2004 YAMAHA BIG BEAR PRO 400 brake

8-55 1. Adjusting bolt 2. Locknut
a. Throttle lever free play
1. Boulon de réglage 2. Contre-écrou
a. Jeu du levier d’accélération
1. Perno de ajuste 2. Contratuerca
a. Juego libre de la palanca del acelerador
1. Brake pad a. Wear limit
1. Plaquette de frein a. Limite d’usure
1. Pastillas del freno a. Límite de desgaste
EBU00307
Throttle lever adjustmentNOTE:Adjust the engine idling speed before adjusting the
throttle lever free play.1. Loosen the locknut.
2. Turn the adjusting bolt until the throttle lever
free play is 3.0–5.0 mm.
3. Tighten the locknut.
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 page 8-79 for removal and in-
stallation procedures.) _
U4SH6B.book Page 55 Tuesday, May 27, 2003 4:39 PM

8-57 1. Wear indicator 2. Wear limit
1. Indicateur d’usure 2. Limite d’usure
1. Indicador de desgaste 2. Límite de desgaste
1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
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.
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.
U4SH6B.book Page 57 Tuesday, May 27, 2003 4:39 PM

8-59
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.


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. Recommended brake fluid: DOT 4
U4SH6B.book Page 59 Tuesday, May 27, 2003 4:39 PM

8-61
EBU11860
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.
U4SH6B.book Page 61 Tuesday, May 27, 2003 4:39 PM

8-63 a. Front brake lever free play
a. Jeu du levier de frein avant
a. Juego de la palanca del freno delantero
EBU11880
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.
_
U4SH6B.book Page 63 Tuesday, May 27, 2003 4:39 PM

8-65 1. Locknut 2. Adjusting bolt
a. Brake pedal position
1. Contre-écrou 2. Boulon de réglage
a. Position de la pédale de frein
1. Contratuerca 2. Perno de ajuste
a. Posición del pedal del freno
EBU00334*
Rear brake pedal and lever adjustment
Pedal height adjustment
1. Loosen the locknut.
2. Turn the adjusting bolt so that the top of the
brake pedal is positioned 5.0 mm below the
top of the footrest.
3. Tighten the locknut.
U4SH6B.book Page 65 Tuesday, May 27, 2003 4:39 PM

8-67 1. Adjusting nut (brake cable)
2. Adjusting nut (brake rod)
1.Écrou de réglage (câble de frein)
2.Écrou de réglage (tringle de frein)
1. Tuerca de ajuste (cable de freno)
2. Tuerca de ajuste (varilla hasta)
a. Brake pedal free play
a. Jeu à la pédale de frein
a. Juego libre del pedal del freno
Brake pedal free play adjustment
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.
U4SH6B.book Page 67 Tuesday, May 27, 2003 4:39 PM

8-69 1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
1. Adjusting nut (brake cable) 2. Lever
3. Pin a. Gap
1.Écrou de réglage (câble de frein) 2. Levier
3. Axe a. Jeu
1. Tuerca de ajuste (cable de freno)2. Palanca
3. Pasador a. Separación
Brake lever free play adjustment
1. Loosen the locknut and fully turn in the ad-
justing bolt at the brake lever.
2. Screw in the adjusting nut on brake cable to
provide a gap of 0–1.0 mm between the lever
and the pin.
U4SH6B.book Page 69 Tuesday, May 27, 2003 4:39 PM