brake YAMAHA WARRIOR 350 2003 Owner's Guide

7-77

If your ATV encounters shallow water:
Ride slowly and carefully through slow moving
water, watching for obstacles. Be sure to let
water drain from the ATV and CHECK YOUR
BRAKES FOR PROPER OPERATION when
you come out of the water. Do not continue to
ride your ATV until you have regained ade-
quate braking ability. (See pages 7-63 ~ 7-65.)
U5NF61.book Page 77 Wednesday, June 13, 2001 5:18 PM

8-7
EBU00262
3-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 element•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.
•Tighten if necessary.
•Replace gasket(s) 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.
•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.U5NF61.book Page 7 Wednesday, June 13, 2001 5:18 PM

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

Recommended brake fluid: DOT 4


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 routing.
•Correct if necessary.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U5NF61.book Page 8 Wednesday, June 13, 2001 5:18 PM

8-39 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 mm
Front
Avant
Delantero1. 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
EBU00309*
Front and rear brake pad inspection
Each brake pad is provided with a wear indicator
groove. The indicators allow checking of brake
pad wear without disassembling the brake. Apply
the brake and inspect the wear indicators grooves.
If the pad is worn to the point that the wear indica-
tor grooves are almost in contact with the disc
plate, ask a Yamaha dealer to replace the pads.
U5NF61.book Page 39 Wednesday, June 13, 2001 5:18 PM

8-41 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
Front
Avant
Delantero1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimoRear
Arrière
Trasero
EBU00918*
Inspecting the brake fluid level
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
when necessary.
Observe these precautions:

When checking the fluid level, make sure the
top of the master cylinder is level by turning the
handlebars.


Use only the designated quality brake fluid.
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake performance.
Recommended brake fluid: DOT 4
U5NF61.book Page 41 Wednesday, June 13, 2001 5:18 PM

8-43

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 master
cylinder when refilling. Water will significantly
lower the boiling point of the fluid and may re-
sult 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.
U5NF61.book Page 43 Wednesday, June 13, 2001 5:18 PM

8-45
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.
U5NF61.book Page 45 Wednesday, June 13, 2001 5:18 PM

8-47 a. Zero mm
a.Zéro mm
a. Cero mm
EBU00951
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.
U5NF61.book Page 47 Wednesday, June 13, 2001 5:18 PM

8-49 a. 10 mm
EBU00952*
Rear brake adjustment
Pedal height adjustment
The top of the brake pedal should be positioned
10 mm below the top of the footboard. 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 servic-
ing:

Make sure the brakes operate smoothly
and that the brake pedal position is cor-
rect.


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.
_
U5NF61.book Page 49 Wednesday, June 13, 2001 5:18 PM

8-51 1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
EBU00953
Parking brake adjustment
Parking brake adjustment may be required if the
parking brake does not hold properly.
1. Fully loosen the parking brake cable adjust-
ing bolt locknut and the adjusting bolt on the
clutch lever.
2. Loosen the adjusting bolt locknut and the ad-
justing bolt on the rear brake caliper.
3. Turn the adjusting bolt on the clutch lever so
that cable length
a is 46 ~ 50 mm.NOTE:If the cable cannot be adjusted to specification,
consult a Yamaha dealer. _
U5NF61.book Page 51 Wednesday, June 13, 2001 5:18 PM