2003 YAMAHA BEAR TRACKER 250 brake

8-8 * It is recommended that these items be serviced by a Yamaha dealer.
** Lithium soap base grease.
NOTE:Recommended brake fluid: DOT 4
Brake fluid replacement:
1. When disassembling the master cylinder or caliper, 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, replace the oil seals every two years.
3. 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**.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.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U4XE64.book Page 8 Thursday, May 30, 2002 1:49 PM

8-43 1. Brake pad a. Wear limit: 1 mm
1. Plaquette de frein a. Limite d’usure: 1 mm
1. Pastilla del freno a. Límite de desgaste: 1 mm
1. Wear indicator 2. Wear limit
1. Indicateur d’usure 2. Limite d’usure
1. Indicador de desgaste 2. Límite de desgaste
EBU00312
Front brake pad inspection
Inspect the brake pads for damage and wear. If
the thickness is less than the specified value, have
a Yamaha dealer replace the pads.NOTE:The wheels need to be removed to inspect the
brake pads. See page 8-65 for removal proce-
dures.
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.
U4XE64.book Page 43 Thursday, May 30, 2002 1:49 PM

8-45 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
EBU00755
Brake fluid level inspection
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 lower level and replenish when necessary.
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 fluid.
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake perfor-
mance.
3. Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reac-
tion and lead to poor brake performance.
4. Be careful that water does not enter the mas-
ter cylinder when refilling. Water will signifi-
cantly lower the boiling point of the fluid and
may result in vapor lock. Recommended brake fluid: DOT 4
U4XE64.book Page 45 Thursday, May 30, 2002 1:49 PM

8-47
5. Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
6. Have a Yamaha dealer check the cause if the
brake fluid level goes down.
EBU01118
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.
U4XE64.book Page 47 Thursday, May 30, 2002 1:49 PM

8-49 a. Free play: ZERO mm
a. Jeu: ZÉRO mm
a. Juego libre: CERO mm
EBU00681
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.
U4XE64.book Page 49 Thursday, May 30, 2002 1:49 PM

8-51 1. Brake cable adjusting nut
2. Brake rod adjusting nut
1.Écrou de réglage du câble de frein
2.Écrou de réglage de la tringle de frein
1. Tuerca de ajustado del cable de freno
2. Tuerca de ajustado de la varrilla hasta
a. Free play: 20–30 mm
a. Jeu: 20 à 30 mm
a. Juego libre: 20–30 mm
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.
U4XE64.book Page 51 Thursday, May 30, 2002 1:49 PM

8-53 1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
1. Brake cable adjusting nut
a. Gap: 0–1 mm
1.Écrou de réglage du câble de frein
a. Jeu: 0 à 1 mm
1. Tuerca de ajustado del cable de freno
a. Separación: 0–1 mm
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.
U4XE64.book Page 53 Thursday, May 30, 2002 1:49 PM

8-55 1. Locknut 2. Adjusting bolt
a. Free play: 5–7 mm
1. Contre-écrou 2. Boulon de réglage
a. Jeu: 5 à 7 mm
1. Contratuerca 2. Perno de ajuste
a. Juego libre: 5–7 mm
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.
U4XE64.book Page 55 Thursday, May 30, 2002 1:49 PM