2003 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 ..................................... 4-11
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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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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5-17
EBU00493
Final gear oil
Make sure the final gear oil is at the specified level.
Add oil as necessary. (See pages 8-21–8-25 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.
EBU01083
Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
the idle position when released. Have a Yamaha
dealer repair as necessary for proper operation.Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
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8-7
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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 8-8.
•Correct if necessary.Rear brake*•Check operation.
•Adjust if necessary.Clutch*•Check operation.
•Adjust if necessary.U4XE64.book Page 7 Thursday, May 30, 2002 1:49 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 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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8-13 1. Oil filler cap 2. Dipstick
3. Maximum level mark 4. Minimum level mark
1. Bouchon de remplissage d’huile 2. Jauge
3. Repère de niveau maximum 4. Repère de niveau minimum
1. Tapa de relleno de aceite 2. Varilla de nivel de aceite
3. Marca de nivel máximo 4. Marca de nivel mínimo
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Engine oil
Engine oil level measurement
1. Place the machine on a level surface.
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 engine oil filler cap and wipe the
dipstick off with a clean rag. Insert the dip-
stick in the filler hole without screwing it in.
4. Remove the dipstick and check 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.
6. Install the engine oil filler cap.CAUTION:_ Make sure no foreign material enters the
crankcase. _
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8-19
CAUTION:_ Be sure no foreign material enters the crank-
case. _12. 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 engine oil:
See page 10-2.
Oil quantity:
Periodic oil change:
1.5 L
With oil filter element cleaning:
1.6 L
Total amount:
1.8 L
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8-21 1. Final gear oil
2. Correct oil level
3. Oil filler bolt
1. Huile de transmission finale
2. Niveau d’huile correct
3. Boulon de l’orifice de remplissage d’huile
1. Aceite de la transmisión final
2. Nivel de aceite exacto
3. Perno de llenado de aceite
EBU00825
Final gear oil
Final gear oil measurement
1. Place the machine on a level place.
2. Remove the oil filler bolt and check the oil lev-
el. It should be up to the brim of the hole. If
the level is low, add oil to raise it to the proper
level.CAUTION:
Be sure no foreign material enters the final
gear case. 3. Install the oil filler bolt and tighten it to the
specified torque.
Final gear oil replacement
1. Remove the final gear case cover.
2. Place the machine on a level place.
3. Place a container under the final gear case to
collect the used oil. Tightening torque:
Oil filler bolt:
23 Nm (2.3 m·kgf)
U4XE64.book Page 21 Thursday, May 30, 2002 1:49 PM