2003 Yamaha Motorsports Big Bear 400 Owners Manual

2003 Yamaha Motorsports Big Bear 400 Manual

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  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 1
    READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER'S MANUAL YFM400R WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-16-12 5GW-F8199-13
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 2
    EBU00776
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 3
    of your ATV, please consult a Yamaha dealer. AN IMPORTANT SAFETY MESSAGE: G READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. G PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. G NEVER
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 4
    INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 5
    of manufacture. Please check your local riding laws and regulations before operating this machine. EBU01067 AFFIX DEALER LABEL HERE YFM400R OWNER'S MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st edition, June 2002 All rights reserved. Any reprinting or unauthorized use without the written
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 6
    EBU00014 WARNING Indicates a potential hazard that could result in serious injury or death. 4 CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS...1-1 SAFETY INFORMATION...2-1 DESCRIPTION AND MACHINE IDENTIFICATION ...3-1 Identification number records...3-2 Key identification number
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 7
    Rear shock absorber adjustment...4-18 Auxiliary DC jack...4-19 5 PRE-OPERATION CHECKS ...5-1 Front and rear brakes ...5-3 Fuel ...5-5 Engine oil ...5-7 Final gear oil...5-8 Throttle lever ...5-8 Fittings and fasteners...5-8 Lights...5-9 Switches...5-9 Tires ...5-9 How to measure tire pressure ...5-
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 8
    if ...7-40 What to do ...7-40 8 PERIODIC MAINTENANCE AND ADJUSTMENT...8-1 Owner's manual and tool kit...8-1 Periodic maintenance/ lubrication ...8-3 Engine oil...8-5 Final gear oil beam adjustment...8-37 Tail/brake light bulb replacement ...8-37 Troubleshooting ...8-39 Troubleshooting chart ...8-40
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 9
    9 CLEANING AND STORAGE...9-1 A. Cleaning...9-1 B. Storage ...9-3 SPECIFICATIONS...10-1 NOISE REGULATION...11-1 MAINTENANCE RECORD ...12-1 ATV LIMITED WARRANTY ...13-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ...14-1 10 11 12 13 14
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 10
    EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1-1
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 11
    performance and can lead to an accident. Never exceed the maximum front cargo limit of : 40kg (88 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's Manual. 5ND-F4877-00 1-2
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 12
    performance and can lead to an accident. Never exceed the maximum rear cargo limit of : 80kg (176 lbs) NEVER sit on the carrier. Refer to instructions in the Owner's Manual. 5ND-F4897-00 5 1-3
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 13
    7 8 MAXIMUM .LOADING LIMIT PULLING LOAD: TONGUE WEIGHT: 4020 904 147 33 (410kgf) N lbf ( 15kgf) N lbf 5FU-F151K-00 1-4
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 14
    riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: G Read this manual and all labels carefully and follow the operating procedures described. G Never operate an ATV without proper training or
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 15
    time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 16
    sharply to one side. Go straight down the hill where possible. Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 17
    chance of skidding or sliding out of control. Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 18
    . Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 19
    WARNING POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 20
    WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation. 2-7
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 21
    switch Handlebar switches 9 10 11 12 13 14 NOTE: The machine you have purchased may differ slightly from those shown in the figures of this manual. 3-1
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 22
    EBU00600 EBU00035 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 23
    EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 24
    EBU00039 CONTROL FUNCTIONS WARNING Indicates a potential hazard that could result in serious injury or death. EBU00942 Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights and taillight come on when the
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 25
    EBU00802 EBU00732 Indicator and warning lights Oil temperature warning light "OIL TEMP" When the oil temperature reaches a specified level, this light comes on to warn that the engine oil temperature is too hot. If the warning light comes on during operation, stop the engine as soon as it is safe
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 26
    EBU00733 Oil temperature warning light checking method ACB-10E Turn the main switch to "ON" and the engine stop switch to " ". Oil temperature warning light does not come on. Push start switch with the transmission in neutral. Oil temperature warning light comes on. Check engine oil temperature.
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 27
    EBU00051 EBU00052 Speedometer The speedometer shows riding speed. This speedometer is equipped with an odometer and trip odometer. The trip odometer can be reset to "0" with the reset knob. Use the trip odometer to estimate how far you can ride on a tank of fuel before going to reserve. This
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 28
    EBU00053 EBU00607 Handlebar switches Start switch " " The starter motor cranks the engine when this switch is pushed. CAUTION: See starting instructions prior to starting the engine. (See page 6-1 for details.) _ EBU01204 1. Lights switch " / 2. Engine stop switch " 3. Start switch " " /OFF"
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 29
    HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can't find or solve the
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 30
    EBU01159 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. WARNING POTENTIAL HAZARD Improper adjustment
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 31
    EBU00070 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 1. Rear brake pedal 1. Front brake lever EBU00073 Rear brake pedal and lever The brake pedal is located on the right side of the machine and the brake lever
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 32
    EBU00074 Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. WARNING POTENTIAL HAZARD
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 33
    EBU00084 EBU01028* Shift pedal This machine is equipped with a constantmesh 5-speed forward and 1-speed reverse transmission. The shift pedal is located on the left side of the engine. Reverse is at the bottom position. Neutral is one position above reverse. Reverse knob The reverse knob is used
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 34
    EBU00590 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out. WARNING POTENTIAL HAZARD Starting the engine in gear and/or starting the engine without setting the parking brake. WHAT CAN
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 35
    EBU00092 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1. Fuel tank cap 4-12
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 36
    EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 37
    EBU00095 Starter (choke) " " Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to "Starting a cold engine" for proper operation.
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 38
    EBU00567 Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted. 1. Seat lock
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 39
    EBU00581 EBU00582 Storage box Maximum load limit: 2 kg (4.4 lb) Front carrier Maximum load limit: 40 kg (88 lb) CAUTION: To protect from damage, do not put metal products, like tools or sharply edged products directly in the storage box. If they must be stored, wrap them in appropriate cushion
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 40
    EBU01104 Front shock absorber adjustment The spring preload can be adjusted to suit the rider's weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 41
    EBU01103 Rear shock absorber adjustment The spring preload can be adjusted to suit the rider's weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 42
    EBU01002 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running. 1. Set the light switch to "OFF". 2. Start the engine. (See
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 43
    CAUTION: _ G G G Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to blow. If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may become
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 44
    PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM Front brake Rear brake Fuel Engine oil Final gear oil Throttle Wheels and tires Fittings and fasteners Lights ROUTINE • Check operation, free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 45
    use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 5-2
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 46
    EBU01252 Front and rear brakes Brake levers and brake pedal Check for correct free play in the front brake lever. If the free play is incorrect, have a Yamaha dealer adjust it. Check for correct free play in the rear brake lever and brake pedal. If the free play is incorrect, adjust it. (See pages
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 47
    accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have a Yamaha dealer check for the cause. 5-4
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 48
    EBU01085 Fuel Make sure there is sufficient gasoline in the tank. Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: Total: 15 L (3.3 Imp gal, 4.0 US gal) Reserve: 4.0 L (0.9 Imp gal, 1.1 US gal) Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 49
    does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 50
    or higher. Make sure that no foreign material enters the crankcase. -20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C Recommended engine oil classification: API Service SE, SF, SG type or higher Oil quantity: Periodic oil change: 2.9 L (2.6 Imp qt, 3.1 US qt) With oil filter replacement: 3.0 L (2.6 Imp qt
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 51
    . EBU01162 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. 5-8
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 52
    EBU01003 EBU00157 Lights Check the headlights and tail/brake light to make sure they are in working condition. Repair as necessary for proper operation. EBU01170 Tires WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 53
    2. The tires should be set to the recommended pressure: G Recommended tire pressure Front 25 kPa (0.25 kgf/cm2, 3.6 psi) Rear 25 kPa (0.25 kgf/cm2, 3.6 psi) G Check and adjust tire pressures when the tires are cold. G Tire pressures must be equal on both sides. 3. Tire pressure below the minimum
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 54
    EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressure
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 55
    EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. 3 mm (0.12 in) 5-12
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 56
    familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner's Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer. 6-1
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 57
    NOTE: G When the transmission is in neutral, the neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it. G The engine can be started in any gear if the rear brake lever is applied. However, it is recommended to shift into neutral before starting the
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 58
    NOTE: G If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. G If the battery is
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 59
    EBU00195 Reverse knob operation and reverse driving CAUTION: Before shifting, stop the machine and return the throttle lever to its closed position. Otherwise the transmission may be damaged. 1. Bring the machine to a complete stop and return the throttle lever to the closed position with the
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 60
    EBU01295 Shifting This model has a 5-speed forward and 1-speed reverse transmission with centrifugal automatic clutch. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, return the
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 61
    EBU00207 4. Once the machine has attained adequate speed, release the throttle lever. 5. Shift into second gear and release the shift pedal. 6. Open the throttle gradually. 7. Follow the same procedure when shifting to the next higher gear. WARNING POTENTIAL HAZARD Opening the throttle before
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 62
    EBU00209 Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 63
    EBU00211 2. 10-20 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely through the gears but do not use full throttle at any time. 3. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally. Parking When parking, stop the engine and shift into
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 64
    EBU01296 Parking on a slope WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, put the ATV in low
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 65
    EBU00221 Accessories and loading EBU00222 G Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. G Choose only accessories designed for your ATV. Your Yamaha dealer has a
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 66
    EBU00588 Loading Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: G Never exceed the weight limits shown. An overloaded ATV can be unstable. MAXIMUM LOADING
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 67
    G G G G Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed 2nd gear whenever you are carrying heavier loads or when towing a trailer. Allow more braking distance. A heavier vehicle takes
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 68
    EBU01297 WARNING _ Indicates a potential hazard that could result in serious injury or death. 6-13
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 69
    Riding Your ATV 7 7-1
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 70
    7-2
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 71
    recreation. This section, Riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this 7-3 begin to ride, be sure you have read this Owner's Manual completely and understand the operation of the controls. Pay particular attention
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 72
    the course and the operating techniques described in this Owner's Manual. For more information about the training course, contact an authorized more difficult maneuvers. WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 73
    Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 74
    This ATV is designed to carry operator and cargo only - passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. HOW TO
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 75
    Apparel WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 76
    Do not operate after consuming alcohol or drugs. Operator's performance capability is reduced by the influence of alcohol or drugs. WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 77
    . HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner's Manual for this vehicle on pages 5-9-5-10. Always maintain proper tire pressure as described in the Owner's Manual on page 5-11. WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 78
    WARNING _ Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 79
    ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in your Owner's Manual for carrying cargo or pulling a trailer. 7-11
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 80
    During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 81
    Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don't
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 82
    added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer. 7-14
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 83
    Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 84
    BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 85
    Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 86
    Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 87
    WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough,
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 88
    When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 89
    ATV is designed for off-road use only, and handling maneuvers are more difficult to perform on pavement. Set the parking brake and follow the instruction on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV. As you get on the ATV
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 90
    CAUTION: _ WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD Make sure the engine has
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 91
    that this skill be learned first at low speed. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner's Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 92
    Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 93
    CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 94
    of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner's Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 95
    AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner's Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. 7-27 When crossing the side
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 96
    If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and
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    Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner's Manual. 7-29
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 98
    of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in this Owner's Manual. Note: a special technique is required when braking as you go down a hill. Always check the terrain carefully before you start down any hill. Shift
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 99
    7-31
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    AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner's Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. 7-32
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    When crossing the side of a hill: Always follow proper procedures as described in the Owner's Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. 7-33
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 102
    an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner's Manual. 7-34
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 103
    Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. CAUTION: _ After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 104
    ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner's Manual. 7-36
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    7-37
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    SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 107
    With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 108
    WHAT TO DO IF ...This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. WHAT TO DO ...G If your ATV doesn't turn when you want it to: Bring
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 109
    G G If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 110
    dealer perform service if you are not familiar with machine service. EBU01299 WARNING POTENTIAL HAZARD Servicing an engine while performing maintenance unless otherwise specified. 8-1 Owner's manual and tool kit You are recommended to put this owner's manual in the vinyl bag and always carry it
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 111
    and should be installed and used according to instructions. If you have questions, consult an authorized Yamaha ATV dealer. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1. Owner's tool kit 2. Low-pressure tire gauge The service information included in this manual is intended to provide you, the owner, with
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 112
    EBU00261 PERIODIC MAINTENANCE/LUBRICATION ITEM Valves* Spark plug Air filter element Carburetor* Cylinder head cover breather system* Exhaust system* Spark arrester Fuel line* Engine oil Engine oil filter element Engine oil strainer Final gear oil Front brake* Rear brake* Clutch ROUTINE Check
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 113
    ITEM Reverse release cable* Wheels* Wheel bearings ROUTINE Check operation. Adjust if necessary. Check balance/damage/run out. Replace if necessary. Check bearing assembly for looseness/damage. Replace if damaged. Check operation. Replace if damaged. Check toe-in. Adjust if necessary. Lubricate.
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 114
    EBU01181 Engine oil Engine oil level measurement 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes, and then stop it. 3. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag. Insert the dipstick in the filler hole without screwing it in. 4.
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 115
    6. Insert the dipstick into the oil filler hole, and then tighten the engine oil filler cap. Engine oil replacement and oil filter element cleaning 1. Place the ATV on a level surface. 2. Warm up the engine for several minutes and stop it. 3. Place a container under the engine to collect the used
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 116
    1. Engine oil drain bolt 3. Compression spring 2. O-ring 4. Engine oil strainer 6. Clean the oil strainer and oil filter element with solvent. 7. Check the O-ring for damage and replace it if necessary. 8. Install the oil filter element and O-ring. 9. Install the oil filter cover by installing the
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 117
    Recommended oil: See page 10-2. Oil quantity: Periodic oil change: 2.9 L (2.6 Imp qt, 3.1 US qt) With oil filter replacement: 3.0 L (2.6 Imp qt, 3.2 US qt) Total amount: 3.5 L (3.1 Imp qt, 3.7 US qt) 1. O-ring 2. Engine oil filter element Tightening torques: Drain bolt: 32 Nm (3.2 m·kgf, 23 ft·lbf)
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 118
    EBU01145 12. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 13. Turn the engine off, and then check the oil level and correct it if necessary. Final gear oil Final gear oil
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 119
    Final gear oil replacement 1. Remove the final gear case cover by removing the bolts. 1. Final gear oil 3. Final gear oil filler bolt 2. Correct oil level 1. Final gear case cover 2. Bolt (× 2) 8-10
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 120
    2. Place the machine on a level surface. 3. Place a container under the final gear case to collect the used oil. 4. Remove the oil filler bolt and the drain bolt to drain the oil. 6. Add the recommended final gear oil to the brim of the filler hole. Recommended oil: See page 10-3. Oil quantity: 0.
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 121
    of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder. Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 122
    EBU01301 Air filter element cleaning NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. _ _ 1. Air filter case cover 2. Holder (× 3) 3. Pull the air filter element out. 1.
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 123
    4. Remove the foam cover from the air filter element. 5. Tap the element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air as shown. If the air filter element is damaged, replace it. 1. Air filter element 2. Foam cover 6. Wash the foam cover gently but
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 124
    WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the foam cover. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the foam cover. 7. Squeeze the excess water or solvent out of the
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 125
    CAUTION: _ Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 126
    EBU00754 Spark arrester cleaning Select a well-ventilated area free of combustible materials and make sure the exhaust pipe and muffler are cool. 1. Remove the purging bolt. 2. Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 127
    EBU00296 WARNING POTENTIAL HAZARD Improperly purging the exhaust system. Hot exhaust system. WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester:
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 128
    EBU01302 Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. _ _ 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 129
    noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician. Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 130
    EBU01303 EBU00313 Front brake pad check Inspect the brake pads for damage and wear. If the brake pad thickness is less than 1 mm (0.04 in), have a Yamaha dealer replace the pads. Rear brake shoe inspection A wear indicator is provided on the rear brake. This indicator allows checking of brake
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 131
    EBU01304 Brake fluid level check Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 132
    the cause if the brake fluid level goes down. Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. G Replace the oil seals
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 133
    a Yamaha dealer adjust it. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: sure the brakes operate G Make smoothly and that the free play
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 134
    EBU01305 Rear brake pedal and lever adjustment Brake pedal free play adjustment 1. Fully loosen the adjusting nut on the brake cable. 2. Turn the adjusting nut on the brake rod until the free play is 20-30 mm (0.8- 1.2 in). a. Rear brake pedal free play 1. Adjusting nut (brake cable) 2. Adjusting
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 135
    Brake lever free play adjustment 1. Loosen the locknut and fully turn in the adjusting bolt at the brake lever. 2. Turn in the adjusting nut on brake cable to provide a gap of 0-1 mm (0-0.04 in) between the lever and the pin. 1. Locknut 2. Adjusting bolt 1. Adjusting nut (brake cable) 3. Pin 2.
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 136
    or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: sure the brakes operate G Make smoothly and that the free play is correct. G Make sure the brakes do not drag. Replacement of brake components requires
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 137
    EBU00834 EBU00346 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and brake levers, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 138
    EBU00356 3. Tighten the locknut to specification. Tightening torque: 15 Nm (1.5 m·kgf, 11 ft·lbf) NOTE: Turn the adjusting bolt counterclockwise to decrease the clutch free play and turn it clockwise to increase the free play. Cable inspection and lubrication WARNING POTENTIAL HAZARD Damaged
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 139
    EBU01112 Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 140
    EBU01121 Wheel installation 1. Install the wheel and the nuts. NOTE: G Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel. G The arrow mark on the tire must point toward the rotating direction of the wheel. _ _ 2. Lower the ATV so that
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 141
    EBU00380 Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a Yamaha dealer. CAUTION: Do not try to remove the sealing caps of the battery cells.
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 142
    EBU00385 EBU00853* Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. CAUTION: A special battery charger (constant voltage/ampere or constant voltage) is required
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 143
    WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse. 1. Main fuse 2. Spare main
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 144
    EBU01306 Replacing a headlight bulb If a headlight bulb burns out, replace the bulb as follows. 1. Remove the headlight assembly by removing the screws. 2. Disconnect the headlight coupler. 3. Remove the headlight unit from the headlight assembly by removing the screw. 4. Remove the headlight bulb
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 145
    WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it. 6. Put a new
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 146
    EBU01089 EBU00945 Headlight beam adjustment CAUTION: _ Tail/brake light bulb replacement 1. Open the storage box. (See page 4-16.) 2. Remove the nuts together with washers. It is advisable to have a Yamaha dealer make this adjustment. _ To raise the beam, turn the adjusting screw in direction
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 147
    1. Tail/brake light bulb holder 4. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 1. Tail/brake light bulb holder 2. Bulb 5. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. 6. Install the bulb holder (
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 148
    trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting , but they are often inferior. Consequently, they have a shorter service life and can lead to expensive repair bills. WARNING POTENTIAL HAZARD
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 149
    EBU00440 Troubleshooting chart Turn the fuel cock to "ON". There is fuel. 1. Fuel Check if there is fuel in the fuel tank. Some fuel. Turn the fuel
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 150
    EBU00419 CLEANING AND STORAGE A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 151
    6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 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 protective finish. When finished, start the
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 152
    EBU00530 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 153
    7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the machine. 9-4
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 154
    EBU00428 SPECIFICATIONS MODEL Dimension: Overall length Overall width Overall height Seat height Wheel base Ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Type Cylinder arrangement: Displacement Bore × stroke Compression ratio Starting system Lubrication
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 155
    20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 5 6 -20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C 7 8 9 10 11 12 13 14 Recommended engine oil classification API Service SE, SF, SG or higher CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 156
    MODEL Final gear oil: Type Quantity Periodic oil change Total amount Air filter: Fuel: Type Tank capacity Reserve amount Carburetor: Type/manufacturer Spark plug: Type/manufacturer Gap Clutch: Type YFM400 SAE 80 API "GL-4" Hypoid gear oil 0.23 L (0.20 lmp qt, 0.24 US qt) 0.25 L (0.22 lmp qt, 0.26
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 157
    MODEL Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear raito: YFM400 Spur gear 76/24 (3.166) Shaft drive 28/24 × 24/18 × 33/09 (5.703) Constant mesh, 5-speed forward, 1-speed reverse Left foot
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 158
    MODEL Suspension: Front Rear Shock absorber: Front Rear Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type/voltage capacity Headlight type: Bulb voltage, wattage × quantity: Headlight Tail/brake light Meter lighting Indicator and warning
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 159
    MODEL Fuses: Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Carburetor warmer fuse 30 A 15 A 10 A 10 A 10 A YFM400 10-6
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 160
    EBU00430 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 161
    12 Months 18 Months 24 Months 30 Months 36 Months 42 Months 48 Months 54 Months 60 Months 7 8 9 10 11 12 13 14 DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 6 1 2 3 4 5 12-1
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 162
    EBU00432 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 13-1
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 163
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 13-2
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 164
    EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 165
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 14-2
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 166
    EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death.
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 167
    EBU00437
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 168
    control. with a passenger-passengers affect balance and steering and increase risk of losing control. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) NEVER operate: YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN USA
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 169
  • 2003 Yamaha Motorsports Big Bear 400 | Owners Manual - Page 170
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5GW-F8199-13
LIT-11626-16-12
READ THIS MANUAL CAREFULLY!
It contains important safety information.
This ATV should not be ridden by anyone under 16 years of age.
WARNING
YFM400R
OWNER’S MANUAL