lock YAMAHA BIG BEAR PRO 400 2003 User Guide

8-53 1. Locknut 2. Adjuster
1. Contre-écrou 2. Dispositif de réglage
1. Contratuerca 2. Ajustador
EBU00303
Valve clearance adjustment
The correct valve clearance changes with use, re-
sulting in improper fuel/air supply or engine noise.
To prevent this, the valve clearance must be ad-
justed regularly. This adjustment however, should
be left to a professional Yamaha service techni-
cian.
EBU00305
Select lever safety system cable adjustment
The select lever safety system cable stretches
with use, resulting in improper function.
To prevent this, the cable must be adjusted regu-
larly. This adjustment, however, should be left to a
Yamaha dealer.
EE.book Page 53 Monday, June 18, 2001 10:18 AM

8-55 1. Adjusting bolt 2. Locknut a. 3 ~ 5 mm
1. Bouchon de réglage 2. Contre-écrou
1. Perno de ajuste 2. Contratuerca
1. Brake pad a. Wear limit: 1 mm
1. Plaquette de frein a. Limite d’usure: 1 mm
1. Pastillas del freno a. Límite de desgaste: 1 mm
EBU00307
Throttle lever adjustmentNOTE:Adjust the engine idling speed before adjusting the
throttle lever free play.1. Loosen the locknut.
2. Turn the adjusting bolt until the throttle lever
free play is 3 ~ 5 mm.
3. Tighten the locknut.
EBU00312
Front brake pad inspection
Inspect the brake pads for damage and wear. If
the thickness is less than the specified value, have
a Yamaha dealer replace the pads.NOTE:The wheels need to be removed to inspect the
brake pads. See page 8-81 for removal proce-
dures.
EE.book Page 55 Monday, June 18, 2001 10:18 AM

8-59
3. Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reac-
tion and lead to poor brake performance.
4. Be careful that water does not enter the mas-
ter cylinder when refilling. Water will signifi-
cantly lower the boiling point of the fluid and
may result in vapor lock.
5. Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
6. Have a Yamaha dealer check the cause if the
brake fluid level goes down. Recommended brake fluid:DOT 4
EE.book Page 59 Monday, June 18, 2001 10:18 AM

8-67 1. Locknut 2. Adjusting bolt a. 5 mm
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
EBU00334*
Rear brake pedal and lever adjustment
Pedal height adjustment
1. Loosen the locknut.
2. Turn the adjusting bolt so that the top of the
brake pedal is positioned 5 mm below the top
of the footrest.
3. Tighten the locknut.
EE.book Page 67 Monday, June 18, 2001 10:18 AM

8-71 1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
1. Adjusting nut (brake cable) a. 0 ~ 1 mm
1.Écrou de réglage (câble de frein)
1. Tuerca de ajuste (cable de freno)
Brake lever free play adjustment
1. Loosen the locknut and fully turn in the ad-
justing bolt at the brake lever.
2. Screw in the adjusting nut on brake cable to
provide a gap of 0 ~ 1 mm between the lever
and the pin.
EE.book Page 71 Monday, June 18, 2001 10:18 AM

8-73 1. Locknut 2. Adjusting bolt a. 4 ~ 7 mm
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
3. Turn the adjusting bolt until free play at the
brake lever pivot is 4 ~ 7 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.
EE.book Page 73 Monday, June 18, 2001 10:18 AM

8-77 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)
EE.book Page 77 Monday, June 18, 2001 10:18 AM

8-91 1. Cover
1. Cache
1. Cubierta
1. Bulb holder
1. Douille d’ampoule
1. Portalámparas
EBU00402
Replacing the headlight bulb
If the headlight bulb burns out, replace the bulb as
follows:
1. Remove the cover.
2. Turn the bulb holder counterclockwise and
remove the defective bulb.
WARNING
The headlight bulb is hot when it is on and im-
mediately 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. Reinstall the cover. Adjust the headlight
beam if necessary.
EE.book Page 91 Monday, June 18, 2001 10:18 AM

8-93 1. Adjusting screw (× 2)
1. Vis de réglage (× 2)
1. Tornillo de ajuste (× 2)
EBU00409
Headlight beam adjustmentCAUTION:
It is advisable to have a Yamaha dealer make
this adjustment.1. Vertical adjustment:
To raise the beam, turn the adjusting screw
clockwise.
To lower the beam, turn the screw counter-
clockwise.
EE.book Page 93 Monday, June 18, 2001 10:18 AM

8-95 1. Storage box 2. Nut (× 2)
1. Compartiment de rangement 2.Écrou (× 2)
1. Caja portaobjetos 2. Tuerca (× 2)
1. Bulb holder 2. Bulb
1. Fixation d’ampoule 2. Ampoule
1. Portabombillas 2. Bombilla
EBU00945
Tail/brake light bulb replacement
1. Open the storage box. (See page 4-37.)
2. Remove the nuts together with washers.
3. Remove the bulb holder (together with the
bulb) by turning it counterclockwise.
4. Remove the defective bulb from the bulb
holder by pushing it inward and turning it
counterclockwise.
5. Install a new bulb in the bulb holder by push-
ing it inward and turning it clockwise.
6. Install the bulb holder (together with the
bulb).
7. Install the washers, and then install the nuts.
EE.book Page 95 Monday, June 18, 2001 10:18 AM