2002 YAMAHA BEAR TRACKER 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 ....................7-69
Sliding and skidding ............................7-71
67
What to do if ... ................................... 7-75
What to do ... ...................................... 7-75
PERIODIC MAINTENANCE AND
ADJUSTMENT ......................................... 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication ......... 8-7
Engine oil ............................................ 8-13
Final gear oil ....................................... 8-23
Spark plug inspection ......................... 8-29
Air filter cleaning ................................. 8-33
Carburetor adjustment ....................... 8-39
Idle speed adjustment ....................... 8-41
Valve clearance adjustment .............. 8-43
Throttle lever adjustment ................... 8-43
Front brake pad inspection ................ 8-45
Rear brake shoe inspection ............... 8-45
Brake fluid level inspection ................ 8-47
Brake fluid replacement ...................... 8-49
Front brake adjustment ...................... 8-51
Rear brake adjustment ...................... 8-53
Adjusting the rear brake light switch ... 8-59
Clutch adjustment .............................. 8-61
Cable inspection and lubrication......... 8-63
Brake lever and brake pedal
lubrication ........................................ 8-65
Steering shaft lubrication ................... 8-65
8
EE.book Page 2 Monday, June 25, 2001 3:46 PM

Wheel removal .................................. 8-67
Wheel installation ............................... 8-69
Battery ............................................... 8-71
Replenishing the battery fluid ............. 8-75
Fuse replacement .............................. 8-79
Replacing the headlight bulb ............. 8-81
Headlight beam adjustment ............... 8-83
Tail/brake light bulb replacement ....... 8-85
Troubleshooting ................................. 8-89
Troubleshooting chart ........................ 8-91
CLEANING AND STORAGE .................. 9-1
A. Cleaning .......................................... 9-1
B. Storage ........................................... 9-7
SPECIFICATIONS ................................ 10-1
CONVERSION TABLE ......................... 11-1
91011EE.book Page 3 Monday, June 25, 2001 3:46 PM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
BrakesCheck operation, condition and free play.
Adjust if necessary.5-5 ~ 5-7,
8-45 ~ 8-57
FuelCheck fuel level.
Fill with fuel if necessary.5-9 ~ 5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13 ~ 5-15,
8-13 ~ 8-21
Final gear oilCheck for leakage. 5-17, 8-23 ~ 8-27
ThrottleCheck for proper throttle cable operation. 5-17, 8-43
Wheels and tiresCheck tire pressure, wear and damage.5-21 ~ 5-27,
8-67 ~ 8-69
Fittings and FastenersCheck all fittings and fasteners. 5-19
LightsCheck for proper operation. 5-19, 8-81 ~ 8-85
BatteryCheck fluid level.
Fill with distilled water if necessary.5-19, 8-71 ~ 8-77
EE.book Page 1 Monday, June 25, 2001 2:27 PM

5-5
EBU00882
Front and rear brakes
Brake levers and brake pedal
Check for correct free play in the brake levers and
brake pedal. If the free play is incorrect, adjust it.
Check operation of the levers and pedal. They
should move smoothly and there should be a firm
feeling when the brake is applied. If not, have the
ATV inspected by a Yamaha dealer. (See pages
8-51–8-57.)
Brake fluid level (Front brake)
Check the brake fluid level. Add fluid if necessary.
(See pages 8-47–8-49.)
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
hose, joint or master cylinder 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.Recommended brake fluid: DOT 4
EE.book Page 5 Monday, June 25, 2001 2:27 PM

5-19
EBU00152
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.
EBU00803
Lights
Check the headlight and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU00912
Switches
Check the operation of the light switch, engine
stop switch and any other switches. Repair as nec-
essary for proper operation.
EBU00499
Battery
Check fluid level and fill if necessary. Use only dis-
tilled water if refilling is necessary. (See pages
8-71 ~ 8-77.)
EE.book Page 19 Monday, June 25, 2001 2:27 PM

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*•Check valve clearance.
•Adjust if necessary.
Spark plug•Check condition.
•Adjust gap and clean.
•Replace if necessary.Air filter•Clean.
•Replace if necessary.Every 20~40 hours
(More often in wet or dusty areas.)
Carburetor*•Check idle speed/starter operation.
•Adjust if necessary.Cylinder head breather
system*•Check breather hose for cracks or damage.
•Replace if necessary.Exhaust system*•Check for leakage.
•Retighten if necessary.
•Replace gasket if necessary.Fuel line*•Check fuel hose for cracks or damage.
•Replace if necessary.Engine oil
•Replace (Warm engine before draining).Engine oil filter
•Clean.Engine oil strainer
•Clean.Final gear oil•Check oil level/oil leakage.
•Replace.Front brake*•Check operation/fluid leakage/see NOTE page 8-4.
•Correct if necessary.Rear brake*•Check operation.
•Adjust if necessary.Clutch*•Check operation.
•Adjust if necessary.EE.book Page 7 Monday, June 25, 2001 2:27 PM

8-8 * It is recommended that these items be serviced by a Yamaha dealer.
** Lithium soap base grease.
NOTE:Recommended brake fluid: DOT 4
Brake fluid replacement:
1. When disassembling the master cylinder or cali-
per, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and cal-
iper, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if
cracked or damaged.
WARNING
Indicates a potential hazard that could
result in serious injury or death.
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.
•Correct if damaged.
•Check toe-in.
•Adjust if necessary.Steering shaft*
•Lubricate every 6 months**.Fittings and Fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.Battery*•Check specific gravity.
•Check that the breather hose is working properly.
•Correct if necessary.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
EE.book Page 8 Monday, June 25, 2001 2:27 PM

8-47 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
EBU00755
Brake fluid level inspection
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 lower level and replenish when necessary.
Observe these precautions:
1. When checking the fluid level, make sure the
top of the master cylinder is level by turning
the handlebars.
2. Use only the designated quality brake fluid.
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake perfor-
mance.
3. Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reac-
tion and lead to poor brake performance.
4. Be careful that water does not enter the mas-
ter cylinder when refilling. Water will signifi-
cantly lower the boiling point of the fluid and
may result in vapor lock. Recommended brake fluid: DOT 4
EE.book Page 47 Monday, June 25, 2001 2:27 PM