2002 YAMAHA BEAR TRACKER 250 check oil

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
Rear brake pedal and lever ............... 4-13
Parking brake .................................... 4-15
Shift pedal ......................................... 4-17
Drive select lever ................................ 4-17
Recoil starter ..................................... 4-19
1234
Fuel tank cap .................................... 4-19
Fuel cock ........................................... 4-21
Starter (choke) .................................. 4-23
Seat.................................................... 4-25
Storage box........................................ 4-29
Front carrier ....................................... 4-29
Rear carrier ........................................ 4-29
Rear shock absorber adjustment ....... 4-31
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Final gear oil ...................................... 5-17
Throttle lever ..................................... 5-17
Fittings and Fasteners ...................... 5-19
Lights ................................................. 5-19
Switches............................................. 5-19
Battery ............................................... 5-19
Tires .................................................. 5-21
How to measure tire pressure ........... 5-25
Tire wear limit .................................... 5-27
5
EE.book Page 1 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

5-17
EBU00493
Final gear oil
Make sure the final gear oil is at the specified level.
Add oil as necessary. (See pages 8-23 ~ 8-27 for
details.)
If desired, an SAE 80W90 hypoid gear oil may be
used for all conditions.NOTE:_ GL-4 is a quality and additive rating, GL-5 or GL-6
rated hypoid gear oils may also be used. _
EBU00151
Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
idle position when released. Repair as necessary
for proper operation.Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
EE.book Page 17 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

8-13 1. Dipstick 2. Maximum level mark
3. Minimum level mark
1. Jauge 2. Repère de niveau maximum
3. Repère de niveau minimum
1. Varilla de nivel de aceite 2. Marca de nivel máximo
3. Marca de nivel mínimo
EBU00866
Engine oil
Engine oil level measurement
1. Place the machine on a level place.
2. Warm up the engine for several minutes and
stop it. Wait at least ten minutes for the oil to
drain back into the crankcase before check-
ing the oil level.NOTE:_ Be sure to wait at least ten minutes until the oil lev-
el settles before checking. _3. Remove the dipstick and wipe it off with a
clean rag. Insert the dipstick in the filler hole
without screwing it in.
4. Remove the dipstick and inspect the oil level.
5. The oil level should be between the maxi-
mum and minimum marks. If the level is low,
add oil to raise it to the proper level.CAUTION:_ Make sure no foreign material enters the
crankcase. _
EE.book Page 13 Monday, June 25, 2001 2:27 PM

8-19
CAUTION:_ Be sure no foreign material enters the crank-
case. _11. Warm up the engine for several minutes at
idle speed. Check for oil leakage while warm-
ing up.CAUTION:_ If oil leakage is found, stop the engine immedi-
ately and check for the cause. _
Recommended oil:
See page 10-2.
Oil quantity:
Periodic oil change:
1.5 L
With oil filter replacement:
1.6 L
Total amount:
1.8 L
EE.book Page 19 Monday, June 25, 2001 2:27 PM

8-21 1. Oil gallery bolt 2. Cloth
1. Boulon de rampe de graissage 2. Chiffon
1. Tornillo del conducto de aceite 2. Trapo
Oil pressure check
1. Put a cloth around the cylinder.
2. Slightly loosen the oil gallery bolt in the cylin-
der head.
3. Start the engine and keep it idling until oil be-
gins to seep from the oil gallery. If no oil
comes out after one minute, turn the engine
off so it will not seize and find the cause.
4. Start the engine and check the oil pressure.
5. After checking, tighten the oil gallery bolt to
the specified torque.CAUTION:_ Be sure to inspect the oil pressure after replac-
ing the engine oil. _
Tightening torque:
Oil gallery bolt:
7 Nm (0.7 m·kgf)
EE.book Page 21 Monday, June 25, 2001 2:27 PM