2004 YAMAHA YFM350R brake

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 cylinders or calipers, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
On the inner parts of the master cylinders and calipers, replace the oil seals every two years.
Replace the brake hoses every four years, or if cracked or damaged.
Steering system*Check operation.
Repair if damaged.
Check toe-in.
Adjust if necessary.Front and rear
suspension*Check operation.
Correct if necessary.Upper and lower arm
pivot and steering shaft*Lubricate every 6 months with lithium-soap-based grease.Rear arm pivot*
Lubricate every 6 months with lithium-soap-based grease.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
U5YT60.book Page 8 Friday, December 12, 2003 1:55 PM

8-45 1. Wear indicator groove
1. Rainure d’indication d’usure
1. Ranura indicadora de desgaste
Front
Avant
Delantero1. Wear indicator groove
1. Rainure d’indication d’usure
1. Ranura indicadora de desgasteRear
Arrière
Trasero
EBU13981
Front brake pad inspection
Each brake pad is provided with a wear indicator
groove. The indicator grooves allow checking of
brake pad wear without disassembling the brake.
Apply the brake and inspect the wear indicator
grooves. If a brake pad is worn to the point that the
wear indicator groove is almost in contact with the
disc plate, ask a Yamaha dealer to replace the
brake pads as a set.NOTE:_ The wheels need to be removed to inspect the
brake pads. (See pages 8-83–8-85 for wheel re-
moval and installation procedures.) _
EBU13990
Rear brake pad inspection
Each brake pad is provided with a wear indicator
groove. The indicator grooves allow checking of
brake pad wear without disassembling the brake.
Apply the brake and inspect the wear indicator
grooves. If a brake pad is worn to the point that the
wear indicator groove is almost in contact with the
disc plate, ask a Yamaha dealer to replace the
brake pads as a set.
U5YT60.book Page 45 Friday, December 12, 2003 1:55 PM

8-47 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
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
U5YT60.book Page 47 Friday, December 12, 2003 1:55 PM

8-49

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.
U5YT60.book Page 49 Friday, December 12, 2003 1:55 PM

8-51
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.
U5YT60.book Page 51 Friday, December 12, 2003 1:55 PM

8-53 a. Brake lever free play
a. Jeu du levier de frein
a. Juego libre de la palanca de freno
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.
_
U5YT60.book Page 53 Friday, December 12, 2003 1:55 PM

8-55 a. Brake pedal position
a. Position de la pédale de frein
a. Posición del pedal de freno
EBU14971
Brake pedal height adjustment
The top of the brake pedal should be positioned
50.2 mm above the top of the frame as shown. If
the brake pedal is not positioned as specified,
have a Yamaha dealer adjust it.
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 brake pedal position is cor-
rect.


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.
_
U5YT60.book Page 55 Friday, December 12, 2003 1:55 PM

8-57 1. Locknut 2. Adjusting bolt
A. Cable length
1. Contre-écrou 2. Boulon de réglage
A. Longueur de câble
1. Contratuerca 2. Perno de ajuste
A. Longitud del cable
EBU14751
Parking brake adjustment
Parking brake adjustment may be required if the
parking brake does not hold properly. The cable
length
A should be adjusted to 64–68 mm.
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.
U5YT60.book Page 57 Friday, December 12, 2003 1:55 PM