2005 YAMAHA BRUIN 250 brake light

EBU00015
1-CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ....................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION AND MACHINE
IDENTIFICATION .................................... 3-1
Identification number records ............... 3-3
Key identification number .................... 3-5
Vehicle identification number ............... 3-7
Model label ........................................... 3-9
CONTROL FUNCTIONS ......................... 4-1
Main switch........................................... 4-1
Indicator lights ..................................... 4-3
Handlebar switches ............................. 4-5
Throttle lever ....................................... 4-9
Speed limiter ...................................... 4-11
Front brake lever ............................... 4-13
Brake pedal and rear brake lever ....... 4-15
Parking brake ..................................... 4-17
Shift pedal ......................................... 4-19
Drive select lever ............................... 4-19
Recoil starter ..................................... 4-21
1234
Fuel tank cap .................................... 4-21
Fuel cock ........................................... 4-23
Starter (choke) ................................... 4-25
Seat.................................................... 4-27
Storage compartment ........................ 4-29
Front carrier ....................................... 4-31
Rear carrier ........................................ 4-31
Rear shock absorber adjustment ....... 4-33
PRE-OPERATION CHECKS ................... 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Final gear oil ...................................... 5-15
Throttle lever ...................................... 5-15
Fittings and fasteners......................... 5-17
Lights ................................................. 5-17
Switches............................................. 5-17
Battery ............................................... 5-17
Tires .................................................. 5-19
How to measure tire pressure ............ 5-23
Tire wear limit .................................... 5-25
5
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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
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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

4-21 1. Recoil starter
1. Lanceur à réenroulement
1. Arranque por tracción de cable
1. Fuel tank cap
1. Bouchon du réservoir de carburant
1. Tapón del depósito de combustible
EBU00591
Recoil starter
Firmly grasp the handle and pull slightly until en-
gagement can be felt. Then pull forcefully, being
careful not to pull the rope all the way out.
WARNING
Put the transmission in neutral and set the
parking brake before starting the engine or the
ATV could start to move unexpectedly, which
could cause an accident.
EBU00092
Fuel tank cap
Remove the fuel tank cap by turning it counter-
clockwise.
U1P060.book Page 21 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
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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

6-5 a. Starter (choke) 1. Fully-open
2. Half open 3. Closed
a. Starter (enrichisseur) 1. Complètement ouvert
2. Mi-ouvert 3. Fermé
a. Starter (choke) 1. Abre completamente
2. Semiabierto 3. Cerrado
NOTE:_

When the transmission is in neutral, the neu-
tral indicator light should come on. If the light
does not come on, ask a Yamaha dealer to
inspect it.


The engine can be started in any gear if the
rear brake lever is applied. However, it is rec-
ommended to shift into neutral before starting
the engine.
_5. Use the starter (choke) in reference to the fig-
ure:
Position
1: Cold engine start-ambient tempera-
ture below 5°C.
Position
2: Cold engine start-ambient tempera-
ture at 0°C–30°C and warming up
position.
Position
3: Cold engine start-ambient tempera-
ture above 25°C and warm engine
start position.
6. Completely close the throttle lever and start
the engine by pushing the start switch.
U1P060.book Page 5 Monday, August 2, 2004 12:19 PM