brake YAMAHA YFM350R-W 2007 Owner's Guide

8-6
8
EBU28130NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.27*Moving parts and
cablesLubricate.√√√√
28*Throttle lever hous-
ing and cableCheck operation and correct if necessary.
Check throttle cable free play and adjust if neces-
sary.
Lubricate throttle lever housing and cable.√√√√√
29*Exhaust systemCheck for leakage and replace gasket(s) if neces-
sary.
Check for looseness and tighten all screw clamps
and joints if necessary.√√√
30 Spark arresterClean.√√√
31*Front and rear brake
switchesCheck operation and correct if necessary.√√√√√
32*Lights and switchesCheck operation and correct if necessary.
Adjust headlight beam.√√√√√ NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300U10P60E0.book Page 6 Thursday, June 15, 2006 4:19 PM

8-7
8 Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
Every two years replace the piston seals and O-ring of the brake equalizer.
Replace the brake hoses every four years and if cracked or damaged.
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EBU24130Checking the front and rear brake pads The front and rear brake pads must be checked for
wear at the intervals specified in the periodic main-
tenance and lubrication chart.EBU24150Front brake pads
Each brake pad is provided with a wear indicator
groove, which allows you to check the brake pad
wear without having to disassemble the brake. To
check the brake pad wear, check the wear indica-
tor groove. If a brake pad has worn to the point that
the wear indicator groove is almost in contact with
the disc plate, have a Yamaha dealer replace the
brake pads as a set.
NOTE:The wheels need to be removed to check thebrake pads. (See page 8-40.)EBU24200Rear brake pads
Each brake pad is provided with a wear indicator
groove, which allows you to check the brake pad
wear without having to disassemble the brake. To
check the brake pad wear, check the wear indica-
tor groove. If a brake pad has worn to the point that
the wear indicator groove is almost in contact with
the disc plate, have a Yamaha dealer replace the
brake pads as a set.1. Wear indicator groove
U10P60E0.book Page 20 Thursday, June 15, 2006 4:19 PM

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EBU24251Checking the brake fluid level Insufficient brake fluid may allow air to enter the
brake system, possibly causing it to become inef-
fective.
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.Front brake
Rear brake1. Wear indicator groove
1. Minimum level mark
1. Minimum level mark
U10P60E0.book Page 21 Thursday, June 15, 2006 4:19 PM

8-22
8Observe these precautions:

When checking the fluid level, make sure that
the top of the brake fluid reservoir is level.
Use only the recommended quality brake fluid,
otherwise the rubber seals may deteriorate,
causing leakage and poor braking performance.
Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor braking 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 imme-
diately.
As the brake pads wear, it is normal for the brake
fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a
Yamaha dealer check the cause.
EBU24290Changing the brake fluid Have a Yamaha dealer change the brake fluid at
the intervals specified in the NOTE after the peri-
odic maintenance and lubrication chart. In addi-
tion, have the oil seals of the master cylinders and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are dam-
aged or leaking.
Oil seals: Replace every two years.
Brake hoses: Replace every four years.EBU24390Checking the front brake lever free play The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have a
free play of zero mm (zero in) as shown. If the free
play is incorrect, have a Yamaha dealer check the
brake system. Recommended brake fluid:
DOT 4
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WARNING
EWB02070Operating 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 proceduresshould be performed by a Yamaha dealer.
EBU24591Checking the brake pedal position The brake pedal position must be checked and, if
necessary, adjusted at the intervals specified in the
periodic maintenance and lubrication chart.
The top of the brake pedal should be positioned
50.2 mm (1.98 in) above the top of the frame as
shown. If the brake pedal is not positioned as spec-
ified, have a Yamaha dealer adjust it.
WARNING
EWB02110Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
1. Brake lever free play
1. Brake pedal position
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8After servicing:

Make sure the brakes operate smoothly and
that the brake pedal position 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 proceduresshould be performed by a Yamaha dealer.EBU24710Adjusting the parking brake free play The parking brake free play must be checked and,
if necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
Cable length “A” should measure 64–68 mm
(2.52–2.68 in). Adjust the parking brake free play
as follows.1. Release the parking brake by moving the
parking brake lever to the right.
2. Fully loosen the locknut and the adjusting bolt
at the rear brake caliper.
3. Loosen the locknut on the brake cable.
4. Turn the adjusting nut on the brake cable in di-
rection (a) to increase the cable length, and in
direction (b) to decrease it.
1. Locknut
2. Adjusting bolt
3. Cable length “A”
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8
NOTE:If the cable length cannot be adjusted to specifica-tion, consult a Yamaha dealer.
5. Tighten the locknut on the brake cable.
6. Turn in the adjusting bolt at the rear brake cal-
iper until it feels tight, then turn it out 1/8 turn
and tighten its locknut to the specified torque.CAUTION:ECB00520When tightening the locknut, hold the adjust-
ing bolt with a wrench so that it does not turntogether with the locknut.
WARNING
EWB02090Operating with improperly serviced or adjust-
ed brakes could cause the brakes to malfunc-
tion, resulting in reduced braking
performance. This could increase the chance
of a collision or accident. After adjusting the
parking brake free play, block the rear of the
ATV off the ground and spin the rear wheels.
Check to make sure there is no brake drag. If
brake drag is noticed, perform the adjustmentagain.EBU24740Brake light switches The operation of the brake light switches must be
checked and, if necessary, adjusted at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
The brake light switch for the brake pedal can be
adjusted as follows, but the other brake light
switches should be adjusted by a Yamaha dealer.
1. Locknut
2. Adjusting nut
Tightening torque:
Locknut (rear brake caliper):
16 Nm (1.6 m·kgf, 11 ft·lbf)
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8
NOTE:The brake light switch is properly adjusted when
the brake light comes on just before braking takeseffect.
Turn the adjusting nut while holding the 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).
EBU24820Adjusting the clutch lever free play The clutch lever free play must be checked and, if
necessary, adjusted at the intervals specified in the
periodic maintenance and lubrication chart.
The clutch lever free play should measure 5.0–
10.0 mm (0.20–0.39 in) as shown. If the free play
is incorrect, adjust it as follows.
1. Loosen the locknut at the clutch lever.
1. Brake light switch
2. Brake light switch adjusting nut
1. Locknut
2. Clutch lever free play adjusting bolt
3. Clutch lever free play
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8 essary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.
WARNING
EWB02130Inspect cables frequently and replace if dam-
aged. Corrosion can result when the cable
sheaths become damaged, and cables can
also become frayed or kinked, which could re-
strict the operation of controls and lead to anaccident or injury.EBU24920Checking and lubricating the brake and
clutch levers The operation of the brake and clutch levers
should be checked before each ride, and the lever
pivots should be lubricated if necessary.Brake lever
Clutch lever Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease (all-purpose
grease)U10P60E0.book Page 31 Thursday, June 15, 2006 4:19 PM