2006 YAMAHA BRUIN 250 brake

8-9
NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
On the inner parts of the master cylinder and caliper, replace the oil seals every two years.
Replace the brake hoses every four years, or if cracked or damaged.
Battery*Check specific gravity.
Check that the breather hose is routed correctly.
Correct if necessary.Lights and switches*Check operation.
Adjust headlight beams.
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
EE.book Page 9 Friday, May 27, 2005 5:00 PM

8-21 1. Footboard 2. Bolt (× 8)
1. Repose-pied 2. Boulon (× 8)
1. Plataforma para los pies 2. Perno (× 8)
1. Adjusting nut (brake rod)
1.Écrou de réglage (tringle de frein)
1. Tuerca de ajuste (barra del freno)
CAUTION:_ When removing the engine oil drain bolt, the
compression spring, oil strainer and O-ring
will fall out. Take care not to lose these parts. _NOTE:_ Skip steps 5–11 if the oil filter element is not being
cleaned. _5. Remove the footboard by removing the bolts.
6. Fully loosen the brake pedal free play adjust-
ing nut, push the brake pedal downward, and
then remove the oil filter element cover bolts.
EE.book Page 21 Friday, May 27, 2005 5:00 PM

8-29 1. Bolt A (× 6) 2. Bolt B (× 2)
1. Boulon A (× 6) 2. Boulon B (× 2)
1. Perno A (× 6) 2. Perno B (× 2)
14. Start the engine, and then let it idle for seve-
ral minutes while checking it for oil leakage. If
oil is leaking, immediately turn the engine off
and check for the cause.
15. Turn the engine off, and then check the oil
level and correct it if necessary.
16. Install the footboard by installing the bolts,
and then tightening them to the specified
torque.
17. Adjust the brake pedal free play. (See page
8-67.) Tightening torque:
Footboard bolt A:
3.8 Nm (0.38 m·kgf)
Footboard bolt B:
6.5 Nm (0.65 m·kgf)
EE.book Page 29 Friday, May 27, 2005 5:00 PM

8-55 1. Brake pad (× 2) a. Brake pad thickness
1. Plaquette de frein (× 2) a.Épaisseur de plaquette de frein
1. Pastilla del freno (× 2) a. Espesor de la pastilla del freno
EBU03050
Select lever safety system cable adjustment
The select lever safety system cable stretches
with use, resulting in improper function. To prevent
this, the cable must be adjusted regularly. This ad-
justment, however, should be left to a Yamaha
dealer.
EBU13770
Front brake pad check
Check the brake pads for damage and wear. If a
brake pad thickness is less than 1.0 mm, have a
Yamaha dealer replace the pads as a set.NOTE:_ The wheels need to be removed to check the
brake pads. (See pages 8-81–8-83 for removal
and installation procedures.) _
EE.book Page 55 Friday, May 27, 2005 5:00 PM

8-57 1. Wear indicator 2. Wear limit line
1. Indicateur d’usure 2. Ligne de limite d’usure
1. Indicador de desgaste 2. Límite de la línea de desgaste
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.
EE.book Page 57 Friday, May 27, 2005 5:00 PM

8-59 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
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
EE.book Page 59 Friday, May 27, 2005 5:00 PM

8-61

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.
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.
EE.book Page 61 Friday, May 27, 2005 5:00 PM

8-63 1. Front brake lever
a. Front brake lever free play
1. Levier de frein avant
a. Jeu du levier de frein avant
1. Palanca del freno delantero
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.
_
EE.book Page 63 Friday, May 27, 2005 5:00 PM