brake YAMAHA BIG BEAR PRO 400 2003 Service Manual

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

8-75 1. Rear brake light switch 2. Adjusting nut
1. Contacteur de feu stop sur frein arrière 2.Écrou de réglage
1. Interruptor de la luz de freno trasero 2. Tuerca de ajuste
EBU00834
Adjusting the rear brake light switch
The rear brake light switch, which is activated by
the brake pedal and brake levers, is properly ad-
justed when the brake light comes on just before
braking takes effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding the rear brake
light switch in place. To make the brake light come
on earlier, turn the adjusting nut in direction
a. To
make the brake light come on later, turn the adjust-
ing nut in direction
b.
EE.book Page 75 Monday, June 18, 2001 10:18 AM

8-79
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.
EBU00652
Brake and shift pedal/brake lever lubrication
Lubricate the pivoting parts of each lever and ped-
al.Recommended lubricant:
Engine oil
Recommended lubricant:
Engine oil
EE.book Page 79 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

9-3
CAUTION:
Excessive water pressure may cause water
seepage and deterioration of wheel bearings,
brakes, transmission seals and electrical de-
vices. Many expensive repair bills have result-
ed from improper high pressure detergent
applications such as those available in coin-
operated car washers.4. Once the majority of the dirt has been hosed
off, wash all surfaces with warm water and
mild, detergent-type soap. An old toothbrush
or bottle brush is handy for hard-to-get-at
places.
5. Rinse the machine off immediately with clean
water and dry all surfaces with a chamois,
clean towel or soft absorbent cloth.
6. Clean the seat with a vinyl upholstery cleaner
to keep the cover pliable and glossy.
EE.book Page 3 Monday, June 18, 2001 10:18 AM

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.
EE.book Page 5 Monday, June 18, 2001 10:18 AM

10-5
Gear Ratio:
Chassis:
Frame type Steel tube frame
Caster angle 2.5°
Trail 15 mm
Tire:
Ty p e T u b e l e s s
Size (front) AT25
× 8-12
(rear) AT25
× 10-12
Brake:
Front brake type Disc brake
operation Right hand operation
Rear brake type Drum brake
operation Left hand and right foot operation Model YFM400FP/YFM400FW
38/13
× 20/24
× 22/20 (2.680) 38/13
× 20/24
× 27/15 (4.384)
34/18
× 20/24
× 22/20 (1.731)
30/22
× 20/24
× 22/20 (1.249)
26/25
× 20/24
× 22/20 (0.953)
24/29
× 20/24
× 22/20 (0.759)
36/13
× 27/16 (4.673)34/18
× 20/24
× 27/15 (2.832)
30/22
× 20/24
× 27/15 (2.044)
26/25
× 20/24
× 27/15 (1.560)
24/29
× 20/24
× 27/15 (1.242) High range Low range
1st
2nd
3rd
4th
5th
Reverse
EE.book Page 5 Monday, June 18, 2001 10:18 AM

10-6
Suspension:
Front suspension Double wishbone
Rear suspension Swingarm (monocross)
Shock absorber:
Front shock absorber Coil spring / Oil damper
Rear shock absorber Coil spring / Oil damper
Wheel travel:
Front wheel travel 100 mm
Rear wheel travel 110 mm
Electrical:
Ignition system D.C. C.D.I.
Generator system A.C. magneto
Battery type YTX 20L-BS
Battery voltage, capacity 12 V, 18 AH
Headlight type: Bulb type
Bulb voltage, wattage
× quantity:
Headlight 12 V, 30 W / 30 W
× 2
Tail / brake light 12 V, 5 W / 21 W × 1
Meter light 12 V, 3 W
× 1
Indicator light:
Neutral 12 V, 1.7 W
× 1
Reverse 12 V, 1.7 W × 1
Oil temperature 12 V, 1.7 W
× 1 Model YFM400FP/YFM400FW
EE.book Page 6 Monday, June 18, 2001 10:18 AM