2005 YAMAHA BIG BEAR PRO 400 clutch

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

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
8-17–8-31.)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.
U1C160.book Page 13 Wednesday, May 12, 2004 4:55 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.
U1C160.book Page 17 Wednesday, May 12, 2004 4:55 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. _
U1C160.book Page 37 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

8-25
13. Add the specified amount of the recommend-
ed engine oil, and then install and tighten the
engine oil filler cap.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 oil:
See page 10-2.
Oil quantity:
Without oil filter element replacement:
2.40 L
With oil filter element replacement:
2.50 L
U1C160.book Page 25 Wednesday, May 12, 2004 4:55 PM

8-81 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)
U1C160.book Page 81 Wednesday, May 12, 2004 4:55 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.
U1C160.book Page 2 Wednesday, May 12, 2004 4:55 PM