2004 YAMAHA WOLVERINE 450 brake

8-93 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
EBU06221
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 nec-
essary. 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.
The rear brake fluid master cylinder reservoir is lo-
cated under panel C. (See pages 8-21–8-25 for
panel removal and installation procedures.)
Observe these precautions:

When checking the fluid level, make sure the
top of the master cylinder reservoirs are level.


Use only the designated quality brake fluid.
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake performance.
Recommended brake fluid: DOT 4
U5ND61.book Page 93 Thursday, June 5, 2003 7:02 PM

8-95

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 reservoirs when refilling. Water will sig-
nificantly 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.
U5ND61.book Page 95 Thursday, June 5, 2003 7:02 PM

8-97
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.
U5ND61.book Page 97 Thursday, June 5, 2003 7:02 PM

8-99 a. Front brake lever free play
a. Jeu au levier de frein avant
a. Juego libre de la palanca de lo 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.
_
U5ND61.book Page 99 Thursday, June 5, 2003 7:02 PM

8-101 1. Locknut 2. Adjusting bolt
c. Rear brake lever free play
1. Contre-écrou 2. Boulon de réglage
c. Jeu au levier de frein arrière
1. Contratuerca 2. Perno de ajuste
c. Juego libre de la palanca del freno trasero
a. Brake pedal position
a. Position de la pédale de frein
a. Posición del pedal del freno
EBU06892
Rear brake lever adjustment
The rear brake lever free play should be 0.5–
2.0 mm.
1. Loosen the locknut.
2. Turn the adjusting bolt in direction
a to in-
crease the free play, and in direction
b to de-
crease the free play.
3. Tighten the locknut.
If the correct free play cannot be obtained, ask a
Yamaha dealer to make that adjustment.
Brake pedal position adjustmentNOTE:_ Adjust the rear brake before checking the rear
brake pads. _The top of the brake pedal should be positioned
72 mm above the top of the footrest. If not, have a
Yamaha dealer adjust it.
U5ND61.book Page 101 Thursday, June 5, 2003 7:02 PM

8-103
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.
_
U5ND61.book Page 103 Thursday, June 5, 2003 7:02 PM

8-105 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
EBU12590
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 B. (See page 8-21 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.
U5ND61.book Page 105 Thursday, June 5, 2003 7:02 PM

8-109
EBU00717
Brake lever and brake pedal lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5ND61.book Page 109 Thursday, June 5, 2003 7:02 PM