2004 YAMAHA BEAR TRACKER 250 oil level

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
What to do if ........................................7-75
What to do...........................................7-75
67
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 ....................................... 8-21
Spark plug inspection ......................... 8-27
Air filter element cleaning ................... 8-31
Carburetor adjustment ....................... 8-37
Idle speed adjustment ........................ 8-39
Valve clearance adjustment .............. 8-41
Throttle lever adjustment ................... 8-41
Front brake pad check ........................ 8-43
Rear brake shoe inspection ............... 8-43
Brake fluid level check ........................ 8-45
Brake fluid replacement ...................... 8-47
Front brake lever free play.................. 8-49
Rear brake adjustment ....................... 8-51
Adjusting the rear brake light switch ... 8-57
Clutch adjustment .............................. 8-59
Cable inspection and lubrication......... 8-61
Brake lever and brake pedal
lubrication ........................................ 8-63
Steering shaft lubrication .................... 8-63
Wheel removal.................................... 8-65
Wheel installation ............................... 8-67
Battery ............................................... 8-69
8
U4XE65.book Page 2 Tuesday, May 6, 2003 1:38 PM

5-1
EBU00113
1-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,
8-45–8-49
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, 8-13–8-19
Final gear oilCheck for leakage. 5-15, 8-21–8-25
ThrottleCheck for proper throttle cable operation. 5-15, 8-41
Wheels and tiresCheck tire pressure, wear and damage.5-19–5-25,
8-65–8-67
Fittings and fastenersCheck all fittings and fasteners. 5-17
Lights and switchesCheck for proper operation. 5-17, 8-79–8-85
BatteryCheck fluid level.
Fill with distilled water if necessary.5-17, 8-69–8-75
U4XE65.book Page 1 Tuesday, May 6, 2003 1:38 PM

5-13
EBU10842
Engine oil
Make sure the engine oil is at the specified level.
Add oil as necessary. (See pages 8-13–8-19.)CAUTION:_

In order to prevent clutch slippage (since
the engine oil also lubricates the clutch),
do not mix any chemical additives. Do not
use oils with a diesel specification of “CD”
or oils of a higher quality than specified. In
addition, do not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign material enters
the crankcase.
_
Recommended engine oil type and quantity:
See page 10-2.
U4XE65.book Page 13 Tuesday, May 6, 2003 1:38 PM

5-15
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
U4XE65.book Page 15 Tuesday, May 6, 2003 1:38 PM

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*Check valve clearance.
Adjust if necessary.
Spark plugCheck condition.
Adjust gap and clean.
Replace if necessary.Air filter elementClean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*Check starter (choke) operation.
Adjust engine idling speed.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 element
Clean.Engine oil strainer
Clean.Final gear oilCheck 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.U4XE65.book Page 7 Tuesday, May 6, 2003 1:38 PM

8-8 * It is recommended that these items be serviced by a Yamaha dealer.
NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
On the inner parts of the master cylinder and caliper, replace the oil seals every two years.
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 with lithium-soap-based grease
(all-purpose grease).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.Lights and switches*Check operation.
Adjust headlight beams.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U4XE65.book Page 8 Tuesday, May 6, 2003 1:38 PM

8-13 1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
1. Bouchon de remplissage d’huile de moteur
2. Jauge
3. Repère de niveau maximum
4. Repère de niveau minimum
1. Tapa del filtro de aceite de motor
2. Varilla de nivel de aceite
3. Marca de nivel máximo
4. Marca de nivel mínimo
EBU11002
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. _
U4XE65.book Page 13 Tuesday, May 6, 2003 1:38 PM

8-15 1. Engine oil drain bolt 2. O-ring
3. Compression spring 4. Engine oil strainer
1. Boulon de vidange de l’huile moteur
2. Joint torique
3. Ressort de compression
4. Crépine à huile de moteur
1. Perno de drenaje del aceite de motor
2. Junta tórica
3. Muelle de compresión
4. Tamiz de aceite de motor
Engine oil replacement and oil filter element
cleaning
1. Place the machine on a level surface.
2. Warm up the engine for several minutes and
stop it.
3. Place a container under the engine to collect
the used oil.
4. Remove the engine oil filler cap and then the
drain bolt to drain the oil.CAUTION:_ When removing the drain bolt, the compres-
sion spring, oil strainer and O-ring will fall out.
Take care not to lose these parts. _
U4XE65.book Page 15 Tuesday, May 6, 2003 1:38 PM