2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition Owners Manual
2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition Manual
2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition manual content summary:
- 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 1
READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER'S MANUAL YFM40FBW WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-20-45 4S1-F8199-10 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 2
EBU17091 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | 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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 4
IN SERIOUS 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! Failure to follow WARNING instructions could result in severe injury or death to the ATV operator - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 5
time of manufacture. Please check your local riding laws and regulations before operating this ATV. EBU17401 AFFIX DEALER LABEL HERE YFM40FBW OWNER'S MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. 1st edition, July 2006 All rights reserved. Any reprinting or unauthorized use without the written - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 6
EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ...1-1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ...2-1 DESCRIPTION ...3-1 Left view ...3-1 Right view...3-1 Controls and instruments ...3-2 INSTRUMENT - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 7
...7-30 SLIDING AND SKIDDING ...7-30 WHAT TO DO IF...7-31 WHAT TO DO...7-31 PERIODIC MAINTENANCE AND MINOR REPAIR ...8-1 Owner's manual and tool kit ...8-1 Periodic maintenance chart for the emission control system ...8-3 General maintenance and lubrication chart ...8-5 Checking the spark plug - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 8
47 Removing a wheel ...8-48 Installing a wheel ...8-49 Troubleshooting ...8-50 Troubleshooting chart ...8-52 CLEANING AND STORAGE ...9-1 Cleaning ...9-1 Storage 11-3 Maintenance record ...11-4 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY ...11-5 YAMAHA EXTENDED SERVICE (Y.E.S.) ...11-7 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 9
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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 10
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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 11
. G 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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 12
EWB00021 WARNING 1 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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 13
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. 1 1-5 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 14
EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 2 2-1 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 15
EBU17670 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement label from your Yamaha dealer. 2 2-2 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 16
2 2-3 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 17
2 2-4 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 18
EBU17680 DESCRIPTION EBU17690 EBU17700 Left view 3 Right view 1. Front shock absorber assembly spring preload adjusting ring 2. Fuel cock 3. Recoil starter 4. Throttle stop screw 5. Fuses 6. Battery 7. Storage compartment and tool kit 8. Rear shock absorber assembly spring preload adjusting ring - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 19
EBU17712 Controls and instruments NOTE: The ATV you have purchased may differ slightly from the figures shown in this manual. 3 1. 2. 3. 4. 5. 6. 7. 8. Rear brake lever Parking brake lock plate Starter (choke) Speedometer Reverse knob Auxiliary DC jack Front brake fluid reservoir On-Command - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 20
EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. 4 EBU17770 Main switch The positions of the main switch are as follows: ON All electrical systems are supplied with power. The headlights, meter lighting and - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 21
EBU17813 Indicator lights and warning light NOTE: If the indicator light flashes under any other circumstances or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. EBU17870 Neutral indicator light "NEUTRAL" This indicator light comes on - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 22
If the warning light stays on, allow the engine to cool. If the warning light stays on when the engine is cool, have a Yamaha dealer check the electrical circuit. ECB00010 EBU28341 4 CAUTION: The engine may overheat if the ATV is overloaded. In this case, reduce the load to specification. G Start - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 23
4 1. 2. 3. 4. Reset knob Speedometer Odometer Tripmeter 1. Fuel gauge 2. Red line EBU18050 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank. When the needle reaches the red line, refill the tank at the first opportunity. NOTE: If the ATV runs out of fuel, move the fuel - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 24
Handlebar switches Start switch " " Push this switch to crank the engine with the starter. ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. 4 EBU18160 1. 2. 3. 4. Light switch " / /OFF" Start switch " " Engine stop switch " / " Override switch "OVERRIDE - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 25
EBU28350 EWB00110 Override switch "OVERRIDE" WARNING POTENTIAL HAZARD Riding too fast while the ATV is in fourwheel-drive differential gear lock. WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the ATV. The effort needed to turn - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 26
4 "4WD" (four-wheel drive): Power is supplied to the rear and front wheels. To change from two-wheel drive to four-wheel drive, stop the ATV and push the switch in to the "4WD" position. The four-wheel-drive indicator light " " comes on. To change from four-wheel drive to two-wheel drive, stop the - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 27
EBU28360 On-Command differential gear lock switch "4WD"/"LOCK" This ATV is equipped with a switch allowing you to lock the differential gear when in four-wheel drive. Select the appropriate switch position according to the terrain and the conditions. G "4WD" (four-wheel drive): Power is supplied to - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 28
4 1. On-Command differential gear lock switch "4WD"/"LOCK" To release the differential gear lock, stop the ATV and push the switch to the "4WD" position. EWB00091 WHAT CAN HAPPEN The ATV handles differently in four-wheel drive than in differential gear lock in some circumstances. Changing from - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 29
HOW TO AVOID THE HAZARD Always ride at a slow speed when the ATV is in differential gear lock, and allow extra time and distance for maneuvers. NOTE: G If the differential gear lock is not engaging properly, turn the handlebar back and forth to help it engage. G Riding before the differential gear - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 30
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 problem yourself. EBU18311 crease the maximum engine power available and the maximum speed of the ATV, turn the adjusting - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 31
WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 32
EBU18450 Parking brake Use the parking brake before starting the engine or parking the ATV, 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. 4 1. Brake pedal 1. Parking brake lock - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 33
WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 34
4 1. Reverse knob "REV" EBU27371 1. Recoil starter EWB02361 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 or starting the engine - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 35
EBU18720 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 4 1. Fuel level 2. Fuel tank filler tube 1. Fuel tank cap EBU18730 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. Recommended fuel: UNLEADED - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 36
content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or ATV performance problems. EWB00270 WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 37
OFF ON 4 1. Arrow mark positioned over "OFF" 1. Arrow mark positioned over "ON" With the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running. With the fuel cock lever in this position, fuel flows to the - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 38
RES Move the starter (choke) in direction (b) to turn off the starter (choke). See the "Starting a cold engine" section on page 6-1 for proper operation. 4 1. Arrow mark positioned over "RES" This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 39
4 1. Seat lock lever 1. Seat holder 2. Projection EBU18901 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. Storage compartment ECB00130 CAUTION: Do not store metal - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 40
EBU18970 Rear carrier G G Do not exceed the load limit of 80.0 kg (176 lb) for the rear carrier. Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV. EBU19130 4 Adjusting the front and rear shock absorber assemblies 1. Storage compartment G G Do not exceed the load limit of 2.0 kg - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 41
4 1. Spring preload adjusting ring 2. Position indicator 1. Special wrench NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. Spring preload setting: Minimum (soft): 1 Standard: 2 Maximum (hard): 5 4-22 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 42
EWB00350 WARNING POTENTIAL HAZARD Improper shock absorber assembly adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorber assemblies on the left and right side to the same - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 43
G G 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 difficult. Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged. 4 EWB00010 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 44
items in the table has to be performed by a Yamaha dealer. Refer to the "Periodic maintenance and lubrication chart" on page 8-3 to determine which service should be performed by a Yamaha dealer. ITEM Fuel ROUTINE • Check fuel level in fuel tank, and add recommended fuel if necessary. • Check fuel - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 45
you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. 5-2 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 46
EBU19530 EBU19590 Fuel Make sure that there is sufficient fuel in the tank. (See page 4-16.) EWB00500 Final gear oil Make sure that the final gear oil is at the specified level. Add oil as necessary. (See page 8-15.) EBU19600 WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 47
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. EBU19761 5 Throttle lever Check the operation of the throttle lever - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 48
EBU19801 Tires EWB00551 WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 49
G G G Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. Minimum tire pressure: Front: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Use no more than the following pressures when seating the tire - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 50
5 Recommended pressure: Front 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Rear 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Maximum: Front 28.0 kPa (4.1 psi) (0.280 kgf/cm²) Rear 28.0 kPa (4.1 psi) (0.280 kgf/cm²) EBU19830 1. - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 51
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 CAUTION: See the "Engine break-in" section on page - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 52
4. Shift the transmission into neutral. The neutral indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the electrical circuit. NOTE: The engine can be started under the following conditions: G The transmission is in neutral. G The rear brake lever is - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 53
G If the battery is discharged, pull the recoil starter to start the engine. EBU20291 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 54
EWB00660 WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or even a person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no people or obstacles behind you. When it is safe to - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 55
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. EWB00690 WARNING POTENTIAL HAZARD Opening the throttle before releasing the shift pedal. WHAT CAN HAPPEN The ATV could wheelie. This would - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 56
EWB00650 EBU20672 WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating and lose traction. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 57
at any time. 320 km (200 mi) or 20 hours and beyond The ATV can now be operated normally. ECB00220 CAUTION: If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV. EBU20721 1. Parking brake lock plate 6 Parking When parking the - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 58
EBU20830 Parking on a slope EWB00790 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, place the ATV - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 59
G G G ity or suitability. Choose a genuine Yamaha accessory, or one that is equivalent in design and quality. Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV. Do not mount an - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 60
G G G G 6 G G G Load cargo on the carriers as close to the center of the ATV as possible. Put cargo at the rear of the front carrier, at the front of the rear carrier, and center it. Tie down cargo securely to the carriers. Make sure cargo in the trailer cannot move around. A shifting load can - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 61
EBU21131 RIDING YOUR ATV 7 7-1 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 62
safely. Before you begin to ride, be sure you have read this Owner's Manual completely and understand the operation of the controls. Pay partic- WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 63
offered by Yamaha. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner's Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-8872887. Riding your ATV requires skills acquired - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 64
This ATV is designed to carry operator and cargo only - passengers prohibited. EWB00910 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. - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 65
Apparel EWB00920 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. - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 66
sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. 7 EWB00930 WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 67
accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner's Manual for this ATV on page 5-5. Always maintain proper tire pressure as described in the Owner's Manual on page 5-6. EWB00010 Do not operate at speeds too fast for your skills or the conditions. EWB00960 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 68
Speed limiter For riders less experienced with this model, the throttle lever housing is equipped with a 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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 69
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 7-9 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 70
During operation Always keep your feet on the footboards during operation, otherwise they may contact the rear wheels. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 71
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. Modifications EWB01000 WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 72
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. EWB01010 WARNING POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 73
HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets. EWB01030 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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 74
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. EWB01040 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 75
HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. EWB01060 7 WARNING When riding in an area where you might - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 76
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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 77
When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 78
this skill be learned first at low speed. EWB01310 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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 79
turn to avoid tipping over. Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. 1. Lean towards inside of turn. 2. Support your weight on the outer footboard. 7 This procedure should be practiced at slow speed many times in a large off-road area with no - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 80
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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 81
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 a hill: Always follow proper procedures as described in the Owner's Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 82
could come off the ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the ATV immediately on the uphill side. EWB02420 WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 83
brake. 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. G 7 7-23 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 84
control or cause the 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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 85
7 7-25 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 86
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 a hill: Always follow proper procedures as described in the Owner's Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 87
7 7-27 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 88
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. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 89
1. Air filter case check hose ECB00240 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 fresh water if it has been operated in salt water or muddy conditions. 7 7-29 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 90
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 If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 91
on extremely slippery surfaces such as ice, since all control may be lost. EWB01170 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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 92
G G G 7 G If your ATV begins to tip while turning: Lean more into the turn to regain balance. If necessary, gradually let off the throttle and/or steer to the outside of the turn. (See page 7-18.) If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 93
maintenance and lubrication chart should be considered as a general guide under normal riding conditions. However, DEPENDING ON THE WEATHER dealer perform the service if you are not familiar with maintenance work. EBU21701 Owner's manual and tool kit Be sure to put this owner's manual in the plastic - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 94
use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized Yamaha ATV dealer. 1. Owner's tool kit 2. Low-pressure tire gauge 8 The service information included in this manual and the tools provided in the owner's tool kit are intended - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 95
EBU21742 Periodic maintenance chart for the emission control system NOTE: G For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. G For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 96
INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first month km (mi) hours 6 7 * Exhaust system Spark arrester • Check for leakage and replace gasket(s) if necessary. • Check for looseness and tighten all screw clamps and joints if necessary. • Clean. 1 320 (200) 20 3 1300 (800) 80 6 EVERY - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 97
EBU21863 General maintenance and lubrication chart INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first month km (mi) hours 1 2 3 * * Air filter element Clutch Front brake • Clean and replace if necessary. • Check operation and adjust if necessary. • Check operation and correct if - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 98
INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first month km (mi) hours 9 10 11 12 13 14 Drive shaft universal joint Chassis fasteners Shock absorber assemblies Stabilizer bushes Knuckle pivots Steering shaft Steering system Axle boots Engine oil Engine oil filter element Engine oil - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 99
2500 5000 (1600) (1600) (3200) 160 160 320 24 * √ √ √ √ √ √ √ √ √ 25 26 * * 8 EBU28390 NOTE: G The air filter needs more frequent service if you are riding in unusually wet or dusty areas. G Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. 8-7 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 100
• Every two years replace the internal components of the brake master cylinder and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged. 8 8-8 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 101
EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU23211 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 102
normally). NOTE: If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 103
3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. Tightening torque: Spark plug: 17.5 Nm (1.75 m·kgf, 12.7 ft·lbf) NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4-1/2 turn past - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 104
To change the engine oil (with or without oil filter element cleaning) 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap, and then remove - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 105
ECB00310 CAUTION: When removing the engine oil drain bolt, the compression spring, oil strainer and O-ring will fall out. Take care not to lose these parts. NOTE: Skip steps 5-9 if the oil filter element is not being cleaned. 5. Remove the oil filter element cover by removing the bolts, and then - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 106
Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 10. Install the oil strainer, compression spring, Oring and engine oil drain bolt. Tighten the engine oil drain bolt to the specified torque. ECB00320 Recommended oil: See page 10-1. Oil quantity: Without oil filter - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 107
EBU28560 Final gear oil The final gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 108
To change the final gear oil 1. Remove the final gear case guard by removing the bolts. 1. Final gear oil drain bolt 8 1. Final gear case guard 2. Bolt 5. Install the drain bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft· - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 109
ECB00420 CAUTION: Be sure no foreign material enters the final gear case. 7. Install the oil filler bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 1. Final gear oil filler bolt 2. Correct oil level 3. Final gear oil - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 110
In addition, the differential gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the differential gear oil level 1. Place the ATV on a level surface. NOTE: The differential gear oil level must be - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 111
To change the differential gear oil 1. Place the ATV on a level surface. 2. Place an oil pan under the differential gear case to collect the used oil. 3. Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case. 5. Add - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 112
Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 7. Check the differential gear case for oil leakage. If oil is leaking, check for the cause. EBU23671 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 113
1. Air filter case cover 2. Air filter case cover holder 1. Air filter element assembly 3. Pull the air filter element assembly out of the air filter case. 4. Remove the sponge material from the air filter element. 8 8-21 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 114
6. Squeeze the excess water or solvent out of the sponge material and let it dry. ECB00470 CAUTION: Do not twist the sponge material when squeezing it. G Do not apply oil to the sponge material. G 1. Air filter element 2. Sponge material 7. Check the sponge material and replace it if damaged. 8. - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 115
9. Pull the sponge material over the air filter element. 10. Insert the air filter element assembly into the air filter case, and then install the air filter case cover by hooking the holders onto the air filter case. 11. Install the seat. NOTE: The air filter element should be cleaned every 20- 40 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 116
2. Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel. 3. Stop the engine and allow the exhaust pipe to cool. 4. Install the purging bolt, and then tighten it to the specified torque. - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 117
ECB00480 CAUTION: The carburetor has been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine. EBU24000 crease the engine idling speed, turn the throttle stop screw in direction - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 118
EBU24043 Adjusting the throttle cable free play The throttle cable free play should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The throttle cable free play should measure 3.0- 5.0 mm (0.12-0.20 in) at the throttle lever. - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 119
EBU24080 EBU24171 Adjusting the reverse lock release cable The reverse lock release cable stretches with use, which can result in improper function. Therefore, the reverse lock release cable should be checked and adjusted at the intervals specified in the periodic maintenance and lubrication chart - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 120
EBU28421 EBU24251 Rear brake friction plates The rear brake is provided with a wear indicator, which allows you to check the brake friction plate wear without having to disassemble the brake. To check the brake friction plate wear, check the position of the wear indicator while applying the brake. - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 121
G Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4 tion, have the oil seals of the brake master cylinder and calipers as well as the brake hoses replaced at the intervals listed - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 122
adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: G Make sure the brakes operate smoothly and that the free play is correct. G Make sure the brakes do not drag. G Make sure the brakes are - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 123
1. Brake lever free play 1. Loosen the locknut at the brake lever and fully turn in the brake lever free play adjusting bolt. 1. Locknut 2. Brake lever free play adjusting bolt 2. Fully loosen the brake lever free play adjusting nut on the brake cable at the final gear case. 8 8-31 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 124
1. Brake lever free play adjusting nut 8 3. Push the brake camshaft lever in direction (a) until it stops [apply approximately 47 N (10.6 lbf) (4.8 kgf) of force], and then turn the brake pedal free play adjusting nut on the brake cable at the final gear case so that gap "A" measures 2.5-3.0 mm - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 125
1. Brake lever free play adjusting nut 2. Brake camshaft lever 3. Gap "B" 1. Locknut 2. Brake lever free play adjusting bolt 6. Tighten the locknut at the brake lever. NOTE: When adjusting the rear brake lever free play: G Be sure not to step on the brake pedal. G Make sure the brake pedal does - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 126
or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: G Make sure the brakes operate smoothly and that the free play is correct. G Make sure the brakes do not drag. Replacement of brake components requires - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 127
EBU24740 Brake light switches The operation of the brake light switches must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 128
NOTE: When tightening the locknut, hold the adjusting bolt with a screwdriver so that the adjusting bolt does not turn together with the locknut. EBU24890 Checking and lubricating the cables The operation and the condition of all control cables should be checked before each ride, and the cables and - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 129
WHAT CAN HAPPEN Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. Replace damaged cables. EBU24911 Front brake - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 130
EBU24930 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Brake pedal Shift pedal - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 131
Recommended lubricant: Lithium-soap-based grease EBU25021 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer replace the stabilizer bushes if necessary. EBU25050 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 132
EBU25212 Battery This model is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. Check and, if necessary, tighten the battery lead connections. ECB00620 CAUTION: Never attempt to remove the battery - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 133
2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. To install the battery NOTE: Be sure the battery is fully charged. 1. Place the battery in its compartment. 2. Make sure to properly connect the battery leads to the battery - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 134
EBU25313 Replacing a fuse 8 1. 2. 3. 4. 5. Main fuse Spare main fuse Spare fuse Four-wheel-drive motor fuse Fuse box 1. 2. 3. 4. 5. Headlight fuse Ignition fuse Auxiliary DC jack fuse Carburetor warmer fuse Spare fuse The main fuse and the fuse box are located under the seat. (See page 4-19.) - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 135
2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Ignition fuse: 15.0 A Four-wheel-drive motor fuse: 10.0 A Auxiliary DC jack fuse: 10.0 A Carburetor warmer fuse: 10.0 A EWB02151 HOW TO AVOID THE HAZARD Always - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 136
1. Coupler 2. Screw 1. Headlight beam adjusting screw 2. Headlight unit screw 8 3. Remove the headlight unit from the headlight assembly by removing the headlight beam adjusting screw and headlight unit screws. 4. Remove the headlight bulb holder cover by pulling it off. 8-44 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 137
6. Remove the defective bulb by pulling it out. EWB02180 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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 138
ECB00670 CAUTION: Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. 10. Place the headlight unit in the original position, and then install the screws. 11. Place the headlight assembly in the original position, and then install the screws. 12. - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 139
1. Headlight beam adjusting screw EBU25631 1. Storage compartment 2. Nut Replacing the tail/brake light bulb If the tail/brake light bulb burns out, replace it as follows. 1. Open the storage compartment. (See page 4-20.) 2. Remove the tail/brake light assembly by removing the nuts together with - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 140
1. Tail/brake light bulb holder 2. Tail/brake light assembly 1. Tail/brake light bulb holder 2. Tail/brake light bulb 8 4. Remove the defective bulb by pushing it in and turning it counterclockwise. 5. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 141
G Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel. 1. Wheel nut 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. EBU25700 1. Arrow mark 8 Installing a - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 142
trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills. EWB02260 1. - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 143
HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces. 8 8-51 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 144
EBU25751 Troubleshooting chart 1. Fuel There is enough fuel. Check the fuel level in the fuel tank. There is no fuel. Supply fuel. Check the compression. The engine - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 145
EBU25860 CLEANING AND STORAGE EBU25870 Cleaning Frequent, thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the ATV: a. Block off the end of the exhaust pipe to prevent water - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 146
and, if necessary, protect it against dust with a porous cover. ECB00720 Long-term Before storing your ATV for several months: 1. Follow all the instructions in the "Cleaning" section of this chapter. 2. Turn the fuel cock lever to "OFF". 3. Drain the carburetor float chamber by loosening the drain - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 147
6. 7. 8. 9. b. Pour a teaspoonful of engine oil into the spark plug bore. c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 148
cylinder Displacement: 387.0 cm³ Bore × stroke: 83.0 × 71.5 mm (3.27 × 2.81 in) -20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C Recommended engine oil grade: API service SG type or higher, JASO standard MA Engine oil quantity: Without oil filter element replacement: 2.90 L (3.07 US qt) (2.55 Imp.qt) 10-1 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 149
With oil filter element replacement: 3.00 L (3.17 US qt) (2.64 Imp.qt) Spark plug (s): Manufacturer/model: NGK/DR8EA Spark plug gap: 0.6-0.7 mm (0.024-0.028 in) Final gear oil: Type: Yamaha Friction Modified Shaft Drive Gear Oil (Part No.: ACC-SHAFT-LU-00) Quantity: 0.50 L (0.53 US qt) (0.44 Imp. - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 150
Reverse gear: 22/17 × 35/15 (3.020) Chassis: Frame type: Steel tube frame Caster angle: 3.0 ° Trail: 17.0 mm (0.67 in) Front tire: Type: Tubeless Size: AT25 x 8-12 Manufacturer/model: ITP/MUD LITE Rear: 25.0 kPa (3.6 psi) (0.250 kgf/cm²) Minimum: Front: 22.0 kPa (3.2 psi) (0.220 kgf/cm²) Rear: 22 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 151
Rear brake: Type: Wet multiple disc brake Operation: Left hand and right foot operation Headlight: Bulb type: Krypton bulb Bulb voltage, wattage x quantity: Headlight: 12 V, 30.0/30.0 W × 2 Tail/brake light: 12 V, 5.0/21.0 W × 1 Meter lighting: 12 V, 1.7 W × 1 Neutral indicator light: 12 V, 1.7 W - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 152
Four-wheel-drive motor fuse: 10.0 A 10 10-5 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 153
EBU25981 CONSUMER INFORMATION EBU26011 EBU26020 Identification numbers Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 154
1. Vehicle identification number (front left side) 1. Model label NOTE: The vehicle identification number is used to identify your ATV. EBU26050 11 Model label The model label is affixed at the location in the illustration. Record the information on this label in the space provided. This - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 155
EBU26060 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 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 156
) 15000 (9600) 17500 (11200) 20000 (12800) 22500 (14400) 25000 (16000) hours 20 80 160 320 480 640 800 960 1120 1280 1440 1600 DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 11 11-4 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 157
to: 1. Operate and maintain the ATV as specified in the appropriate owner's manual; 2. Give notice to an authorized Yamaha ATV dealer of any and all An inspection and registration fee will be charged for this service. EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation, USA also warrants - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 158
specified in the Owner's and Service Manual. We do recommend, however, service, you must take it to any authorized Yamaha ATV dealer within the continental United States. Be sure to bring your warranty registration card or other valid proof of the original date of purchase. If a question or problem - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 159
no extra cost. TRIP gives you up to $150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 160
isn ' t convenient, contact Yamaha with your Primar y ID number (your frame number). We ' ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O. Box 6555 Cypress, CA 90630 11 WARNING Indicates a potential hazard that could result in serious injury or death. 11-8 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 161
EBU26132 11 11-9 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 162
INDEX A Accessories and loading ...6-8 Accessories, auxiliary jack ...4-23 Air filter element, cleaning ...8-20 Axle boots ...8-34 D Differential gear lock indicator light ...4-3 Differential gear oil ...5-3, 8-17 Drive shaft universal joint, lubricating ...8-38 E Engine break-in ...6-6 Engine, - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 163
switch ...4-6 Owner's manual and tool kit ...8-1 T Tail/brake light bulb, replacing ...8-47 Throttle cable free play, adjusting ...8-26 Throttle lever ...4-10, 5-4 Tire pressure, measuring ...5-6 Tires ...5-5 Tire wear limit ...5-7 Troubleshooting ...8-50 Troubleshooting chart ...8-52 P Parking - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 164
W Warranty, extended ...11-7 Warranty, limited ...11-5 Wheel bearings, checking ...8-38 Wheel, installing ...8-49 Wheel, removing ...8-48 - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 165
- 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 166
and 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 IN USA 2006.08-1.7×2 CR (E) - 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 167
- 2007 Yamaha Motorsports Big Bear 400 IRS 4x4 Exploring Edition | Owners Manual - Page 168
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READ THIS MANUAL CAREFULLY!
It contains important safety information.
This ATV should not be ridden by anyone under 16 years of age.
WARNING
OWNER’S MANUAL
4S1-F8199-10
LIT-11626-20-45
YFM40FBW