2004 YAMAHA BEAR TRACKER 250 engine

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
Brake pedal and rear brake 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 ...................................... 5-15
Throttle lever ...................................... 5-15
Fittings and fasteners......................... 5-17
Lights ................................................. 5-17
Switches............................................. 5-17
Battery ............................................... 5-17
Tires .................................................. 5-19
How to measure tire pressure ........... 5-23
Tire wear limit .................................... 5-25
5
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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
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2-1
EBU00019
SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BEHAZARDOUS TO OPERATE.
An ATV handles
differently from other vehicles including
motorcycles and cars. A collision or rollover can
occur quickly, even during routine maneuvers
such as turning and riding on hills or over
obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do
not follow these instructions:


Read this manual and all labels carefully and
follow the operating procedures described.


Never operate an ATV without proper instruc-
tion.


Always follow the age recommendation:
– A child under 16 years old should never oper-
ate an ATV with engine size greater than 90cc.
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2-17
WARNING


Always turn off the engine when refueling.


Do not refuel right after the engine has
been running and is still very hot.


Do not spill gasoline on the engine or ex-
haust pipe/muffler when refueling. Never
refuel while smoking, or while in the vicini-
ty of sparks, open flames, or other sources
of ignition such as the pilot lights of water
heaters and clothes dryers. Gasoline can
catch fire and you could be burned.


When transporting the machine in another
vehicle, be sure it is kept upright and that
the fuel cock is in the “OFF” position. Oth-
erwise, fuel may leak out of the carburetor
or fuel tank.


Gasoline is poisonous. If you should swal-
low some gasoline or inhale a lot of gaso-
line vapor, or get some gasoline in your
eyes, see your doctor immediately. If gaso-
line spills on your skin, wash with soap
and water. If gasoline spills on your cloth-
ing, change your clothes.
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4-1
EBU00040
1-CONTROL FUNCTIONS
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Main switch
Functions of the respective switch positions are as
follows:
ON:
The engine can be started only at this position and
the headlights and taillight come on when the light
switch is on.
OFF:
All electrical circuits are switched off. The key can
be removed in this position.
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4-5 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 “”
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Handlebar switches
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Engine stop switch “ENG. STOP”
Make sure that the engine stop switch is in the
“RUN” position before starting the engine. The en-
gine stop switch controls ignition and can be used
at all times to stop the engine, especially in an
emergency. The engine will not start or run when
the engine stop switch is turned to “OFF”.
EBU00056
Start switch “START”
The starter motor cranks the engine when this
switch is pushed.CAUTION:
See starting instructions prior to starting en-
gine (see page 6-3 for details).
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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”
Set the switch to the “LO” position to turn on the
low beam and the taillight.
Set the switch to the “HI” position to turn on the
high beam and the taillight.
Set the switch to the “OFF” position to turn off all of
the lights.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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4-9 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 “”
EBU00059
Horn switch “”
Press the switch to sound the horn.
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