brake YAMAHA BEAR TRACKER 250 2004 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 plugCheck condition.
Adjust gap and clean.
Replace if necessary.Air filter elementClean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*Check starter (choke) operation.
Adjust engine idling speed.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 element
Clean.Engine oil strainer
Clean.Final gear oilCheck oil level/oil leakage.
Replace.Front brake*Check operation/fluid leakage/see NOTE page 8-8.
Correct if necessary.Rear brake*Check operation.
Adjust if necessary.Clutch*Check operation.
Adjust if necessary.U4XE65.book Page 7 Tuesday, May 6, 2003 1:38 PM

8-8 * It is recommended that these items be serviced by a Yamaha dealer.
NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
On the inner parts of the master cylinder and caliper, replace the oil seals every two years.
Replace the brake hoses every four years, or if cracked or damaged.
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 with lithium-soap-based grease
(all-purpose grease).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.Lights and switches*Check operation.
Adjust headlight beams.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U4XE65.book Page 8 Tuesday, May 6, 2003 1:38 PM

8-43 1. Brake pad (× 2) a. Brake pad thickness
1. Plaquette de frein (× 2) a.Épaisseur de plaquette de frein
1. Pastilla del freno (× 2) a. Espesor de la pastilla del freno
1. Wear indicator 2. Wear limit line
1. Indicateur d’usure 2. Ligne de limite d’usure
1. Indicador de desgaste 2. Límite de la línea de desgaste
EBU13770
Front brake pad check
Check the brake pads for damage and wear. If a
brake pad thickness is less than 1 mm, have a
Yamaha dealer replace the pads as a set.NOTE:_ The wheels need to be removed to check the
brake pads. (See page 8-65 for removal and in-
stallation procedures.) _
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.
U4XE65.book Page 43 Tuesday, May 6, 2003 1:38 PM

8-45 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
EBU13040
Brake fluid level check
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 minimum level mark and replenish if neces-
sary. A low brake fluid level may indicate worn
brake pads and/or brake system leakage. If the
brake fluid level is low, be sure to check the brake
pads for wear and the brake system for leakage.
Observe these precautions:

When checking the brake fluid level, make sure
the top of the brake fluid reservoir is level.


Use only the designated quality brake fluid, oth-
erwise, the rubber seals may deteriorate, caus-
ing leakage and poor brake performance.
Recommended brake fluid: DOT 4
U4XE65.book Page 45 Tuesday, May 6, 2003 1:38 PM

8-47

Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor brake performance.


Be careful that water does not enter the brake
fluid reservoir when refilling. Water will signifi-
cantly lower the boiling point of the fluid and
may result in vapor lock.


Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid im-
mediately.


Have a Yamaha dealer check the cause if the
brake fluid level goes down.
EBU11860
Brake fluid replacement
Complete fluid replacement should be done only
by trained Yamaha service personnel. Have a
Yamaha dealer replace the following components
during periodic maintenance or when they are
damaged or leaking.

Replace the oil seals every two years.


Replace the brake hoses every four years.
U4XE65.book Page 47 Tuesday, May 6, 2003 1:38 PM

8-49 1. Front brake lever
a. Front brake lever free play
1. Levier de frein avant
a. Jeu du levier de frein avant
1. Palanca del freno delantero
a. Juego de la palanca del freno delantero
EBU11880
Front brake lever free play
The front brake lever should have a free play of
zero mm at the lever end. If not, have a Yamaha
dealer check the brake system.
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.
_
U4XE65.book Page 49 Tuesday, May 6, 2003 1:38 PM

8-51 1. Adjusting nut (brake cable)
2. Adjusting nut (brake rod)
1.Écrou de réglage (câble de frein)
2.Écrou de réglage (tringle de frein)
1. Tuerca de ajuste (cable del freno)
2. Tuerca de ajuste (varilla del freno)
a. Brake pedal free play
a. Jeu à la pédale de frein
a. Juego libre del pedal del freno
EBU01074
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.
U4XE65.book Page 51 Tuesday, May 6, 2003 1:38 PM

8-53 1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
1. Adjusting nut (brake cable) 2. Lever
3. Pin a. Gap
1. Écrou de réglage (câble de frein) 2. Levier
3. Axe a. Jeu
1. Tuerca de ajuste (cable del freno) 2. Palanca
3. Pasador a. Separación
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.
E-8.fm Page 53 Tuesday, May 6, 2003 2:54 PM

8-55 1. Locknut 2. Adjusting bolt
a. Rear brake lever free play
1. Contre-écrou 2. Boulon de réglage
a. Jeu du levier de frein arrière
1. Contratuerca 2. Perno de ajuste
a. Juego de la palanca de freno trasero
3. Turn the adjusting bolt until free play reaches
5–7 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 requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
U4XE65.book Page 55 Tuesday, May 6, 2003 1:38 PM

8-57 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.
U4XE65.book Page 57 Tuesday, May 6, 2003 1:38 PM