2005 YAMAHA BIG BEAR PRO 400 oil level

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
U1C160.book Page 2 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

5-13
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

5-15
EBU00495
Final gear oil/Differential gear oil
Make sure the final gear oil/differential gear oil is at
the specified level. Add oil as necessary. (See
pages 8-33–8-41.)
If desired, an SAE 80W90 hypoid gear oil may be
used for all conditions.NOTE:_ GL-4 is a quality and additive rating. GL-5 or GL-6
rated hypoid gear oils may also be used. _
EBU01083
Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
the idle position when released. Have a Yamaha
dealer repair as necessary for proper operation.Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
U1C160.book Page 15 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

8-9
NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add fluid as required.
On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
Replace the brake hoses every four years, or if cracked or damaged.
U1C160.book Page 9 Wednesday, May 12, 2004 4:55 PM

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

8-19 1. Engine oil drain bolt 2. O-ring
3. Compression spring 4. Oil strainer
1. Boulon de vidange de l’huile 2. Joint torique
3. Ressort de compression 4. Crépine à huile
1. Perno de drenaje del aceite de motor 2. Junta tórica
3. Muelle de compresión 4. Colador de aceite
1. Clamp
1. Bride
1. Mordaza
5. If the engine oil is at or below the minimum
level mark, add sufficient oil of the recom-
mended type to raise it to the correct level.CAUTION:_ Make sure that no foreign material enters the
crankcase. _6. Insert the dipstick into the oil filler hole, and
then tighten the engine oil filler cap.
To change the engine oil (with or without oil fil-
ter element cleaning)
1. Place the ATV on a level surface.
2. Warm up the engine for several minutes, and
then turn it off.
3. Place a container under the engine to collect
the used oil.
4. Remove the engine oil filler cap, and then re-
move the engine oil drain bolt to drain the oil
from the crankcase.
U1C160.book Page 19 Wednesday, May 12, 2004 4:55 PM