2005 YAMAHA BIG BEAR PRO 400 torque

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

8-3 1. Owner’s manual
2. Low-pressure tire gauge
1. Manuel du propriétaire
2. Manomètre basse pression pour pneus
1. Manual del propietario
2. Manómetro de baja presión
1. Owner’s tool kit
1. Trousse à outils du propriétaire
1. Equipo de herramientas del propietario
EBU00256
Owner’s manual and tool kit
You are recommended to put this owner’s manual
and low-pressure tire gauge in the vinyl bag and
always carry them in the storage box. Put the own-
er’s tool kit in the space under the seat. The ser-
vice information included in this manual is
intended to provide you, the owner, with the nec-
essary information for completing your own pre-
ventive maintenance and minor repairs. The tools
provided in the Owner’s tool kit are sufficient for
this purpose, except that a torque wrench is also
necessary to properly tighten nuts and bolts.NOTE:If you do not have a torque wrench available dur-
ing a service operation requiring one, take your
machine to a Yamaha dealer to check the torque
settings and adjust them as necessary.
U1C160.book Page 3 Wednesday, May 12, 2004 4:55 PM

8-23 1. Engine oil filter element 2. O-ring (× 2)
1.Élément du filtre à huile moteur 2. Joint torique (× 2)
1. Element del filtro de aceite de motor 2. Junta tórica (× 2)
11. Install the oil filter element cover by installing
the bolts, and then tighten them to the speci-
fied torque.
12. Install the oil strainer, compression spring,
O-ring and engine oil drain bolt. Tighten the
engine oil drain bolt to the specified torque.CAUTION:_ Before installing the engine oil drain bolt, be
sure to install the O-ring, compression spring
and oil strainer. _
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf)
Tightening torque:
Engine oil drain bolt:
32 Nm (3.2 m·kgf)
U1C160.book Page 23 Wednesday, May 12, 2004 4:55 PM

8-29 1. Bolt (× 3)
1. Boulon (× 3)
1. Perno (× 3)
1. Oil filler bolt
1. Boulon de l’orifice de remplissage d’huile
1. Perno del orificio de llenado de aceite
EBU00462
Transfer gear oil replacementNOTE:When replacing the transfer gear oil, replace the
engine oil also.1. Remove the transfer gear case guard.
2. Place the machine on a level place.
3. Place a container under the transfer gear
case.
4. Remove the oil filler bolt and drain bolt to
drain the oil.
5. Install the drain bolt and tighten to specifica-
tion.
Tightening torque:
Drain bolt (transfer gear case):
20 Nm (2.0 m·kgf)
U1C160.book Page 29 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

8-35 1. Bolt (× 3)
1. Boulon (× 3)
1. Perno (× 3)
1. Drain bolt
1. Boulon de vidange
1. Perno de drenaje
Replacing the final gear oil
1. Remove the final gear case cover by remov-
ing the bolts.
2. Place the ATV on a level surface.
3. Place a container under the final gear case to
collect the used oil.
4. Remove the oil filler bolt and the drain bolt to
drain the oil.
5. Install the drain bolt, and then tighten it to the
specified torque.
6. Add the recommended final gear oil to the
brim of the filler hole. Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf)
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
Oil quantity:
0.19 L
U1C160.book Page 35 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