33
Differential gear oil replacement ......... 8-39
Axle boots ........................................... 8-41
Spark plug inspection ......................... 8-43
Air filter cleaning ................................. 8-47
Carburetor adjustment ........................ 8-55
Idle speed adjustment ........................ 8-57
Valve clearance adjustment ............... 8-59
Select lever safety system cable
adjustment ........................................ 8-59
Throttle lever adjustment .................... 8-61
Front brake pad check ........................ 8-61
Rear brake shoe inspection ................ 8-63
Brake fluid level check ........................ 8-63
Brake fluid replacement ...................... 8-67
Front brake lever free play.................. 8-69
8
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2-3

Never allow a child under age 16 to operate an
ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she
does not have the abilities to operate it safely.


Never carry a passenger on an ATV.


Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways, park-
ing lots and paved streets.


Never operate an ATV on any paved street,
paved road or motorway.


Watch carefully for other vehicles when operat-
ing on unpaved public streets or roads. Make
sure you know your country’s laws and regula-
tions before you ride on unpaved public streets
or roads.


Never operate an ATV without wearing an ap-
proved motorcycle helmet that fits properly.
You should also wear eye protection (goggles
or face shield), gloves, boots, a long-sleeved
shirt or jacket, and long pants.


Never consume alcohol or drugs before or
while operating this ATV.
U1C160.book Page 3 Wednesday, May 12, 2004 4:55 PM

5-1
EBU00113
1-PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-61–8-79
Rear brakeCheck operation, pedal height and free play.
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oil/
Transfer gear oilCheck oil level.
Fill with oil if necessary.5-13, 8-17–8-27
Final gear oil/
Differential gear oilCheck for leakage. 5-15, 8-29–8-41
ThrottleCheck for proper throttle cable operation. 5-15, 8-61
Wheels and tiresCheck tire pressure, wear and damage.5-19–5-25,
8-85–8-87
Fittings and fastenersCheck all fittings and fasteners. 5-17
Lights and switchesCheck for proper operation. 5-17, 8-97–8-101
Axle bootsCheck operation. 8-41
U1C160.book Page 1 Wednesday, May 12, 2004 4:55 PM

7-11 1. Protective clothing 2. Goggles
3. Gloves 4. Boots
5. Helmet
1. Vêtement de protection 2. Lunettes
3. Gants 4. Bottes
5. Casque
1. Vestimenta adequada 2. Gafas
3. Guantes 4. Botas
5. Homologado
Apparel
Always wear an approved helmet that fits properly.
You should also wear:
eye protection
(goggles or face shield)
gloves
boots
long-sleeved shirt or jacket
long pants
WARNING
_ Never operate this ATV without wearing an ap-
proved motorcycle helmet, eye protection and
protective clothing. Operating without an ap-
proved motorcycle helmet increases your
chances of a severe head injury or death in the
event of an accident. Operating without eye
protection can result in an accident and in-
creases your chances of a severe injury in the
event of an accident. Operating without protec-
tive clothing increases your chances of severe
injury in the event of an accident. _
U1C160.book Page 11 Wednesday, May 12, 2004 4:55 PM

8-8
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.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 8-9.
Correct if necessary.Rear brake*Check operation.
Adjust if necessary.Clutch*Check operation.
Adjust if necessary.Drive select lever
safety system*Check operation.
Adjust if necessary.Wheels*Check balance/damage/runout.
Repair if necessary.Wheel bearing*Check bearing assemblies for looseness/damage.
Replace if damaged.Steering system*Check operation.
Replace if damaged.
Check toe-in.
Adjust if necessary.Axle boots*Check condition.
Replace if damaged.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
U1C160.book Page 8 Wednesday, May 12, 2004 4:55 PM

8-41 1. Boot (× 2)
1. Soufflet (× 2)
1. Guardapolvo (× 2)
1. Boot (× 2)
1. Soufflet (× 2)
1. Guardapolvo (× 2)
CAUTION:_ Be sure no foreign material enters the differen-
tial gear case. _6. Install the filler bolt and tighten it to specifica-
tion.
7. Check for oil leakage. If oil leakage is found,
check for the cause.
EBU00862
Axle boots
Check the protective boots for holes or tears. If any
damage is found, have them replaced by a
Yamaha dealer.Tightening torque:
Filler bolt (differential gear case):
23 Nm (2.3 m·kgf)
U1C160.book Page 41 Wednesday, May 12, 2004 4:55 PM