2012 Yamaha Motorsports Big Bear 400 4x4 IRS Owners Manual
2012 Yamaha Motorsports Big Bear 400 4x4 IRS Manual
2012 Yamaha Motorsports Big Bear 400 4x4 IRS manual content summary:
- 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 1
READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER'S MANUAL YFM40FBB YFM40FBHB WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-25-02 4S1-F8199-15 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 2
EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | 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 notice labels on the ATV. G Never - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 4
CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 5
at the time of manufacture. Please check your local riding laws and regulations before operating this ATV. EBU17402 YFM40FBB/YFM40FBHB OWNER'S MANUAL ©2011 by Yamaha Motor Corporation, U.S.A. 1st edition, February 2011 All rights reserved. Any reprinting or unauthorized use without the written - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 6
EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU17420 TABLE OF CONTENTS LOCATION OF THE WARNING AND SPECIFICATION LABELS ...1-1 SAFETY INFORMATION ...2-1 DESCRIPTION ...3-1 Left view ...3-1 Right view...3-1 Controls and - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 7
TERRAIN ...7-20 SLIDING AND SKIDDING...7-21 WHAT TO DO IF...7-22 WHAT TO DO...7-22 PERIODIC MAINTENANCE AND ADJUSTMENT...8-1 Owner's manual and tool kit ...8-2 Periodic maintenance chart for the emission control system ...8-3 General maintenance and lubrication chart ...8-5 Checking the spark plug - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 8
48 Removing a wheel ...8-50 Installing a wheel ...8-50 Troubleshooting ...8-52 Troubleshooting chart ...8-53 CLEANING AND STORAGE ...9-1 Cleaning ...9-1 Storage 11-4 Maintenance record ...11-5 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY ...11-6 YAMAHA EXTENDED SERVICE (Y.E.S.) ...11-8 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 9
EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 1 2 3 4 5 6 7 8 9 10 1-1 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 10
EBU17670 1 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. 1 2 5ND-F4877-30 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 11
4 6 1 WARNING UNDER 16 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. 5 7 NEVER operate this ATV if you are under age 16. 1P0-F816L-00 1-3 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 12
1 8 Certification of Compliance This ATV complies with applicable provisions of ANSI/SVIA 1-2010 and is subject to an approved ATV action plan submitted by YAMAHA and on file with the U.S. Consumer Product safety Commission. YAMAHA MOTOR CORPORATION U.S.A. 10 6555 Katella Avenue, Cypress, - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 13
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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 14
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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 15
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 and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 16
EWB00072 G 2 WARNING Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nausea, confusion, and eventually death. Carbon Monoxide is a colorless, odorless, tasteless gas which may be - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 17
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor's Safety Hotline at 1-800-852-5344. 2 2-5 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 18
EBU17680 DESCRIPTION EBU17690 EBU17700 Left view 3 Right view 12 3 4 5 6 1 2 3 4 8 1. 2. 3. 4. 5. 6. 7. 8. 7 1. 2. 3. 4. 5. 6. 7. Spark arrester Air filter case Engine oil filler cap Spark plug Oil filter element Brake pedal Rear brake light switch 7 6 5 Fuel cock Recoil starter Throttle stop - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 19
EBU17712 Controls and instruments TIP 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 four- - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 20
EBU17725 INSTRUMENT AND CONTROL FUNCTIONS EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 4 EBU17770 Main switch The positions of the main switch are as follows: ON All electrical systems are supplied with power. The headlights, - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 21
EBU17815 Indicator lights and warning light Furthermore, this indicator light flashes: when the override switch is being pushed, G when the engine is being raced for 10 seconds or more. G TIP If the indicator light flashes under any other circumstances or the speedometer does not show the speed - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 22
ECB00010 4 NOTICE G The engine may overheat if the ATV is overloaded. In this case, reduce the load to specification. G Start the engine after making sure that the warning light is out. Continuous use while the warning light is on may cause damage to the engine. EBU29611 TIP Due to the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | 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. TIP If the ATV runs out of fuel, move the fuel - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 24
EBU18061 EBU18101 Handlebar switches Start switch " " Push this switch to crank the engine with the starter. See the starting instructions on page 6-1 prior to starting the engine. EBU18162 4 Light switch " / /OFF" Set this switch to " " to turn on the low beams, the taillight and the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 25
EBU28510 EWB00150 Override switch "OVERRIDE" 1 WARNING Always ride at a slow speed when the ATV is in four-wheel-drive differential gear lock, and allow extra time and distance for maneuvers. All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 26
EBU28432 On-Command four-wheel-drive switch "2WD"/"4WD" EWB00163 4 WARNING Always stop the ATV before changing from two-wheel drive to four-wheel drive and vice versa. The ATV handles differently in twowheel drive than in four-wheel drive in some circumstances. Changing from two-wheel drive to - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 27
EBU28372 On-Command differential gear lock switch "4WD"/"LOCK" EWB00131 control and have an accident if you cannot make a sharp enough turn for the speed you are traveling. This ATV is equipped with a switch allowing you to lock the differential gear when in four-wheel drive. Select the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 28
4 1. On-Command four-wheel-drive switch "2WD"/"4WD" 2. On-Command differential gear lock switch "4WD"/"LOCK" 1. Differential gear lock lever 2. On-Command four-wheel-drive switch "2WD"/"4WD" To lock the differential gear in four-wheel drive, make sure the On-Command four-wheel-drive switch is - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 29
and hold the override switch to disable the differential gear lock speed limiter. (See page 4-6 for a detailed explanation of this switch.) EBU18282 Throttle lever Once the engine is running, pushing the throttle lever will increase the engine speed. Regulate the speed of the ATV by varying the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 30
Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. EBU18323 Speed limiter 4 Your ATV is equipped with an adjustable speed limiter. The speed limiter keeps the throttle from fully opening, - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 31
4 1. Front brake lever EBU18442 1. Brake pedal Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 32
EBU18461 Parking brake Use the parking brake before starting the engine or after 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 G Always be sure you have - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 33
4 1. Shift pedal EBU18641 1. Reverse knob "REV" EBU27610 Reverse knob "REV" The reverse knob is used to shift into reverse. See the "Operating the reverse knob and driving in reverse" section on page 6-4 before operating this ATV in reverse. Recoil starter Firmly grasp the handle and pull - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 34
WARNING Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions. 1. Before refueling, turn off the engine and be sure that no one is sitting on the vehicle. Never refuel while smoking, or while in - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 35
of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers. 2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole. Stop filling when the fuel reaches the bottom of the filler tube. - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 36
not exceed 10% (E10). Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems. Fuel cock The fuel cock supplies fuel from the tank to the carburetor while also filtering it. The fuel cock lever positions are explained - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 37
ON RES 4 1. Arrow mark positioned over "ON" 1. Arrow mark positioned over "RES" With the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding. This indicates reserve. With the fuel cock lever in this - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 38
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. Seat lock lever 1. Starter (choke) " EBU18881 " To install the seat Insert the projections on the front of the seat into the seat holders - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 39
4 1. Seat holder 2. Projection EBU18902 1. Storage compartment G G Storage compartment ECB00130 Do not exceed the load limit of 2.0 kg (4 lb) for the storage compartment. Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV. NOTICE Do not store metal or sharply edged objects, like - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 40
EBU18972 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. EBU19183 4 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 41
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 EWB00011 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 42
inspection and maintenance procedures and schedules described in the Owner's Manual. EWB00481 5 WARNING Failure to inspect or maintain the vehicle the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 43
ITEM ROUTINE • Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check brake pads for wear, and replace if necessary. • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary. • Check hydraulic system for leakage. Correct - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 44
EBU19541 Fuel Make sure that there is sufficient fuel in the tank. (See page 4-15.) EBU19560 G G Engine oil Make sure that the engine oil is at the specified level. Add oil as necessary. (See page 8-11.) 5 EBU19590 Check for correct free play in the rear brake lever and brake pedal. If the free - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 45
Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, check the brake pads and friction plates for wear. (See page 8-28.) EBU19761 pressure below the minimum specified could also cause the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 46
5 1. Low-pressure tire gauge 1. Tire wear limit Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. Tire information This ATV is equipped with tubeless tires with valves. EWB02551 WARNING Use of improper tires on this ATV may cause loss of control, - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 47
Front: Manufacturer/model: ITP/MUD LITE Size: AT25 x 8-12 Type: Tubeless Rear: Manufacturer/model: ITP/MUD LITE Size: AT25 x 10-12 Type: Tubeless Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 48
OPERATION EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU19901 6 Read the Owner's Manual carefully before riding the ATV. If there is a control or function you do not understand, ask your Yamaha dealer. EWB00631 1. Set the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 49
Position (3): Cold engine start with ambient temperature above 25 °C (80 °F). Ambient temp./starter (choke) position G be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. If the battery is discharged, pull the recoil starter to start the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 50
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 slightly open. EBU20541 Shifting This ATV has a 5-speed forward and 1-speed - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 51
3. Open the throttle gradually. WARNING! Always open the throttle gradually. Opening the throttle abruptly would increase the chance of an accident. It could make the ATV wheelie or overturn. [EWB00741] 4. Once the ATV has attained adequate speed, release the throttle lever. 5. Shift into second - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 52
ECB00170 NOTICE Before shifting, stop the ATV, otherwise the transmission may be damaged. 1. Bring the ATV to a complete stop and shift the transmission into neutral. 2. While applying the rear brake lever or brake pedal, turn the reverse knob clockwise with your right hand. 3. Shift the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 53
first gear, stop the engine, apply the parking brake, and then turn the fuel cock to "OFF". 6 1. Parking brake lock plate NOTICE If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the ATV. 6-6 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 54
EBU20844 Parking on a slope EWB00851 6 WARNING Avoid parking on hills or other inclines. Parking on a hill or other incline could cause the ATV to roll out of control, increasing the chance of an accident. If you must park on an incline, place the ATV transversely across the incline, shift into - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 55
Yamaha or modifications not specifically recommended by Yamaha, even if sold and installed by a Yamaha dealer. Aftermarket parts, accessories, and modifications While you may find aftermarket products similar in design and quality to genuine Yamaha Accessories, recognize that some aftermarket - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 56
G Never exceed the weight limits shown. An overloaded ATV can be unstable. MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, cargo, accessories, and tongue): 210.0 kg (463 lb) Front carrier: 40.0 kg (88 lb) Rear carrier: 80.0 kg (176 lb) Storage compartment: 2.0 kg (4 lb) Trailer - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 57
EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 6 6-10 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 58
EBU21132 RIDING YOUR ATV 7 7-1 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 59
Before you begin to ride, be sure you have read this Owner's Manual completely and understand the operation of the controls. Pay partic- G G WARNING not operate this ATV or allow anyone else to operate it without proper instruction. The risk of an accident is greatly increased if the operator does - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 60
niques described in this Owner's Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Riding your ATV requires skills acquired through practice - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 61
Apparel Always wear the following to reduce risk of injury in an accident: G Approved motorcycle helmet that fits properly G Eye protection (goggles, helmet face shield, or protective eyewear) G Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 62
. Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. WARNING! Failure to inspect the ATV before operating it and to maintain it properly increases the possibility of an accident or equipment - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 63
of control, an overturn, or other accident. To reduce the risk of an accident: 7-6 Take extra precautions when driving with a load or trailer. Follow these instructions and always use common sense and good judgment when carrying cargo or towing a trailer. - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 64
7 MAXIMUM LOADING LIMIT ATV loading limit (total weight of cargo, rider, accessories, and tongue): 210.0 kg (463 lb) Front carrier: 40.0 kg (88 lb) Rear carrier: 80.0 kg (176 lb) Storage compartment: 2.0 kg (4 lb) Trailer hitch: Pulling load (total weight of trailer and cargo): 4900 N (500 kgf, - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 65
this ATV 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. WARNING! Operating this ATV with improper modifications may cause changes in handling which in - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 66
To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 67
WARNING! Never operate this ATV on any public street, road or highway, even a dirt or gravel one. You could collide with another vehicle. [EWB01031] 7 Do not operate on rough, slippery, or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 68
7 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. WARNING! You could collide with another vehicle if operating in off-road areas where you cannot easily be seen. Mount a caution - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 69
area before trying more difficult terrain. Set the parking brake and follow the instruction on page 6-1 to start the engine. Once it has warmed up you Always follow proper procedures for turning as described in this Owner's Manual. Practice turning at low speeds before attempting to turn at faster - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 70
will let the wheel on the inside of the turn slip slightly, allowing the ATV to make the turn properly. 7 1. Lean towards inside of turn. 2. Support your weight on the outer footboard. This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 71
or loss of control. Use proper riding techniques described in this Owner's Manual. G Never operate the ATV on hills too steep for the ATV or 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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 72
7 Do not attempt to climb hills until you have mastered basic maneuvers on flat ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control. To climb a hill, you need traction, - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 73
side, or to a side if pointed straight uphill. Turn the 7-16 ATV around and remount, following the procedure described in the Owner's Manual. WARNING! Stalling, rolling backwards or improperly dismounting while climbing a hill could result in ATV overturning. If you cannot control the ATV, dismount - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 74
WARNING Going down a hill improperly could cause overturns or loss of control. Always follow proper procedures for going down hills as described in this Owner's Manual. G Always check the terrain carefully before you start down any hill. G Never operate the ATV on hills too steep for the ATV or for - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 75
of the ATV. 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. CROSSING A SLOPE EWB01632 WARNING Improperly crossing hills or turning on hills could cause loss - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 76
of drowning or other injuries, use care when crossing through water. Never operate this ATV water deeper than the depth specified in your Owner's Manual, as tires may float, increasing the risk of an overturn. 7-19 Test your brakes after leaving the water. If necessary, apply them several times - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 77
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. Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 78
cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. SLIDING AND SKIDDING EWB01662 7 WARNING Skidding or sliding improperly may cause you to lose control of this ATV. You may also regain traction - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 79
avoided on extremely slippery surfaces such as ice, since all control may be lost. 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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 80
G G 7 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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 81
dealer perform the service. EWB02562 WARNING Brake discs, calipers, drums, and linings can become very hot during use. To avoid possible burns, let brake components cool before touching them. The intervals given in the periodic maintenance charts should be considered as a general guide under normal - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 82
owner's tool kit and low-pressure tire gauge in the storage compartment. 1. Owner's tool kit 2. Low-pressure tire gauge 8 1. Owner's manual The service information included in this manual and the tools provided in the owner's tool kit are intended to assist you in the performance of preventive - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 83
EBU21743 Periodic maintenance chart for the emission control system TIP 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 mind - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 84
INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first month km (mi) hours • 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 6 12 2500 2500 5000 (1600) (1600) - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 85
EBU21865 General maintenance and lubrication chart TIP 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 mind that if the ATV - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 86
INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first month km (mi) hours • Check for cracks or other damage, and replace if necessary. • Replace. 6 * Wheels • Check runout and for damage, and replace if necessary. • Check tread depth and for damage, and replace if necessary. • Check air - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 87
INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first month km (mi) hours 15 16 * * Steering system Axle boots • Check operation and repair or replace if damaged. • Check toe-in and adjust if necessary. • Check for cracks or other damage, and replace if necessary. • Change. • Check ATV for - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 88
320 24 * Throttle lever √ √ √ √ √ 25 26 * * Front and rear brake switches Lights and switches √ √ √ √ √ √ √ √ √ √ EBU28391 8 TIP Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. G Hydraulic brake - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 89
EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU23213 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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 90
ATV is ridden normally). TIP 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. 1. Spark plug gap Spark plug gap: 0.6-0.7 mm (0.024-0.028 in) 8-10 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 91
To install the spark plug 1. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 2. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. Tightening torque: Spark plug: 18 Nm (1.8 m·kgf, - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 92
1. Engine oil filler cap 8 4. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to check the oil level. TIP The engine oil should be between the minimum and maximum level marks. 1. Engine oil dipstick 2. Maximum level mark 3. Minimum level mark 5. If the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 93
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 the engine oil drain bolt to drain the oil from the crankcase. NOTICE: When removing the engine oil drain bolt - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 94
Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 10. Apply a thin coat of clean engine oil to a new O-ring. 1. O-ring 2. Oil filter element 8 6. Clean the oil strainer and oil filter element with solvent. 7. Install the oil filter element and a new O-ring. TIP Make - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 95
engine oil drain bolt, be sure to install the O-ring, compression spring and oil strainer. [ECB00321] Tightening torque: Engine oil drain bolt: 32 Nm (3.2 m·kgf, 23 ft·lbf) 12. Refill with the specified amount of the recommended engine oil, and then install and tighten the engine oil filler cap. - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 96
dition, the final 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 final gear oil level 1. Place the ATV on a level surface. 2. Remove the final gear oil filler bolt and its Oring, and then check - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 97
3. Place an oil pan under the final gear case to collect the used oil. 4. Remove the final gear oil filler bolt, the final gear oil drain bolt and their O-ring to drain the oil from the final gear case. 6. Refill with the recommended final gear oil to the brim of the filler hole as shown. NOTICE: - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 98
However, when using this oil, noise from the final gear case may occur when applying the rear brake. 7. Install the oil filler bolt and its new O-ring, and then tighten the bolt to the specified torque. Tightening torque: Final gear oil filler bolt: 24 Nm (2.4 m·kgf, 17 ft·lbf) 8. Check the final - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 99
3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. 4. Check the gasket for damage, and replace it if necessary. 5. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque. Tightening - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 100
8. Check the differential gear case for oil leakage. If oil is leaking, check for the cause. EBU23686 Cleaning the air filter element 1 2 3 4 1. 2. 3. 4. Differential gear oil filler bolt Gasket Differential gear oil Correct oil level The air filter element should be cleaned at the intervals - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 101
1. Air filter case check hose 1. Place the ATV on a level surface. 2. Remove the seat. (See page 4-19.) 3. Remove the air filter case cover by unhooking the holders. 1. Air filter case cover 2. Air filter case cover holder 4. Pull the air filter element assembly out of the air filter case. 8 8- - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 102
1. Air filter element assembly 5. Remove the sponge material from the air filter element. 8 1. Air filter element 2. Sponge material 6. Clean the sponge material with water or solvent. WARNING! When using solvent to clean the sponge material, always use parts cleaning solvent or water. Never use - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 103
8. Check the sponge material and replace it if damaged. 9. Tap the air filter 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. 10. Pull the sponge material over the air filter element. 11 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 104
12. Install the seat. TIP The air filter element should be cleaned every 20- 40 hours. It should be cleaned more often if the ATV is operated in extremely dusty areas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions. Check the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 105
EWB02340 WARNING Do not start the engine when cleaning the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poisoning, possibly leading to death, and start a fire. Always let the exhaust system cool prior to touching exhaust components. EBU23940 Adjusting the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 106
ECB00480 NOTICE 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 3. Check the engine idling speed and, if necessary, adjust it to - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 107
TIP If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. EBU24047 1 (b) (a) 2 3 Adjusting the throttle lever free play The throttle lever free play should be checked and, if necessary, adjusted at the intervals specified in the periodic - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 108
if the lining thickness is less than 1.0 mm (0.04 in), have a Yamaha dealer replace the brake pads as a set. 8 WARNING Operating with improperly serviced or adjusted brakes could lead to a loss in braking ability and an accident. EBU28413 1 Checking the front brake pads and rear brake friction - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 109
TIP The wheels need to be removed to check the brake pads. (See page 8-50.) EBU28421 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, - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 110
G G 1 G Use only the specified brake fluid; otherwise, the rubber seals may deteriorate, causing leakage. Refill with the same type of brake fluid. Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction. Be careful that water does not enter the brake fluid reservoir when - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 111
EBU24281 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart. In addition, have the oil seals of the brake master cylinder and calipers as well as the brake hoses replaced at the intervals - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 112
TIP Always perform this maintenance completely in the following order whenever adjusting the rear brake. G When adjusting the rear brake, be sure to adjust both the brake pedal and the brake lever. G Before adjusting the brake lever and brake pedal free play, check the rear brake friction plates for - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 113
1. Loosen the locknut at the brake lever and fully turn in the 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. 1. Locknut 2. Brake lever free play adjusting bolt 1. Brake lever free play adjusting nut 8 8- - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 114
3. Push the brake camshaft lever in direction (a) until it stops [apply approximately 47 N (4.7 kgf, 10.6 lbf) 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 (0.10-0.12 in). 4. Push the brake camshaft - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 115
5. Check the brake lever free play and, if necessary, adjust it by turning the brake lever free play adjusting bolt at the brake lever. Turn the brake lever free play adjusting bolt in direction (a) to increase the free play, and in direction (b) to decrease it. EBU24230 Axle boots The axle boots - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 116
1. Rear axle boot (each side) EBU29881 1. Rear brake light switch 2. Rear brake light switch adjusting nut EBU24773 Brake light switches 8 The brake light, which is activated by the brake pedal and brake levers, should come on just before braking takes effect. The rear brake light switch for the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 117
TIP When tightening the locknut, hold the adjusting screw with a screwdriver so that the adjusting screw does not turn together with the locknut. EBU24901 Checking and lubricating the cables The operation and the condition of all control cables should be checked before each ride, and the cables and - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 118
EWB02581 G G WARNING Inspect cables frequently and replace if damaged. 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. Always make sure all control cables - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 119
Rear brake lever Brake pedal EBU28841 Shift pedal 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 8 8-39 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 120
EBU24963 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bearings. TIP - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 121
Recommended lubricant: Lithium-soap-based grease Recommended lubricant: Lithium-soap-based grease EBU29188 Battery The battery is located under the seat. (See page 4-19.) This model is equipped with a VRLA (Valve Regulated Lead Acid) battery. There is no need to check the electrolyte or to add - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 122
EWB02160 8 WARNING Battery electrolyte is poisonous and dangerous, as it contains sulfuric acid, which can cause severe burns. Avoid contact with skin, eyes or clothing. Always shield your eyes when working near batteries. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 123
To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electrical accessories. ECB00931 To install the battery TIP Be sure the battery is - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 124
4. Install the seat. (See page 4-19.) EBU28861 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, the four-wheel-drive - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 125
ECB00640 NOTICE To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. WARNING! Always use a fuse of the specified rating, and never use a substitute object in place of the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 126
1. Coupler 2. Screw 1. Headlight beam adjusting screw 2. Headlight unit screw 8 3. Remove the headlight unit from its cover by removing the headlight beam adjusting screw and headlight unit screws. 4. Remove the headlight bulb holder cover by pulling it off. 8-46 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 127
6. Remove the burnt-out bulb by pulling it out. 7. Insert a new headlight bulb into the bulb holder. NOTICE: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 128
9. Install the bulb holder cover. NOTICE: Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly. [ECB00671] 10. Install the headlight unit cover by installing the screws. 11. Place the headlight assembly in the original position, and then install the - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 129
1. Storage compartment 2. Nut 1. Tail/brake light bulb holder 2. Tail/brake light assembly 3. Remove the tail/brake light bulb holder (together with the bulb) by turning it counterclockwise. 4. Remove the burnt-out bulb by pushing it in and turning it counterclockwise. 8 8-49 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 130
1. Tail/brake light bulb holder 2. Tail/brake light bulb 1. Wheel nut 8 5. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 6. Install the bulb holder (together with the bulb) by turning it clockwise. 7. Install the tail/brake light assembly by - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 131
G Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel. 1. Tapered nut 1. Arrow mark 3. Lower the ATV to the ground. 4. Tighten the wheel nuts to the specified torques. Tightening torques: Front wheel nut: 55 Nm (5.5 m·kgf, 40 ft· - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 132
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. EWB02280 8 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 133
EBU25752 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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 134
EBU25860 CLEANING AND STORAGE EBU25881 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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 135
presence of ammonia) and areas where strong chemicals are stored. [ECB00721] 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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 136
ly, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 137
cylinder Displacement: 387 cm³ Bore × stroke: 83.0 × 71.5 mm (3.27 × 2.81 in) 10 -20 -10 0 10 20 30 40 50 ˚C Recommended engine oil grade: API service SG type or higher, JASO standard MA 10-1 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 138
Engine oil quantity: Without oil filter element replacement: 2.90 L (3.07 US qt, 2.55 Imp.qt) 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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 139
Reverse gear: 22/17 × 35/15 (3.020) Chassis: Frame type: Steel tube frame Caster angle: 4.0 ° Trail: 21.0 mm (0.83 in) Rear: 25.0 kPa (0.250 kgf/cm², 3.6 psi) Minimum: Front: 22.0 kPa (0.220 kgf/cm², 3.2 psi) Rear: 22.0 kPa (0.220 kgf/cm², 3.2 psi) Front wheel: Wheel type: Panel wheel Rim size: - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 140
Front suspension: Type: Double wishbone Spring/shock absorber type: Coil spring/oil damper Wheel travel: 147 mm (5.8 in) Rear suspension: Type: Double wishbone Spring/shock absorber type: Coil spring/oil damper Wheel travel: 192 mm (7.6 in) Tail/brake light: 12 V, 5.0/21.0 W × 1 Meter lighting: 12 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 141
EBU25981 CONSUMER INFORMATION EBU26013 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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 142
1. Vehicle identification number (front left side) 1. Model label EBU29662 TIP 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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 143
1 1. Vehicle Emission Control Information label 11 11-3 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 144
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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 145
) 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 11-5 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 146
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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 147
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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 148
no extra cost. TRIP gives you up to $250 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 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 149
, 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 hazardous situation which, if not avoided, could result in death or serious injury. 11-9 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 150
INDEX A Accessories and loading ...6-7 Accessories, auxiliary jack ...4-21 Air filter element, cleaning ...8-20 Axle boots ...8-35 D Differential gear oil ...5-3, 8-18 Drive shaft universal joint, lubricating ...8-40 E Engine break-in ...6-5 Engine, cold start ...6-1 Engine idling speed ...8-26 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 151
-wheel-drive switch ...4-7 Override switch ...4-6 Owner's manual and tool kit ...8-2 T Tail/brake light bulb, replacing ...8-48 Throttle lever ...4-10, 5-4 Throttle lever free play, adjusting ...8-27 Tires ...5-4 Troubleshooting ...8-52 Troubleshooting chart ...8-53 P Parking ...6-6 Parking brake - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 152
Wheel, installing ...8-50 Wheel, removing ...8-50 - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 153
Yamaha engineering teams that know your Yamaha from the inside out. Genuine Yamaha Service Manuals - Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use. Service manuals are available through your Yamaha dealer or you can order them directly through - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 154
seriously affect handling 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: PRINTED IN USA 2011.02-0.8×1 CR (E) - 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 155
- 2012 Yamaha Motorsports Big Bear 400 4x4 IRS | Owners Manual - Page 156
This ATV should not be ridden by anyone under 16 years of age.
WARNING
OWNER’S MANUAL
4S1-F8199-15
LIT-11626-25-02
YFM40FBB
YFM40FBHB
READ THIS MANUAL CAREFULLY!
It contains important safety information.