2005 YAMAHA BIG BEAR PRO 400 check oil

8-17 1. Engine oil filler cap
1. Bouchon de remplissage d’huile de moteur
1. Tapa del orificio de llenado de aceite de motor
1. Dipstick 2. Maximum level mark
3. Minimum level mark
1. Jauge 2. Repère de niveau maximum
3. Repère de niveau minimum
1. Varilla 2. Marca de nivel máximo
3. Marca de nivel minimo
EBU12334
Engine oil and oil filter element
The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter element cleaned at the intervals speci-
fied in the periodic maintenance and lubrication
chart.
To check the engine oil level
1. Place the ATV on a level surface.
2. Warm up the engine for several minutes, and
then turn it off.
3. Wait a few minutes until the oil level settles
before checking.
4. Remove the engine oil filler cap, and then
wipe the dipstick off with a clean rag. Insert
the dipstick in the filler hole (without screwing
it in), and then remove it again to check the oil
level.NOTE:_ The oil level should be between the minimum and
maximum level marks. _
U1C160.book Page 17 Wednesday, May 12, 2004 4:55 PM

8-21 1. Engine oil filter element cover bolt (× 3)
2. Oil filter element cover
3. Bolt
1. Boulon de couvercle de l’élément de filtre à huile moteur (× 3)
2. Couvercle de l’élément de filtre à huile
3. Boulon
1. Perno de la tapa del elemento del filtro de aceite de motor (× 3)
2. Tapa del elemento del filtro de aceite
3. Perno
CAUTION:_ When removing the engine oil drain bolt, the
compression spring, oil strainer and O-ring
will fall out. Take care not to lose these parts. _NOTE:_ Skip steps 5–11 if the oil filter element is not being
cleaned. _5. Remove the shift pedal by removing the bolt.
6. Remove the clamp by removing the screw.
7. Remove the oil filter element cover by remov-
ing the bolts, and then remove the oil filter el-
ement.
8. Clean the oil strainer and oil filter element
with solvent.
9. Check the O-ring for damage and replace it if
necessary.
10. Install the oil filter element and O-ring.NOTE:_ Make sure the O-ring is seated properly. _
U1C160.book Page 21 Wednesday, May 12, 2004 4:55 PM

8-27
14. Install the clamp by installing the screw.
15. Install the shift pedal by installing the bolt.
16. Start the engine, and then let it idle for seve-
ral minutes while checking it for oil leakage. If
oil is leaking, immediately turn the engine off
and check for the cause.
17. Turn the engine off, and then check the oil
level and correct it if necessary.
U1C160.book Page 27 Wednesday, May 12, 2004 4:55 PM

8-31 1. Drain bolt
1. Boulon de vidange
1. Perno de drenaje
6. Fill the transfer gear case with oil.CAUTION:
Be sure no foreign material enters the transfer
gear case.7. Install the filler bolt and tighten to specifica-
tion.
8. Check for oil leakage. If oil leakage is found,
check for the cause.
9. Reinstall the transfer gear case guard.Recommended oil: See page 10-2
Quantity:
Transfer gear oil and engine oil with
filter replacement:
2.8 L
Tightening torque:
Filler bolt (transfer gear case):
23 Nm (2.3 m·kgf)
U1C160.book Page 31 Wednesday, May 12, 2004 4:55 PM

8-33 1. Final gear oil 2. Correct oil level
3. Oil filler bolt
1. Huile de transmission finale 2. Niveau d’huile correct
3. Boulon de l’orifice de remplissage d’huile
1. Aceite de la transmisión final 2. Nivel de aceite correcto
3. Perno del orificio de llenado de aceite
EBU11453
Final gear oil
Checking the final gear oil
1. Place the ATV on a level surface.
2. Remove the oil filler bolt, and then check the
oil level in the final gear case.NOTE:_ The oil level should be at the brim of the filler hole. _3. If the oil is below the brim of the filler hole,
add sufficient oil of the recommended type to
raise it to the correct level.CAUTION:_ Be sure no foreign material enters the final
gear case. _4. Install the oil filler bolt, and then tighten it to
the specified torque.
Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf)
U1C160.book Page 33 Wednesday, May 12, 2004 4:55 PM

8-37
CAUTION:_ Be sure no foreign material enters the final
gear case. _7. Install the oil filler bolt, and then tighten it to
the specified torque.
8. Check for oil leakage. If oil leakage is found,
check for the cause.
9. Install the final gear case cover bolts, and
then tighten them to the specified torque. Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf)
Tightening torque:
Final gear case cover bolt:
23 Nm (2.3 m·kgf)
U1C160.book Page 37 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

8-65
Observe these precautions:

When checking the brake fluid level, make sure
the top of the brake fluid reservoir is level.


Use only the designated quality brake fluid, oth-
erwise, the rubber seals may deteriorate, caus-
ing leakage and poor brake performance.


Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor brake performance.


Be careful that water does not enter the brake
fluid reservoir when refilling. Water will signifi-
cantly lower the boiling point of the fluid and
may result in vapor lock.


Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid im-
mediately.


Have a Yamaha dealer check the cause if the
brake fluid level goes down. Recommended brake fluid: DOT 4
U1C160.book Page 65 Wednesday, May 12, 2004 4:55 PM