brake YAMAHA WOLVERINE 350 2004 Owner's Guide

8-8
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.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 bearing*Check bearing assemblies for looseness/damage.
Replace if damaged.Front and rear
suspension*Check operation.
Correct if necessary.Steering system*Check operation./Replace if damaged.
Check toe-in./Adjust if necessary.Drive shaft universal
joint*Lubricate.Axle boots*Check operation.
Replace if damaged.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.Lights and switches*Check operation.
Adjust headlight beams.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U5UH60.book Page 8 Wednesday, October 8, 2003 9:05 AM

8-67 a. Brake pad thickness
a.Épaisseur de plaquette de frein
a. Espesor de la pastilla del freno
1. Wear limit line 2. Wear indicator
1. Ligne de limite d’usure 2. Indicateur d’usure
1. Línea del límite de desgaste 2. Indicador 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 pages 8-89–8-91 for removal
and installation 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.
U5UH60.book Page 67 Wednesday, October 8, 2003 9:05 AM

8-69 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
FRONT
Avant
Delantero
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
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8-71

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.
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8-73
EBU01186
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.
U5UH60.book Page 73 Wednesday, October 8, 2003 9:05 AM

8-75 a. Front brake lever free play
a. Jeu au levier de frein avant
a. Juego libre de la palanca de los frenos delanteros
EBU01188
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.
_
U5UH60.book Page 75 Wednesday, October 8, 2003 9:05 AM

8-77 1. Adjusting nut (brake pedal cable)
2. Adjusting nut (brake lever cable)
1.Écrou de réglage (câble de la pédale de frein)
2.Écrou de réglage (câble du levier de frein)
1. Tuerca de ajuste (cable del pedal del freno)
2. Tuerca de ajuste (cable de la palanca del freno)
a. Brake pedal free play
a. Jeu de la pédale de frein
a. Juego libre del pedal del freno
EBU01268
Rear brake pedal and lever adjustment
Brake pedal free play adjustment
1. Fully loosen the adjusting nut on the brake le-
ver cable at the rear wheel.
2. Turn the adjusting nut on the brake pedal ca-
ble until the free play is 20–30 mm.
U5UH60.book Page 77 Wednesday, October 8, 2003 9:05 AM

8-79 1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
1. Adjusting nut (brake lever cable) a. Gap
1.Écrou de réglage (câble du levier de frein) a.Écart
1. Tuerca de ajuste (cable de la palanca del freno) a. Huelgo
Brake lever free play adjustment
1. Loosen the locknut and fully turn in the ad-
justing bolt at the brake lever.
2. Turn in the adjusting nut on brake cable to
provide a gap of 0–1 mm between the brake
camshaft lever and the pin.
U5UH60.book Page 79 Wednesday, October 8, 2003 9:05 AM

8-81 1. Locknut 2. Adjusting bolt
a. Rear brake lever free play
1. Contre-écrou 2. Boulon de réglage
a. Jeu au levier de frein arrière
1. Contratuerca 2. Perno de ajuste
a. Juego libre de la palanca del freno trasero
3. Turn the adjusting bolt at the brake lever
until the free play at the brake lever pivot is
3–5 mm.
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 servic-
ing:

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.
_
U5UH60.book Page 81 Wednesday, October 8, 2003 9:05 AM

8-83 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 del freno trasero
2. Tuerca de ajuste
EBU01259
Adjusting the rear brake light switch
The rear brake light switch, which is activated by
the brake pedal and rear brake lever, is properly
adjusted when the brake light comes on just be-
fore braking takes effect. If necessary, adjust the
brake light switch as follows.
1. Remove panel A. (See page 8-17 for panel
removal and installation procedures.)
2. 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 adjusting nut in direction
b.
3. Install the panel.
U5UH60.book Page 83 Wednesday, October 8, 2003 9:05 AM