2005 YAMAHA BIG BEAR PRO 400 brake 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
Speedometer ........................................ 4-9
Fuel gauge ......................................... 4-11
Handlebar switches ............................ 4-13
Throttle lever ...................................... 4-17
Speed limiter ...................................... 4-19
Front brake lever ................................ 4-21
Brake pedal and rear brake lever ....... 4-23
Parking brake ..................................... 4-25
Shift pedal .......................................... 4-27
1234
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 ....... 5-15
Throttle lever ...................................... 5-15
Fittings and fasteners......................... 5-17
Lights ................................................. 5-17
Switches............................................. 5-17
Tires ................................................... 5-19
How to measure tire pressure ............ 5-23
5
U1C160.book Page 1 Wednesday, May 12, 2004 4:55 PM

Brake pedal and rear brake lever
adjustment........................................ 8-71
Adjusting the rear brake light switch... 8-79
Clutch adjustment............................... 8-81
Cable inspection and lubrication ........ 8-83
Brake and shift pedal/brake lever
lubrication ......................................... 8-83
Wheel removal ................................... 8-85
Wheel installation ............................... 8-85
Battery ................................................ 8-87
Battery maintenance .......................... 8-91
Fuse replacement............................... 8-93
Replacing a headlight bulb ................. 8-97
Headlight beam adjustment................ 8-99
Tail/brake light bulb replacement ..... 8-101
Troubleshooting................................ 8-103
Troubleshooting chart....................... 8-105
CLEANING AND STORAGE ................... 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................. 10-1
CONVERSION TABLE .......................... 11-1
91011U1C160.book Page 3 Wednesday, May 12, 2004 4:55 PM

3-1
EBU00032
1-DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear carrier
2. Seat
3. Front carrier
4. Brake pedal
5. Reverse lock
release wire
6. Headlight
7. Fuel cock
8. Tail/brake light
9. Recoil starter
10. Shift pedal
11. Rear brake lever12. Parking brake
13. Auxiliary DC jack
14. Speedometer
15. Front brake lever
16. Main switch
17. Throttle lever
18. Fuel gauge
19. Drive select lever
20. Horn
21. Starter (choke)
22. Handlebar switchesNOTE:TheThe machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U1C160.book Page 1 Wednesday, May 12, 2004 4:55 PM

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.
U1C160.book Page 29 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

5-17
EBU11620
Fittings and fasteners
Always check the tightness of chassis fittings and
fasteners before a ride. Take the machine to a
Yamaha dealer or refer to the Service Manual for
correct tightening torque.
EBU01003
Lights
Check the headlights and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU11700
Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper op-
eration.
U1C160.book Page 17 Wednesday, May 12, 2004 4:55 PM

6-5 a. Starter (choke) lever
1. Fully-open
2. Half open
3. Closed
a. Starter (enrichisseur)
1. Complètement ouvert
2. Mi-ouvert
3. Fermé
a. Palanca del estárter (estrangulador)
1. Abre completamente
2. Semiabierto
3. Cerrado
NOTE:

When the transmission is in neutral, the neu-
tral indicator light should come on. If the light
does not come on, ask a Yamaha dealer to in-
spect it.


The engine can be started with the transmis-
sion and drive select lever in any position if the
rear brake lever is applied. However, it is rec-
ommended to shift into neutral before starting
the engine.
5. Use the starter (choke) in reference to the fig-
ure:
Position
1: Cold engine start-
ambient temperature below 5°C.
Position
2: Cold engine start-
ambient temperature at 0°C–30°C
and warming up position.
Position
3: Cold engine start-
ambient temperature above 25°C
and warm engine start position.
6. Completely close the throttle lever and start
the engine by pushing the start switch.
U1C160.book Page 5 Wednesday, May 12, 2004 4:55 PM

6-13 a. High b. Low c. Reverse
a. H (grande) b. L (petite) c. R (marche arrière)
a. H (alta) b. L (baja) c. R (marcha atrás)
Shifting: Low – ReverseNOTE:_

The select lever cannot be shifted into reverse
from low without applying the rear brake ped-
al.


Shifting into reverse can be done with the
transmission in any gear.
_1. Bring the machine to a complete stop and re-
turn the throttle lever to the closed position.
2. Apply the rear brake pedal.
3. Shift from low to reverse and vice versa by
moving the drive select lever along the shift
guide.NOTE:_ When in reverse, the reverse indicator light should
be on. If the light does not come on, ask a Yamaha
dealer to inspect the machine. _4. Check behind for people or obstacles, then
release the rear brake pedal.
U1C160.book Page 13 Wednesday, May 12, 2004 4:55 PM