2005 YAMAHA BRUIN 250 brake fluid

OPERATION ............................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine ........................6-9
Warming up ..........................................6-9
Drive select lever operation and
reverse driving ..................................6-11
Shifting ................................................6-15
To start out and accelerate .................6-17
To decelerate ......................................6-19
Engine break-in ...................................6-21
Parking ...............................................6-23
Parking on a slope ..............................6-25
Accessories and loading ....................6-27
RIDING YOUR ATV..................................7-1
Getting to know your ATV .....................7-3
Ride with care and good judgement .....7-5
Be careful where you ride ...................7-27
Turning your ATV ................................7-41
Climbing uphill.....................................7-47
Riding downhill ....................................7-57
Crossing a slope .................................7-61
Crossing through shallow water ..........7-65
Riding over rough terrain ....................7-71
Sliding and skidding ............................7-73
What to do if ........................................7-77
What to do...........................................7-77
67
PERIODIC MAINTENANCE AND
ADJUSTMENT ......................................... 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication.......... 8-7
Engine oil and oil filter element........... 8-17
Final gear oil ....................................... 8-31
Spark plug inspection ......................... 8-37
Air filter element cleaning ................... 8-43
Carburetor adjustment ....................... 8-49
Idle speed adjustment ........................ 8-51
Valve clearance adjustment .............. 8-53
Throttle lever adjustment ................... 8-53
Select lever safety system cable
adjustment ........................................ 8-55
Front brake pad check ........................ 8-55
Rear brake shoe inspection ............... 8-57
Brake fluid level check ........................ 8-59
Brake fluid replacement ...................... 8-61
Front brake lever free play.................. 8-63
Adjusting the brake pedal and rear
brake lever........................................ 8-65
Adjusting the rear brake light switch ... 8-73
Clutch adjustment ............................... 8-75
Cable inspection and lubrication......... 8-77
Brake lever and brake pedal
lubrication ........................................ 8-79
Steering shaft lubrication .................... 8-81
8
U1P060.book Page 2 Monday, August 2, 2004 12:19 PM

Wheel removal ................................... 8-81
Wheel installation ............................... 8-83
Battery ............................................... 8-85
Replenishing the battery fluid ............. 8-89
Fuse replacement .............................. 8-93
Replacing a headlight bulb ................. 8-95
Headlight beam adjustment................ 8-99
Tail/brake light bulb replacement ....... 8-99
Troubleshooting ............................... 8-103
Troubleshooting chart ...................... 8-105
CLEANING AND STORAGE ................... 9-1
A. Cleaning .......................................... 9-1
B. Storage ........................................... 9-7
SPECIFICATIONS ................................ 10-1
CONVERSION TABLE .......................... 11-1
91011U1P060.book Page 3 Monday, August 2, 2004 12:19 PM

3-1
EBU00032
1-DESCRIPTION AND MACHINE
IDENTIFICATION1. Storage compartment
2. Air filter case
3. Engine oil dipstick
4. Front brake fluid reservoir
5. Brake pedal
6. Clutch adjusting bolt
7. Engine oil filter element
8. Rear brake light switch
9. Headlight
10. Fuel cock
11. Recoil starter
12. Fuses
13. Battery
14. Tail/brake light15. Rear shock absorber
spring preload adjusting
ring
16. Engine oil drain bolt
17. Shift pedal
18. Rear brake lever
19. Handlebar switch
20. Parking brake
21. Horn switch
22. Starter (choke)
23. Drive select lever
24. Main switch
25. Fuel tank cap
26. Throttle lever
27. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U1P060.book Page 1 Monday, August 2, 2004 12:19 PM

5-1
EBU00113
1-PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-55–8-63
Rear brakeCheck operation, condition and free play.
Adjust if necessary.5-5–5-7,
8-57, 8-65–8-71
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-17–8-29
Final gear oilCheck for leakage. 5-15, 8-31–8-35
ThrottleCheck for proper throttle cable operation. 5-15, 8-53
Wheels and tiresCheck tire pressure, wear and damage.5-19–5-25,
8-81–8-83
Fittings and fastenersCheck all fittings and fasteners. 5-17
Lights and switchesCheck for proper operation. 5-17, 8-95–8-101
BatteryCheck fluid level.
Fill with distilled water if necessary.5-17, 8-85–8-91
U1P060.book Page 1 Monday, August 2, 2004 12:19 PM

5-5
EBU13151
Front and rear brakes
Brake levers and brake pedal

Check for correct free play in the front brake le-
ver. If the free play is incorrect, have a Yamaha
dealer adjust it.


Check for correct free play in the rear brake le-
ver and brake pedal. If the free play is incorrect,
adjust it. (See pages 8-65–8-71.)


Check the operation of the brake levers and
pedal. They should move smoothly and there
should be a firm feeling when the brakes are
applied. If not, have a Yamaha dealer inspect
the brake system.
Brake fluid level (front brake)
Check the brake fluid level. Add fluid if necessary.
(See pages 8-59–8-61.)
Recommended brake fluid: DOT 4
U1P060.book Page 5 Monday, August 2, 2004 12:19 PM

5-7
Brake fluid leakage (front brake)
Check to see if any brake fluid is leaking out of the
hose, joint or brake fluid reservoir of the front
brake. Apply the brake firmly for one minute. If the
lever moves slowly inward, there may be a leak in
the brake system. If there is any leakage, the
brake system should be inspected by a Yamaha
dealer.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, in-
spect the brake pads and shoes for wear. (See
pages 8-55–8-57.)
WARNING
_ Always check the brakes at the start of every
ride. Do not ride the ATV if you find any prob-
lem with the brakes or you could lose braking
ability, which could lead to an accident. If a
problem cannot be corrected by the adjust-
ment procedures provided in this manual,
have a Yamaha dealer check for the cause. _
U1P060.book Page 7 Monday, August 2, 2004 12:19 PM

5-17
EBU11620
Fittings and fasteners
Always check the tightness of chassis fittings and
fasteners before a ride. Take the machine to a
Yamaha dealer or refer to the Service Manual for
correct tightening torque.
EBU10030
Lights
Check the headlights and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU11700
Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper op-
eration.
EBU00499
Battery
Check fluid level and fill if necessary. Use only dis-
tilled water if refilling is necessary. (See pages
8-85–8-91.)
U1P060.book Page 17 Monday, August 2, 2004 12:19 PM

8-8
Engine oil strainer
Clean.Final gear oilCheck oil level/oil leakage.
Replace.Front brake*Check operation/fluid leakage/see NOTE page 8-9.
Correct if necessary.Rear brake*Check operation.
Adjust if necessary.Select lever safety
system cable*Check operation.
Adjust if necessary.Clutch*Check operation.
Adjust if necessary.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./Replace if damaged.
Check toe-in./Adjust if necessary.Steering shaft*Lubricate every 6 months with lithium-soap-based grease
(all-purpose grease).Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
U1P060.book Page 8 Monday, August 2, 2004 12:19 PM