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8
3. After replenishing, place the cowling in the
original position, and then install the bolt and
quick fastener screw.
WARNING
EWB02721Improper maintenance can result in loss of
braking ability. Observe these precautions:
Insufficient brake fluid may allow air to enter
the brake system, reducing braking perfor-
mance.
Clean the filler cap before removing. Use
only DOT 4 brake fluid from a sealed contain-
er.
Use only the specified brake fluid; otherwise,
the rubber seals may deteriorate, causing
leakage.
Refill with the same type of brake fluid. Add-
ing a brake fluid other than DOT 4 may result
in a harmful chemical reaction.
Be careful that water does not enter the
brake fluid reservoir when refilling. Water will
significantly lower the boiling point of the flu-
id and may result in vapor lock.
NOTICEECB01161Brake fluid may damage painted surfaces or
plastic parts. Always clean up spilled fluid im-
mediately. As the brake pads wear, it is normal for the brake
fluid level to gradually go down. A low brake fluid
level may indicate worn brake pads and/or brake
system leakage; therefore, be sure to check the
1. Cowling
2. Brake fluid reservoir capSpecified brake fluid:
DOT 4
1
2
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8-34
8brake pads for wear and the brake system for
leakage. If the brake fluid level goes down sud-
denly, have a Yamaha dealer check the cause be-
fore further riding.
EBU24293Changing the brake fluidHave a Yamaha dealer change the brake fluid at
the intervals specified in the periodic maintenance
and lubrication chart. In addition, have the oil seals
of the master cylinders and calipers as well as the
brake hoses replaced at the intervals listed below
or whenever they are damaged or leaking.
Oil seals: Replace every two years.
Brake hoses: Replace every four years.
EBU24396Checking the front brake lever free
playThere should be no free play at the brake lever
end. If there is free play, have a Yamaha dealer in-
spect the brake system.1. No brake lever free play
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8
EBU24615Checking the brake pedal heightPeriodically check the brake pedal height. If the
brake pedal is not positioned as specified, have a
Yamaha dealer adjust it.
EBU24717Adjusting the parking brake free playPeriodically check the cable length “A” and adjust
if necessary. 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.
1. Brake pedal heightBrake pedal height:15.3 mm (0.60 in)
1
1. Adjusting bolt
2. Cable length “A”
3. LocknutCable length “A”:47–51 mm (1.85–2.01 in)
1
2
3
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8-36
83. Slide the rubber cover back at the brake ca-
ble.
4. Loosen the locknut.
5. Turn the parking brake free play adjusting nut in direction (a) to increase the cable length,
and in direction (b) to decrease it.
TIPIf the cable length cannot be adjusted to specifi-
cation, consult a Yamaha dealer. 6. Tighten the locknut on the brake cable.
7. Slide the rubber cover to its original position. 8. Turn in the adjusting bolt at the rear brake cal-
iper until it feels tight, then turn it out 1/8 turn
and tighten its locknut to the specified torque.
NOTICE: When tightening the locknut,
hold the adjusting bolt with a wrench so
that it does not turn together with the lock-
nut.
[ECB00522]
WARNING
EWB02091Operating with improperly serviced or adjust-
ed brakes could cause the brakes to malfunc-
tion, resulting in reduced braking
performance. This could increase the chance
of a collision or accident. After adjusting the
parking brake free play, block the rear of the
ATV off the ground and spin the rear wheels.
Check to make sure there is no brake drag. If
brake drag is noticed, perform the adjustment
again.
1. Rubber cover
2. Parking brake free play adjusting nut
3. Locknut
1
(b)
(a) 2
3
Tightening torque:
Locknut (rear brake caliper):16 N·m (1.6 kgf·m, 12 lb·ft)
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EBU24744Brake light switchesThe brake light, which is activated by the brake
pedal and brake lever, should come on just before
braking takes effect.
The brake light switch for the brake pedal can be
adjusted as follows, but the front brake light
switch should be adjusted by a Yamaha dealer.
Turn the rear brake light switch adjusting nut while
holding the brake light switch in place. To make
the brake light come on earlier, turn the adjusting
nut in direction (a). To make the brake light come
on later, turn the adjusting nut in direction (b).
EBU29753Adjusting the clutch lever free playPeriodically check the clutch lever free play and
adjust if necessary.1. Slide the rubber cover back.
2. Loosen the locknut at the clutch lever.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1
2
(a)
(b)
1. Rubber cover
2. Clutch lever free play adjusting bolt
3. Locknut
4. Clutch lever free playClutch lever free play: 8.0–13.0 mm (0.31–0.51 in)
3
1
2
(a)
(b)
4
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8-38
83. To increase the clutch lever free play, turn the
adjusting bolt at the clutch lever in direction
(a), and to decrease it, turn the bolt in direc-
tion (b).
TIPIf the specified clutch lever free play could be ob-
tained as described above, skip steps 4–7. 4. Fully turn the adjusting bolt at the clutch leverin direction (a) to loosen the clutch cable.
5. Loosen the locknut at the crankcase.
6. To increase the clutch lever free play, turn the adjusting nut at the crankcase in direction (a),
and to decrease it, turn the nut in direction (b). 7. Tighten the locknut at the crankcase.
8. Tighten the locknut at the clutch lever, and
then slide the rubber cover to its original po-
sition.
TIPIf the specified free play cannot be obtained as de-
scribed above or if the clutch does not operate
correctly, have a Yamaha dealer check the internal
clutch mechanism. 1. Locknut
2. Clutch lever free play adjusting nut
1
2
(a)
(b)
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8
EBU26866Drive chain slackThe drive chain slack should be checked before
each ride and adjusted if necessary.TIPWhen checking and adjusting the drive chain
slack, there should be no weight on the ATV and
all tires must be touching the ground. To check the drive chain slack1. Place the ATV on a level surface.
2. Move the ATV back and forth to locate the tightest portion of the drive chain, and then
measure the drive chain slack as shown. 3. If the drive chain slack is incorrect, adjust it as
follows.
To adjust the drive chain slack 1. Place the ATV on a level surface.
2. Loosen the rear wheel axle pinch bolts.
3. Insert a rod of a diameter of 8 mm (0.3 in) and a length of 10 cm (4 in) into one of the holes in
the drive chain tensioner as shown.
Drive chain slack:
25.0–35.0 mm (0.98–1.38 in)
1. Drive chain slack
1
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8
TIPA rod can be obtained at a Yamaha dealer to make
this adjustment. 4. Shift the transmission into neutral.
5. To tighten the drive chain, push the ATVbackward. To loosen the drive chain, push
the ATV forward. NOTICE: Improper drive
chain slack will overload the engine as well
as other vital parts of the ATV and can lead
to drive chain slippage or breakage. To prevent this from occurring, keep the drive
chain slack within the specified limits.
[ECB00543]
6. Pull the rod out, and then tighten the rear axle
pinch bolts to the specified torque in the or-
der shown.
1. Rear wheel axle pinch bolt
2. Rod
3. Drive chain tensioner
4. Hole
4
2
11
3
Tightening torque:
Rear axle pinch bolt:21 N·m (2.1 kgf·m, 15 lb·ft)
31 24
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