brake YAMAHA BEAR TRACKER 250 2002 Owner's Guide

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*•Check valve clearance.
•Adjust if necessary.
Spark plug•Check condition.
•Adjust gap and clean.
•Replace if necessary.Air filter•Clean.
•Replace if necessary.Every 20~40 hours
(More often in wet or dusty areas.)
Carburetor*•Check idle speed/starter operation.
•Adjust if necessary.Cylinder head breather
system*•Check breather hose for cracks or damage.
•Replace if necessary.Exhaust system*•Check for leakage.
•Retighten if necessary.
•Replace gasket if necessary.Fuel line*•Check fuel hose for cracks or damage.
•Replace if necessary.Engine oil
•Replace (Warm engine before draining).Engine oil filter
•Clean.Engine oil strainer
•Clean.Final gear oil•Check oil level/oil leakage.
•Replace.Front brake*•Check operation/fluid leakage/see NOTE page 8-4.
•Correct if necessary.Rear brake*•Check operation.
•Adjust if necessary.Clutch*•Check operation.
•Adjust if necessary.EE.book Page 7 Monday, June 25, 2001 2:27 PM

8-8 * It is recommended that these items be serviced by a Yamaha dealer.
** Lithium soap base grease.
NOTE:Recommended brake fluid: DOT 4
Brake fluid replacement:
1. When disassembling the master cylinder or cali-
per, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and cal-
iper, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if
cracked or damaged.
WARNING
Indicates a potential hazard that could
result in serious injury or death.
Wheels*•Check balance/damage/runout.
•Repair if necessary.Wheel bearings*•Check bearing assemblies for looseness/damage.
•Replace if damaged.Front and rear
suspension*•Check operation.
•Correct if necessary.Steering system*•Check operation.
•Correct if damaged.
•Check toe-in.
•Adjust if necessary.Steering shaft*
•Lubricate every 6 months**.Fittings and Fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.Battery*•Check specific gravity.
•Check that the breather hose is working properly.
•Correct if necessary.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
EE.book Page 8 Monday, June 25, 2001 2:27 PM

8-45 1. Brake pad a. Wear limit: 1 mm
1. Plaquette de frein a. Limite d’usure: 1,0 mm
1. Pastilla del freno a. Límite de desgaste: 1,0 mm
1. Wear indicator 2. Wear limit
1. Indicateur d’usure 2. Limite de usure
1. Indicador de desgaste 2. Límite del freno
EBU00312
Front brake pad inspection
Inspect the brake pads for damage and wear. If
the thickness is less than the specified value, have
a Yamaha dealer replace the pads.NOTE:The wheels need to be removed to inspect the
brake pads. See page 8-67 for removal proce-
dures.
EBU00313
Rear brake shoe inspection
A wear indicator is provided on the rear brake.
This indicator allows checking of brake shoe wear
without disassembling the brake. Apply the rear
brake and check the position of the indicator. If the
indicator reaches the wear limit line, ask a
Yamaha dealer to replace shoes as a set.
EE.book Page 45 Monday, June 25, 2001 2:27 PM

8-47 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
EBU00755
Brake fluid level inspection
Insufficient brake fluid may let air enter the brake
system, possibly causing the brakes to become in-
effective.
Before riding, check that the brake fluid is above
the lower level and replenish when necessary.
Observe these precautions:
1. When checking the fluid level, make sure the
top of the master cylinder is level by turning
the handlebars.
2. Use only the designated quality brake fluid.
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake perfor-
mance.
3. Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reac-
tion and lead to poor brake performance.
4. Be careful that water does not enter the mas-
ter cylinder when refilling. Water will signifi-
cantly lower the boiling point of the fluid and
may result in vapor lock. Recommended brake fluid: DOT 4
EE.book Page 47 Monday, June 25, 2001 2:27 PM

8-49
5. Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
6. Have a Yamaha dealer check the cause if the
brake fluid level goes down.
EBU00820*
Brake fluid replacement
1. Complete fluid replacement should be done
only by trained Yamaha service personnel.
2. Have a Yamaha dealer replace the following
components during periodic maintenance or
when they are damaged or leaking.


Replace all rubber seals every two years.


Replace all hoses every four years.
EE.book Page 49 Monday, June 25, 2001 2:27 PM

8-51 a. Free play
a. Jeu
a. Juego libre
EBU00681
Front brake adjustment
The front brake lever should have a free play of
zero mm at the lever end. If not, ask a Yamaha
dealer to adjust it.
WARNING
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly
and that the free play is correct.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
EE.book Page 51 Monday, June 25, 2001 2:27 PM

8-53 1. Brake cable adjusting nut
2. Brake rod adjusting nut
1.Écrou de réglage du câble de frein
2.Écrou de réglage de la tringle de frein
1. Tuerca de ajustado del cable de freno
2. Tuerca de ajustado de la varrilla hasta
a. 20 ~ 30 mm
EBU00328*
Rear brake adjustment
Brake pedal
1. Fully loosen the adjusting nut on the brake
cable.
2. Turn the adjusting nut on the brake rod until
free play is 20 ~ 30 mm.
EE.book Page 53 Monday, June 25, 2001 2:27 PM

8-55 1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
1. Brake cable adjusting nut a. 0 ~ 1 mm
1.Écrou de réglage du câble de frein
1. Tuerca de ajustado del cable de freno
Brake lever
1. Loosen the locknut and fully turn in the ad-
justing bolt on the handlebar.
2. Turn the adjusting nut on brake cable to pro-
vide a gap of 0 ~ 1 mm between the cam
shaft lever and pin.
EE.book Page 55 Monday, June 25, 2001 2:27 PM

8-57 1. Locknut 2. Adjusting bolt a. 5 ~ 8 mm
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
3. Turn the adjusting bolt until free play reaches
5 ~ 8 mm at the lever pivot.
4. Tighten the locknut.
WARNING
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly
and that the free play is correct.


Make sure the brakes do not drag.
Replacement of brake components re-
quires professional knowledge. These pro-
cedures should be performed by a Yamaha
dealer.
EE.book Page 57 Monday, June 25, 2001 2:27 PM

8-59 1. Rear brake light switch
2. Adjusting nut
1. Contacteur de feu stop sur frein arrière
2.Écrou de réglage
1. Interruptor de la luz de freno trasero
2. Tuerca de ajuste
EBU00834
Adjusting the rear brake light switch
The rear brake light switch, which is activated by
the brake pedal and brake levers, is properly ad-
justed when the brake light comes on just before
braking takes effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding the rear brake
light switch in place. To make the brake light come
on earlier, turn the adjusting nut in direction
a. To
make the brake light come on later, turn the adjust-
ing nut in direction
b.
EE.book Page 59 Monday, June 25, 2001 2:27 PM