2009 YAMAHA WOLVERINE 350 brake

7-24
7

If your ATV can’t make it up a hill you are trying
to climb:
Turn the ATV around if you still have forward
speed. If not, stop, dismount on the uphill side of
the ATV and physically turn the ATV around. If
the ATV starts to slip backwards, DO NOT USE
THE REAR BRAKE – the ATV may tip over on
top of you. Dismount the ATV on the uphill side.
(See page 7-14.)
If your ATV is traversing a sloping surface:
Be sure to ride with your weight positioned to-
wards the uphill side of the ATV to maintain
proper balance. If the ATV starts to tip, steer
down the hill (if there are no obstacles in your
way) to regain balance. If you discover that the
ATV is going to tip over, dismount on the uphill
side. (See page 7-18.)
If your ATV encounters shallow water:
Ride slowly and carefully through slow moving
water, watching for obstacles. Be sure to let wa-
ter drain from the ATV and CHECK YOUR
BRAKES FOR PROPER OPERATION when
you come out of the water. Do not continue to
ride your ATV until you have regained adequate
braking ability. (See page 7-19.)
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8-5
8
EBU21864General maintenance and lubrication chart NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320
1 Air filter elementClean and replace if necessary.Every 20–40 hours (more often in wet or
dusty areas)
2*Front brakeCheck operation and correct if necessary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.√√√√√
Replace brake pads. Whenever worn to the limit
3*Rear brakeCheck operation and correct if necessary.
Check brake lever and pedal free play, and adjust
if necessary.√√√√√
Replace brake shoes. Whenever worn to the limit
4*Brake hosesCheck for cracks or other damage, and replace if
necessary.√√√√
Replace. Every 4 years
5*WheelsCheck runout and for damage, and replace if nec-
essary.√ √√√
6*TiresCheck tread depth and for damage, and replace if
necessary.
Check air pressure and balance, and correct if
necessary.√ √√√
7*Wheel hub bearingsCheck for looseness or damage, and replace if
necessary.√ √√√
8*SwingarmCheck for excessive play, and correct if necessary.√√√
U3D563E0.book Page 5 Monday, May 12, 2008 11:12 AM

8-7
8
EBU28390TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and calipers, and change
the brake fluid.Replace the brake hoses every four years and if cracked or damaged.21*Drive select lever
safety system cableCheck operation and adjust or replace if neces-
sary.√√√
22*Throttle lever hous-
ing and cableCheck operation and correct if necessary.
Check throttle cable free play and adjust if neces-
sary.
Lubricate throttle lever housing and cable.√√√√√
23*Front and rear brake
switchesCheck operation and correct if necessary.√√√√√
24*Lights and switchesCheck operation and correct if necessary.
Adjust headlight beams.√√√√√ NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320U3D563E0.book Page 7 Monday, May 12, 2008 11:12 AM

8-25
83. Tighten the locknut.
EBU24060Valve clearance The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU24071Adjusting the drive select lever safety
system cable The drive select lever safety system cable stretch-
es with use, which can result in improper function.
Therefore, the safety system cable should be
checked and adjusted by a Yamaha dealer at the
intervals specified in the periodic maintenance and
lubrication chart.EBU24120Checking the front brake pads and rear
brake shoes The front brake pads and the rear brake shoes
must be checked for wear at the intervals specified
in the periodic maintenance and lubrication chart.EBU24171Front brake pads
Check each front brake pad for damage and mea-
sure the lining thickness. If a brake pad is dam-
aged or if the lining thickness is less than 1.0 mm
(0.04 in), have a Yamaha dealer replace the brake
pads as a set.
1. Locknut
2. Throttle cable free play adjusting bolt
3. Throttle cable free playU3D563E0.book Page 25 Monday, May 12, 2008 11:12 AM

8-26
8
TIPThe wheels need to be removed to check thebrake pads. (See page 8-41.)EBU24180Rear brake shoes
The rear brake is provided with a wear indicator,
which allows you to check the brake shoe wear
without having to disassemble the brake. To check
the brake shoe wear, check the position of the
wear indicator while applying the brake. If a brake
shoe has worn to the point that the wear indicator
reaches the wear limit line or mark, have a
Yamaha dealer replace the brake shoes as a set.
EBU24251Checking the brake fluid level Insufficient brake fluid may allow air to enter the
brake system, possibly causing it to become inef-
fective.
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.
1. Lining thickness
1. Wear limit line
2. Wear indicator
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8-27
8Observe these precautions:

When checking the fluid level, make sure that
the top of the brake fluid reservoir is level.
Use only the recommended quality brake fluid,
otherwise the rubber seals may deteriorate,
causing leakage and poor braking performance.
Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor braking 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 imme-
diately.
As the brake pads wear, it is normal for the brake
fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a
Yamaha dealer check the cause.EBU24281Changing the brake fluid Have a Yamaha dealer change the brake fluid at
the intervals specified in the TIP after the periodic
maintenance and lubrication chart. In addition,
have the oil seals of the brake master cylinder and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are dam-
aged or leaking.
Oil seals: Replace every two years.
Brake hoses: Replace every four years.
1. Minimum level markRecommended brake fluid:
DOT 4
1
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8
EBU24393Checking the front brake lever free play The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have no
free play as shown. If there is free play, have a
Yamaha dealer check the brake system.
WARNING
EWB02471Operating 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 there is no free play.
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 proceduresshould be performed by a Yamaha dealer.EBU24513Adjusting the brake pedal and rear
brake lever free play and checking the
brake pedal position The brake pedal and brake lever free play must be
checked and, if necessary, adjusted at the inter-
vals specified in the periodic maintenance and lu-
brication chart.TIP
Always perform this maintenance completely in
the following order whenever adjusting the rear
brake.
Before adjusting the brake lever and brake pedalfree play, check the rear brake shoes for wear.
1. Brake lever free playU3D563E0.book Page 28 Monday, May 12, 2008 11:12 AM

8-29
8Adjusting the brake pedal free play
The brake pedal free play should measure 20.0–
30.0 mm (0.79–1.18 in) as shown. If the free play
is incorrect, adjust it as follows.
1. Fully loosen the brake lever free play adjust-
ing nut on the brake cable at the rear wheel
hub.
2. Turn the brake pedal free play adjusting nut
on the brake cable at the rear wheel hub in di-
rection (a) to increase the free play, and in di-
rection (b) to decrease it.Adjusting the brake lever free play
The brake lever free play should measure 3.0–5.0
mm (0.12–0.20 in) as shown. If the free play is in-
correct, adjust it as follows.
1. Brake pedal free play
1. Brake pedal free play adjusting nut
2. Brake lever free play adjusting nut
U3D563E0.book Page 29 Monday, May 12, 2008 11:12 AM