warning YAMAHA BIG BEAR PRO 400 2004 Workshop Manual

8-5
WARNING
Never modify this ATV through improper in-
stallation or use of accessories. Improper in-
stallation of accessories or modification of this
vehicle may cause changes in handling which
in some situations could lead to an accident.
All parts and accessories added to this vehicle
should be genuine Yamaha or equivalent com-
ponents designed for use on this ATV and
should be installed and used according to in-
structions. If you have questions, consult an
authorized Yamaha ATV dealer.
U4SH6B.book Page 5 Tuesday, May 27, 2003 4:39 PM

8-43 1. Air filter element
1.Élément du filtre à air
1. Elemento del filtro de aire
1. Element plate 2. Air filter element
3. Frame
1. Plaque d’élément 2.Élément du filtre à air
3. Armature
1. Placa del elemento 2. Elemento del filtro de aire
3. Bastidor
3. Remove the air filter element.
4. Remove the air filter element from the frame.
5. Wash the air filter element gently but thor-
oughly in solvent.
WARNING
_ Always use parts cleaning solvent to clean the
air filter element. Never use low flash point sol-
vents or gasoline to clean the air filter element
because the engine could catch fire or ex-
plode. _6. Squeeze the excess solvent out of the air fil-
ter element and let it dry.CAUTION:_ Do not twist the air filter element when squeez-
ing it. _7. Inspect the air filter element. If damaged, re-
place it.
8. Apply SAE 10W30 engine oil to the air filter
element.NOTE:_ The air filter element should be wet but not drip-
ping. _
U4SH6B.book Page 43 Tuesday, May 27, 2003 4:39 PM

8-63 a. Front brake lever free play
a. Jeu du levier de frein avant
a. Juego de la palanca del freno delantero
EBU11880
Front brake lever free play
The front brake lever should have a free play of
zero mm at the lever end. If not, have a Yamaha
dealer check the brake system.
WARNING
_ Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly
and that the free play is correct.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
_
U4SH6B.book Page 63 Tuesday, May 27, 2003 4:39 PM

8-71 1. Locknut 2. Adjusting bolt
a. Rear brake lever free play
1. Contre-écrou 2. Boulon de réglage
a. Jeu du levier de frein arrière
1. Contratuerca 2. Perno de ajuste
a. Juego de la palanca de freno trasero
3. Turn the adjusting bolt until free play at the
brake lever pivot is 4.0–7.0 mm.
4. Tighten the locknut.
WARNING
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly
and that the free play is correct.


Make sure the brakes do not drag.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
U4SH6B.book Page 71 Tuesday, May 27, 2003 4:39 PM

8-77
EBU00570
Cable inspection and lubrication
WARNING
Inspect cables frequently and replace if dam-
aged. Corrosion can result when the outer cov-
ering of control cables becomes damaged.
Cables can also become frayed or kinked. Op-
eration of controls could be restricted, which
could cause an accident or injury.Lubricate the inner cables and the cable ends. If
the cables do not operate smoothly, ask a Yamaha
dealer to replace them.
EBU00727
Brake and shift pedal/brake lever lubrication
Lubricate the pivoting parts of each lever and ped-
al.Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U4SH6B.book Page 77 Tuesday, May 27, 2003 4:39 PM

8-83
WARNING
Battery electrolyte is poisonous and danger-
ous, causing severe burns, etc. It contains sul-
furic acid. Avoid contact with skin, eyes or
clothing.
Antidote:

EXTERNAL: Flush with water.


INTERNAL: Drink large quantities of water
or milk. Follow with milk of magnesia, beat-
en egg or vegetable oil. Call a physician
immediately.


EYES: Flush with water for 15 minutes and
get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes or other sources of
ignition away. Ventilate when charging or us-
ing in an enclosed space. Always shield your
eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
U4SH6B.book Page 83 Tuesday, May 27, 2003 4:39 PM

8-87 1. Main fuse 2. Spare fuse
1. Fusible principal 2. Fusible de rechange
1. Fusible principal 2. Fusible de repuesto
EBU08990
Fuse replacement
1. The main fuse case and the fuse box are lo-
cated under the seat.
2. If a fuse is blown, turn off the main switch and
install a new fuse of the specified amperage.
Then turn on the switches. If the fuse immedi-
ately blows again, consult a Yamaha dealer.
WARNING
_ Always use a fuse of the specified rating. Nev-
er use any type of material or object in place of
the proper fuse. An improper fuse can cause
damage to the electrical system which could
lead to a fire. _
Specified fuses:
Main fuse: 30 A
Headlight fuse: 15 A
Ignition fuse: 10 A
Auxiliary DC jack fuse: 10 A
Signaling system fuse: 10 A
U4SH6B.book Page 87 Tuesday, May 27, 2003 4:39 PM

8-91 1. Headlight bulb holder cover
1. Cache de la fixation d’ampoule de phare
1. Cubierta del portabombillas del faro
1. Bulb holder
1. Douille d’ampoule
1. Portalámparas
EBU01236
Replacing a headlight bulb
If a headlight bulb burns out, replace the bulb as
follows.
1. Remove the bulb holder cover.
2. Turn the bulb holder counterclockwise and
remove the defective bulb.
WARNING
_ A headlight bulb is hot when it is on and imme-
diately after it is turned off. Wait for the bulb to
cool before touching or removing it. You can
be burned, or a fire could start if the bulb
touches something flammable. _3. Put a new bulb into position and secure it in
place with the bulb holder.
4. Install the bulb holder cover.
5. Adjust the headlight beam if necessary.
U4SH6B.book Page 91 Tuesday, May 27, 2003 4:39 PM

8-97
EBU00413
Troubleshooting
Although Yamaha machines receive a rigid in-
spection before shipment from the factory, trouble
may occur during operation.
Any problem in the fuel, compression, or ignition
systems can cause poor starting and loss of pow-
er. The troubleshooting chart describes a quick,
easy procedure for making checks. If your ma-
chine requires any repair, take it to a Yamaha
dealer.
The skilled technicians at a Yamaha dealership
have the tools, experience, and know-how to prop-
erly service your machine. Use only genuine
Yamaha parts on your machine. Imitation parts
may look like Yamaha parts, but they are often in-
ferior. Consequently, they have a shorter service
life and can lead to expensive repair bills.
WARNING
Do not smoke when checking the fuel system.
Fuel can ignite or explode, causing severe in-
jury or property damage. Make sure there are
no open flames or sparks in the area, including
pilot lights from water heaters or furnaces.
U4SH6B.book Page 97 Tuesday, May 27, 2003 4:39 PM

9-5
7. Automotive type wax may be applied to all
painted and chrome plated surfaces. Avoid
combination cleaner-waxes. Many contain
abrasives which may mar the paint or protec-
tive finish.
When finished, start the engine and let it idle
for several minutes.
WARNING
Wet brakes may have reduced stopping ability,
increasing the chance of an accident. Test the
brakes after washing. Apply the brakes several
times at slow speeds to let friction dry out the
linings.
U4SH6B.book Page 5 Tuesday, May 27, 2003 4:39 PM