oil level YAMAHA BIG BEAR PRO 400 2003 Owners Manual

Tires ....................................................5-21
How to measure tire pressure .............5-25
Tire wear limit......................................5-27
OPERATION ............................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine .........................6-9
Warming up...........................................6-9
Drive select lever operation
and reverse driving ...........................6-11
Reverse lock release wire ...................6-15
Shifting ................................................6-17
To start out and accelerate: ................6-19
To decelerate: .....................................6-21
Engine break-in ...................................6-23
Parking ................................................6-27
Parking on a slope ..............................6-27
Accessories and loading .....................6-29
Accessories.........................................6-29
RIDING YOUR ATV..................................7-1
Getting to know your ATV .....................7-3
Ride with care and good judgement .....7-5
Be careful where you ride ...................7-27
Turning your ATV ................................7-41
Climbing uphill.....................................7-47
Riding downhill ....................................7-57
67
Crossing a slope ................................. 7-61
Crossing through shallow water ......... 7-65
Riding over rough terrain .................... 7-69
Sliding and skidding............................ 7-71
What to do if ....................................... 7-75
What to do .......................................... 7-75
PERIODIC MAINTENANCE AND
ADJUSTMENT ......................................... 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication.......... 8-7
Engine oil ............................................ 8-13
Transfer gear oil replacement............. 8-23
Final gear oil ....................................... 8-27
Differential gear oil replacement ......... 8-31
Axle boots ........................................... 8-35
Spark plug inspection ......................... 8-37
Air filter cleaning ................................. 8-43
Carburetor adjustment ........................ 8-49
Idle speed adjustment ........................ 8-51
Valve clearance adjustment ............... 8-53
Select lever safety system
cable adjustment .............................. 8-53
Throttle lever adjustment .................... 8-55
Front brake pad inspection ................. 8-55
Rear brake shoe inspection ................ 8-57
Brake fluid level inspection ................. 8-57
8
EE.book Page 2 Monday, June 18, 2001 10:18 AM

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,
8-55 ~ 8-73
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 ~ 5-15,
8-13 ~ 8-25
Final gear oil/
Differential gear oilCheck for leakage. 5-17, 8-27 ~ 8-35
ThrottleCheck for proper throttle cable operation. 5-17, 8-55
Wheels and tiresCheck tire pressure, wear and damage.5-21 ~ 5-27,
8-79 ~ 8-83
Fittings and FastenersCheck all fittings and fasteners. 5-19
LightsCheck for proper operation. 5-19, 8-91 ~ 8-95
Axle bootsCheck operation. 8-35
EE.book Page 1 Monday, June 18, 2001 10:18 AM

5-13
EBU00492*
Engine oil/Transfer gear oil
Make sure the engine oil/transfer gear oil is at the
specified level. Add oil as necessary. (See pages
8-13 ~ 8-25.)
Recommended oil:
Recommended engine oil classification:
API Service SE, SF, SG type or higher
-20Ëš -10Ëš 0Ëš
10Ëš20Ëš 30Ëš40Ëš50ËšC
10W/30
15W/4020W/4020W/50
10W/40
5W/30
EE.book Page 13 Monday, June 18, 2001 10:18 AM

5-17
EBU00495*
Final gear oil/Differential gear oil
Make sure the final gear oil/differential gear oil is at
the specified level. Add oil as necessary. (See
pages 8-27 ~ 8-35.)
If desired, an SAE 80W90 hypoid gear oil may be
used for all conditions.NOTE:GL-4 is a quality and additive rating. GL-5 or GL-6
rated hypoid gear oils may also be used.
EBU00151
Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
idle position when released. Repair as necessary
for proper operation.Recommended oil:
See page 10-3.
EE.book Page 17 Monday, June 18, 2001 10:18 AM

8-7
EBL00262PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*•Check valve clearance.
•Adjust if necessary.Spark plug•Check condition.
•Adjust gap and clean.
•Replace if necessary.Air filter•Clean.
•Replace if necessary.Every 20 ~ 40 hours
(More often in wet or dusty areas.)
Carburetor*•Check idle speed/starter operation.
•Adjust if necessary.Crankcase breather
system*•Check breather hose for cracks or damage.
•Replace if necessary.Exhaust system*•Check for leakage.
•Retighten if necessary.
•Replace gasket(s) if necessary.Fuel line*•Check fuel hose for cracks or damage.
•Replace if necessary.Engine oil
•Replace (Warm engine before draining).Transfer gear oil
Engine oil filter
•Replace.Engine oil strainer
•Clean.Final gear oil
•Check oil level/oil leakage.
•Replace every 12 months.Differential gear oil
Front brake*•Check operation/fluid leakage/see NOTE page 8-8.
•Correct if necessary.Rear brake*•Check operation.
•Adjust if necessary.Clutch*•Check operation.
•Adjust if necessary.EE.book Page 7 Monday, June 18, 2001 10:18 AM

8-8 * It is recommended that these items be serviced by a Yamaha dealer.
NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
Drive select lever
safety system*•Check operation.
•Adjust if necessary.Wheels*•Check balance/damage/runout.
•Repair if necessary.Wheel bearing*•Check bearing assemblies for looseness/damage.
•Replace if damaged.Steering system*•Check operation.
•Replace if damaged.
•Check toe-in.
•Adjust if necessary.Axle boots*•Check condition.
•Replace if damaged.Fittings and Fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
EE.book Page 8 Monday, June 18, 2001 10:18 AM

8-13 1. Oil filler cap
1. Bouchon de remplissage d’huile
1. Tapa del orificio de llenado de aceite
1. Dipstick 2. Maximum level mark
3. Minimum level mark
1. Jauge 2. Repère de niveau maximum
3. Repère de niveau minimum
1. Varilla 2. Marca de nivel máximo
3. Marca de nivel minimo
EBU00824
Engine oil
Engine oil level measurement
1. Place the machine on a level place.
2. Warm up the engine for several minutes and
stop it.
3. Remove the oil filler cap and wipe the dipstick
off with a clean rag. Insert the dipstick in the
filler hole without screwing it in.NOTE:_ Wait a few minutes until the oil level settles before
checking. _4. Remove the dipstick and inspect the oil level.
5. The oil level should be between the maxi-
mum and minimum marks. If the level is low,
add oil to raise it to the proper level.CAUTION:_ Be sure no foreign material enters the crank-
case. _
EE.book Page 13 Monday, June 18, 2001 10:18 AM

8-15 1. Clamp
1. Bride
1. Mordaza
1. Drain bolt (engine oil) 2. O-ring
3. Compression spring 4. Oil strainer
1. Boulon de vidange (huile de moteur) 2. Joint torique
3. Ressort de compression 4. Crépine à huile
1. Perno de drenaje (aceite del motor) 2. Junta tórica
3. Muelle de compresión 4. Colador de aceite
Engine oil replacement and oil filter cleaning
1. Place the machine on a level place.
2. Warm up the engine for several minutes and
stop it.
3. Place a container under the engine to collect
the used oil.
4. Remove the clamp.
5. Remove the oil filler cap and drain bolt to
drain the oil.CAUTION:_ When removing the drain bolt, the compres-
sion spring, oil strainer and O-ring will fall out.
Take care not to lose these parts. _
EE.book Page 15 Monday, June 18, 2001 10:18 AM

8-23 1. Bolt (× 3)
1. Boulon (× 3)
1. Perno (× 3)
1. Oil filler bolt
1. Boulon de l’orifice de remplissage
1. Perno del orificio de llenado
EBU00462
Transfer gear oil replacementNOTE:When replacing the transfer gear oil, replace the
engine oil also.1. Remove the transfer gear case guard.
2. Place the machine on a level place.
3. Place a container under the transfer gear
case.
4. Remove the oil filler bolt and drain bolt to
drain the oil.
5. Install the drain bolt and tighten to specifica-
tion.
Tightening torque:
Drain bolt (transfer gear case):
20 Nm (2.0 m·kgf)
EE.book Page 23 Monday, June 18, 2001 10:18 AM

8-27 1. Final gear oil 2. Correct oil level
3. Filler bolt
1. Huile de transmission finale 2. Niveau d’huile correct
3. Boulon de l’orifice de remplissage
1. Aceite de la transmisión final 2. Nivel de aceite correcto
3. Perno de llenado
1. Bolt (× 3)
1. Boulon (× 3)
1. Perno (× 3)
EBU00825
Final gear oil
Final gear oil measurement
1. Place the machine on a level place.
2. Remove the oil filler bolt and check the oil lev-
el. It should be up to the brim of the hole. If
the level is low, add oil to raise it to the proper
level.CAUTION:_ Be sure no foreign material enters the final
gear case. _3. Install the oil filler bolt and tighten it to the
specified torque.
Final gear oil replacement
1. Remove the final gear case cover.
2. Place the machine on a level place.
3. Place a container under the final gear case to
collect the used oil. Tightening torque:
Oil filler bolt:
23 Nm (2.3 m·kgf)
EE.book Page 27 Monday, June 18, 2001 10:18 AM