2003 YAMAHA BEAR TRACKER 250 battery

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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 ..................................... 4-11
Speed limiter ...................................... 4-13
Front brake lever ............................... 4-15
Rear brake pedal and lever ............... 4-15
Parking brake .................................... 4-17
Shift pedal ......................................... 4-19
Drive select lever ............................... 4-19
Recoil starter ..................................... 4-21
1234
Fuel tank cap .................................... 4-21
Fuel cock ........................................... 4-23
Starter (choke) .................................. 4-25
Seat.................................................... 4-27
Storage box........................................ 4-31
Front carrier ....................................... 4-31
Rear carrier ........................................ 4-31
Rear shock absorber adjustment ....... 4-33
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
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Wheel removal .................................. 8-65
Wheel installation ............................... 8-67
Battery ............................................... 8-69
Replenishing the battery fluid ............. 8-73
Fuse replacement .............................. 8-77
Replacing a headlight bulb ................. 8-79
Headlight beam adjustment................ 8-81
Tail/brake light bulb replacement ....... 8-83
Troubleshooting ................................. 8-87
Troubleshooting chart ........................ 8-89
CLEANING AND STORAGE .................. 9-1
A. Cleaning .......................................... 9-1
B. Storage ........................................... 9-7
SPECIFICATIONS ................................ 10-1
CONVERSION TABLE .......................... 11-1
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4-7 1. Light switch “LIGHTS”
2. Engine stop switch “ENG. STOP”
3. Start switch “START”
4. Horn switch “”
1. Contacteur d’éclairage “LIGHTS”
2. Coupe-circuit du moteur “ENG. STOP”
3. Contacteur du démarreur “START”
4. Contacteur de l’avertisseur “”
1. Interruptor de luces “LIGHTS”
2. Interruptor de paro del motor “ENG. STOP”
3. Interruptor de arranque “START”
4. Interruptor de la bocina “”
NOTE:If the starter switch is pushed with the main switch
“ON” and the engine stop switch “OFF”, the starter
motor will be activated but the engine will not start.
To start the engine, be sure to position the engine
stop switch at “RUN”.
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Light switch “LIGHTS”
Turn the switch to the “LO” position to switch on
the low beam and the tail/brake light.
Turn the switch to the “HI” position to switch on the
high beam and the tail/brake light.
Turn the switch to the “OFF” position to switch off
the headlights and the tail/brake light.CAUTION:
Do not use the headlights with the engine
turned off for more than thirty minutes. The
battery may discharge to the point that the
starter motor will not operate properly. If this
should happen, remove the battery and re-
charge it.
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5-1
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PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-49–8-55
Rear brakeCheck operation, condition and free play.
Adjust if necessary.5-5–5-7,
8-51–8-55
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,
8-13–8-19
Final gear oilCheck for leakage. 5-17, 8-21–8-25
ThrottleCheck for proper throttle cable operation. 5-17, 8-41
Wheels and tiresCheck tire pressure, wear and damage.5-21–5-27,
8-65–8-67
Fittings and FastenersCheck all fittings and fasteners. 5-19
LightsCheck for proper operation. 5-19, 8-79–8-85
BatteryCheck fluid level.
Fill with distilled water if necessary.5-19, 8-69–8-75
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5-19
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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.
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Lights
Check the headlights and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
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Switches
Check the operation of all switches. Repair as nec-
essary for proper operation.
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Battery
Check fluid level and fill if necessary. Use only dis-
tilled water if refilling is necessary. (See pages
8-69–8-75.)
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6-7
NOTE:

If the engine fails to start, release the start
switch, then push the start switch again.
Pause a few seconds before the next at-
tempt. Each cranking should be as short as
possible to preserve battery energy. Do not
crank the engine more than 10 seconds on
each attempt.


If the battery is discharged, pull the recoil
starter to start the engine.
_7. If the engine is started with the starter (choke)
in position
1, the starter (choke) should be
returned to position
2 to warm up the en-
gine. If the engine is started with the starter
(choke) in position
2, keep the starter
(choke) in this position to warm up the en-
gine.
8. Continue warming up the engine until it idles
smoothly and return the starter (choke) to po-
sition
3 before riding.CAUTION:
See the “Engine break-in” section prior to op-
erating engine for the first time.
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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 caliper, 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 caliper, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.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
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8-69 1. Battery 2. Battery breather hose
3. Clamp (× 4)
1. Batterie 2. Reniflard de batterie
3. Bride (× 4)
1. Batería 2. Tubo respiradero de batería
3. Abrazadera (× 4)
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Battery
Check the level of the battery fluid and see if the
terminals are tight. Add distilled water if the fluid
level is low.CAUTION:
Do not leave or store the battery on its side.
When inspecting the battery, be sure the
breather hose is routed correctly. If it touches
the frame or exists in such a way as to cause
battery electrolyte or gas to exit onto the
frame, structural and cosmetic damage to the
machine can occur.
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