brake YAMAHA WARRIOR 350 2001 Owner's Guide

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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.
Crankcase 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.
• Replace if necessary.
Engine oil strainer
• Clean.
Drive chain
• Check and adjust slack/alignment/clean/lube.
Brakes*
• Check operation/fluid leakage/see NOTE page 8-8.
• Correct if necessary.
Clutch*
• Check operation.
• Adjust if necessary.
Wheels*
• Check balance/damage/runout.
• Replace if necessary.

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* It is recommended that these items be serviced by a Yamaha dealer.
** Lithium-soap-based grease
NOTE:

Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, 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 caliper cylinder, replace the oil seals every two
years.
3. Replace the brake hoses every four years, or if cracked or damaged.
Wheel bearings*
• Check bearing assembly for looseness/damage.
• Replace if damaged.
Steering system*
• Check operation.
• Repair if damaged.
• Check toe-in.
• Adjust if necessary.
Upper and lower arm
pivot and steering
shaft*
• Lubricate every 6 months.**
Rear arm pivot*
• Lubricate every 6 months.**
Fittings and Fasteners*
• Check all chassis fittings and fasteners.
• Correct if necessary.
Battery*
• Check specific gravity.
• Check breather hose for proper operation.
• Correct if necessary.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year

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1. Wear indicator a. Wear limit 1.0 mm
1. Indicateur d’usure a. Limite d’usure 1,0 mm
1. Indicador de desgaste a. Límite de desgaste 1,0 mmFront
Avant
Delantero
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Front and rear brake pad inspection
Each brake pad is provided with a wear indica-
tor. The indicators allow checking of brake pad
wear without disassembling the brake. Apply
the brake and inspect the wear indicators. If
they are ALMOST in contact with the disc
plate, ask a Yamaha dealer to replace the pads.
1. Wear indicator a. Wear limit 1.0 mm
1. Indicateur d’usure a. Limite d’usure 1,0 mm
1. Indicador de desgaste a. Límite de desgaste 1,0 mmRear
Arrière
Trasero

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1. Minimum level mark “LOWER”
1. Repère de niveau minimum “LOWER”
1. Marca de nivel mínimo “LOWER”Front
Avant
Delantero
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Inspecting the brake fluid level
Insufficient brake fluid may let air enter the
brake system, possibly causing the brakes to
become ineffective.
Before riding, check that the brake fluid is
above the lower level and replenish when nec-
essary.
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 flu-
id. Otherwise, the rubber seals may dete-
riorate, causing leakage and poor brake
performance.NOTE:If DOT 4 is not available, DOT 3 can be used.Recommended brake fluid: DOT 4
1. Minimum level mark “LOWER”
1. Repère de niveau minimum “LOWER”
1. Marca de nivel mínimo “LOWER”Rear
Arrière
Trasero

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3. Refill with the same type of brake fluid.
Mixing fluids may result in a harmful
chemical reaction and lead to poor brake
performance.
4. Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
5. Brake fluid may deteriorate painted sur-
faces or plastic parts. Always clean up
spilled fluid immediately.
6. Have a Yamaha dealer check the cause if
the brake fluid level goes down.

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Brake fluid replacement
1. Complete fluid replacement should be
done only by trained Yamaha service per-
sonnel.
2. Have a Yamaha dealer replace the follow-
ing components during periodic mainte-
nance or when they are damaged or
leaking.
a. Replace all rubber seals every two years.
b. Replace all hoses every four years.

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Front brake lever free play adjustment
The front brake lever free play should be 4 ~
8 mm. If the free play is incorrect, adjust it as
follows.
1. Loosen the locknut.
2. Turn the adjusting bolt so that the brake
lever movement is 4 ~ 8 mm before the
adjusting bolt contacts the master cylin-
der piston.
3. 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:l
Make sure the brakes operate smoothly
and that the free play is correct.
l
Make sure the brakes do not drag.
l
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.
1. Locknut 2. Adjusting bolt a. 4 ~ 8 mm
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste

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a. 10 mm
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Rear brake adjustmentNOTE:Adjust the rear brake before inspecting the rearbrake pads.
Pedal height adjustment
The top of the brake pedal should be posi-
tioned 10 mm below the top of the footrest. 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:l
Make sure the brakes operate smoothly
and that the free play is correct.
l
Make sure the brakes do not drag.
l
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.

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1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
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Parking brake adjustment
Parking brake adjustment may be required if
the parking brake does not hold properly.
1. Fully loosen the parking brake cable ad-
justing bolt and locknut on the left lever
holder.
2. Loosen the locknut and adjusting bolt on
the rear brake caliper.
3. Screw in the adjusting bolt by hand until it
feels tight, then screw it out 1/4 turn.
Tighten the locknut to the specified
torque.CAUTION:When tightening the locknut, hold the adjust-
ing bolt with a wrench so that the adjustingbolt does not turn together with the locknut.Tightening torque:
16 Nm (1.6 m·kg)
1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste

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a. Cable length (46 ~ 50 mm)
a. Longueur de câble (46 à 50 mm)
a. Longitud del cable (46 ~ 50 mm)
4. Turn the adjusting bolt on the lever holder
so that cable length a is 46 ~ 50 mm.
5. Tighten the locknut on the lever holder.
WARNING
Operating with improperly adjusted brakes
could cause the brakes to malfunction result-
ing in reduced braking performance. This
could increase the chance of a collision or acci-
dent. After adjusting the parking brake, block
the rear of the machine off the ground and
spin the rear wheels. Check to make sure there
is no brake drag. If brake drag is noticed, per-form the adjustment again.