warning YAMAHA BIG BEAR PRO 400 2003 Workshop Manual

8-1
EBU00516
1-PERIODIC MAINTENANCE AND
ADJUSTMENTPeriodic inspection, adjustment and lubrication will
keep your machine in the safest and most efficient
condition possible. Safety is an obligation of the
machine owner. The most important points of ma-
chine inspection, adjustment and lubrication are
explained on the following pages.
WARNING
Never service an engine while it is running.
Moving parts can catch clothing or parts of the
body, causing injury. Electrical components
can cause shocks or can start fires. Turn off
the engine when performing maintenance un-
less otherwise specified. Have a Yamaha deal-
er perform service if you are not familiar with
machine service.
EE.book Page 1 Monday, June 18, 2001 10:18 AM

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

8-45 1. Air filter element
1.Élément du filtre à air
1. Elemento filtrante
1. Element plate 2. Air filter element
3. Guide
1. Plaque d’élément 2.Élément du filtre à air
3. Guide
1. Placa del elemento 2. Elemento filtrante
3. Guía
3. Remove the air filter element, and separate it
from the guide.
4. Wash the element gently but thoroughly 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.5. Squeeze the excess solvent out of the filter
and let it dry.CAUTION:
Do not twist the filter element when squeezing
it.6. Inspect the element. If damaged, replace it.
7. Apply SAE10W30 motor oil to the element.NOTE:The element should be wet but not dripping.
EE.book Page 45 Monday, June 18, 2001 10:18 AM

8-63 a. Free play
a. Jeu
a. Juego libre
EBU00951
Front brake adjustment
The front brake lever should have a free play of
zero mm (zero in) at the lever end. If not, ask a
Yamaha dealer to adjust it.
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.
EE.book Page 63 Monday, June 18, 2001 10:18 AM

8-65
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.
EE.book Page 65 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

8-79
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

8-85
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.
EE.book Page 85 Monday, June 18, 2001 10:18 AM

8-89 1. Main fuse 2. Spare fuse
1. Fusible principal 2. Fusible de rechange
1. Fusible principal 2. Fusible de repuesto
1. Headlight fuse 2. Ignition fuse
3. Auxiliary DC jack fuse 4. Signal fuse
5. Spare fuse
1. Fusible de phare 2. Fusible d’allumage
3. Fusible de connecteur 4. Fusible de signalisation
pour accessoires
5. Fusible de rechange
1. Fusible del faro 2. Fusible del sistema de encendido
3. Fusible de la toma 4. Fusible señalización
auxiliar de CC
5. Fusible de repuesto
EBU00745*
Fuse replacement
1. The fuse cases are under the seat.
2. If a fuse is blown, turn off the main switch and
the switch of the circuit in question. Then, in-
stall a new fuse of the specified amperage.
Turn on the main switch. 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. _CAUTION:_ To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse. _
Specified fuses:
Main fuse: 30 A
Headlight fuse: 15 A
Ignition fuse: 10 A
Auxiliary DC jack fuse: 10 A
Signal fuse: 10 A
EE.book Page 89 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