torque YAMAHA BIG BEAR PRO 400 2004 Notices Demploi (in French)

5-17
EBU11620
Fittings and fasteners
Always check the tightness of chassis fittings and
fasteners before a ride. Take the machine to a
Yamaha dealer or refer to the Service Manual for
correct tightening torque.
EBU01003
Lights
Check the headlights and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU11700
Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper op-
eration.
U4SH6B.book Page 17 Tuesday, May 27, 2003 4:39 PM

8-3 1. Owner’s manual
2. Low-pressure tire gauge
1. Manuel du propriétaire
2. Manomètre basse pression pour pneus
1. Manual del propietario
2. Manómetro de baja presión
1. Owner’s tool kit
1. Trousse à outils du propriétaire
1. Equipo de herramientas del propietario
EBU00256
Owner’s manual and tool kit
You are recommended to put this owner’s manual
and low-pressure tire gauge in the vinyl bag and
always carry them in the storage box. Put the own-
er’s tool kit in the space under the seat. The ser-
vice information included in this manual is
intended to provide you, the owner, with the nec-
essary information for completing your own pre-
ventive maintenance and minor repairs. The tools
provided in the Owner’s tool kit are sufficient for
this purpose, except that a torque wrench is also
necessary to properly tighten nuts and bolts.NOTE:If you do not have a torque wrench available dur-
ing a service operation requiring one, take your
machine to a Yamaha dealer to check the torque
settings and adjust them as necessary.
U4SH6B.book Page 3 Tuesday, May 27, 2003 4:39 PM

8-17 1. Engine oil filter element cover bolt (× 3)
2. Oil filter element cover
1. Boulon de couvercle de l’élément de filtre à huile moteur (× 3)
2. Couvercle de l’élément de filtre à huile
1. Perno de la tapa del elemento del filtro de aceite de motor (× 3)
2. Tapa del elemento del filtro de aceite
1. Engine oil filter element 2. O-ring (× 2)
1.Élément du filtre à huile moteur 2. Joint torique (× 2)
1. Element del filtro de aceite de motor 2. Junta tórica (× 2)
6. Remove the shift pedal by removing the bolt.
7. Remove the oil filter element cover, and then
the oil filter element.
8. Clean the oil strainer and oil filter element
with solvent.
9. Inspect the O-ring and replace it if damaged.
10. Install the oil filter element, O-ring, oil filter el-
ement cover, compression spring, oil strainer
and drain bolt. Tighten the drain bolt to the
specified torque.CAUTION:_ Before installing the drain bolt, be sure to in-
stall the O-ring, compression spring and oil
strainer. _
Tightening torque
Drain bolt (engine):
32 Nm (3.2 m·kgf)
Oil filter element cover bolt:
10 Nm (1.0 m·kgf)
U4SH6B.book Page 17 Tuesday, May 27, 2003 4:39 PM

8-23 1. Bolt (× 3)
1. Boulon (× 3)
1. Perno (× 3)
1. Oil filler bolt
1. Boulon de l’orifice de remplissage d’huile
1. Perno del orificio de llenado de aceite
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)
E-8.fm Page 23 Thursday, May 29, 2003 11:49 AM

8-25 1. Drain bolt
1. Boulon de vidange
1. Perno de drenaje
6. Fill the transfer gear case with oil.CAUTION:
Be sure no foreign material enters the transfer
gear case.7. Install the filler bolt and tighten to specifica-
tion.
8. Check for oil leakage. If oil leakage is found,
check for the cause.
9. Reinstall the transfer gear case guard.Recommended oil: See page 10-2
Quantity:
Transfer gear oil and engine oil with
filter replacement:
2.8 L
Tightening torque:
Filler bolt (transfer gear case):
23 Nm (2.3 m·kgf)
U4SH6B.book Page 25 Tuesday, May 27, 2003 4:39 PM

8-29 1. Drain bolt
1. Boulon de vidange
1. Perno de drenaje
4. Remove the oil filler bolt and the drain bolt to
drain the oil.
5. Install the drain bolt, and then tighten it to the
specified torque.
6. Add the recommended final gear oil to the
brim of the filler hole.CAUTION:_ Be sure no foreign material enters the final
gear case. _
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf)
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
Oil quantity:
0.25 L
U4SH6B.book Page 29 Tuesday, May 27, 2003 4:39 PM

8-31 1. Oil filler bolt
1. Boulon de l’orifice de remplissage d’huile
1. Perno del orificio de llenado de aceite
7. Install the oil filler bolt.
8. Check for oil leakage. If oil leakage is found,
check for the cause.
9. Install the final gear case cover bolts, and
then tighten them to the specified torque.
EBU00826
Differential gear oil replacement
1. Place the machine on a level place.
2. Place a container under the differential gear
case to collect the used oil.
3. Remove the filler bolt and drain bolts to drain
the oil. Tightening torque:
Final gear case cover bolt:
23 Nm (2.3 m·kgf)
U4SH6B.book Page 31 Tuesday, May 27, 2003 4:39 PM

8-33 a. Front drain bolt
b. Rear drain bolt
a. Boulon de vidange avant
b Boulon de vidange arrière
a. Perno de drenaje delantero
b. Perno de drenaje trasero
4. Install the drain bolts and tighten to specifica-
tion.
5. Fill the differential gear case with oil.CAUTION:_ Be sure no foreign material enters the differen-
tial gear case. _
Tightening torque:
Drain bolt (differential gear case):
a 23 Nm (2.3 m·kgf)
b 16 Nm (1.6 m·kgf)
Recommended oil:
See page 10-3.
Oil quantity:
Periodic oil change:
0.47 L
Total amount:
0.50 L
U4SH6B.book Page 33 Tuesday, May 27, 2003 4:39 PM

8-35 1. Boot (× 2)
1. Soufflet (× 2)
1. Guardapolvo (× 2)
1. Boot (× 2)
1. Soufflet (× 2)
1. Guardapolvo (× 2)
6. Install the filler bolt and tighten it to specifica-
tion.
7. Check for oil leakage. If oil leakage is found,
check for the cause.
EBU00862
Axle boots
Check the protective boots for holes or tears. If any
damage is found, have them replaced by a
Yamaha dealer.Tightening torque:
Filler bolt (differential gear case):
23 Nm (2.3 m·kgf)
U4SH6B.book Page 35 Tuesday, May 27, 2003 4:39 PM

8-39 a. Spark plug gap
a.Écartement des électrodes
a. Huelgo de la bujía
Before installing the spark plug, measure the elec-
trode gap with a wire thickness gauge and adjust it
to specification.
When installing the spark plug, always clean the
gasket surface and its mating surface. Wipe off
any grime from the threads and tighten it to the
specified torque.Spark plug gap:
0.6–0.7 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf)
U4SH6B.book Page 39 Tuesday, May 27, 2003 4:39 PM