2005 YAMAHA BIG BEAR PRO 400 tires

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

1-5
4For Oceania
Pour l’Océanie
Para Oceanía4For Europe
Pour l’Europa
Para Europa
4SH-21696-M0
25 kPa
0.25 kgf/cm
2
3.6 psi
25 kPa
0.25 kgf/cm
2
3.6 psi
GBDEF
INLPS
Set with tires cold.
Pneus à froid. Bei kalten Reifen.
Ajuste con los
neumáticos an frío.Impostare a pneumatici
freddi.
Ställ in med kalla däck. Wanneer de banden
koud zijn.
Regular com pneus
frios.
U1C160.book Page 5 Wednesday, May 12, 2004 4:55 PM

2-13

Never operate an ATV in fast flowing water or
in water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.


Always be sure there are no obstacles or peo-
ple behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly.


Always use the size and type of tires specified
in this manual.


Always maintain proper tire pressure as de-
scribed in this manual.


Never modify an ATV through improper instal-
lation or use of accessories.


Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow
instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for brak-
ing.
U1C160.book Page 13 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

5-19
EBU00158
Tires
Always use the recommended tires.
WARNING
Use of improper tires on this ATV, or operation
of this ATV with improper or uneven tire pres-
sure, may cause loss of control, increasing
your risk of accident.
Pay attention to the following.
1. The tires listed below have been approved
by Yamaha Motor Co., Ltd. for this model.
Other tire combinations are not recom-
mended.For Oceania
For Europe
Manufacturer Size Type
Front CHENG SHIN AT25
× 8-12 C828
Rear CHENG SHIN AT25
× 10-12 C828
Manufacturer Size Type
Front DUNLOP AT25
× 8-12 KT404
Rear DUNLOP AT25
× 10-12 KT405B
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5-21
2. The tires should be set to the recommend-
ed pressure:

Recommended tire pressure
Front 25 kPa (0.25 kgf/cm
2, 0.25 bar)
Rear 25 kPa (0.25 kgf/cm2, 0.25 bar)


Check and adjust tire pressures when the
tires are cold.


Tire pressures must be equal on both
sides.
3. Tire pressure below the minimum speci-
fied could cause the tire to dislodge from
the rim under severe riding conditions.
The following are minimums:
Front 22 kPa (0.22 kgf/cm
2, 0.22 bar)
Rear 22 kPa (0.22 kgf/cm2, 0.22 bar)
4. Use no more than the following pressures
when seating the tire beads.
Front 250 kPa (2.5 kgf/cm2, 2.5 bar)
Rear 250 kPa (2.5 kgf/cm2, 2.5 bar)
Higher pressures may cause the tire to
burst. Inflate the tires very slowly and
carefully. Fast inflation could cause the
tire to burst.
U1C160.book Page 21 Wednesday, May 12, 2004 4:55 PM

5-23 1. Low-pressure tire gauge
1. Manomètre basse pression pour pneus
1. Manómetro de baja presión
EBU14450
How to measure tire pressure
Use the low-pressure tire gauge.NOTE:_ The low-pressure tire gauge is included as stan-
dard equipment. Make two measurements of the
tire pressure and use the second reading. Dust or
dirt in the gauge could cause the first reading to be
incorrect. _Set pressure with tires cold. Set tire pressures to
the following specifications:ACE-03E
Recommended
pressureMinimum Maximum
Front25 kPa
(0.25 kgf/cm
2,
0.25 bar)22 kPa
(0.22 kgf/cm
2,
0.22 bar)28 kPa
(0.28 kgf/cm
2,
0.28 bar)
Rear25 kPa
(0.25 kgf/cm
2,
0.25 bar)22 kPa
(0.22 kgf/cm
2,
0.22 bar)28 kPa
(0.28 kgf/cm
2,
0.28 bar)
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6-21
EBU00208
To decelerate:
When slowing down or stopping, release the throt-
tle and apply the brakes smoothly and evenly. As
you slow down, shift to a lower gear. Be sure that
the engine has sufficiently slowed before engaging
a lower gear. Improper use of the brakes or shift-
ing can cause the tires to lose traction, reducing
control and increasing the possibility of an acci-
dent.
WARNING
Make sure the engine has sufficiently slowed
before shifting to a lower gear. Engaging a low-
er gear when the engine speed is too high
could make the wheels stop rotating. This
could cause loss of control, an accident and
injury. It could also cause engine or drive train
damage.
U1C160.book Page 21 Wednesday, May 12, 2004 4:55 PM