battery YAMAHA BEAR TRACKER 250 2004 Owners Manual

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

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

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
91011U4XE65.book Page 3 Tuesday, May 6, 2003 1:38 PM

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”.
EBU11560
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. _
U4XE65.book Page 7 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

5-17
EBU11620
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.
EBU10030
Lights
Check the headlights and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU11700
Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper op-
eration.
EBU00499
Battery
Check fluid level and fill if necessary. Use only dis-
tilled water if refilling is necessary. (See pages
8-69–8-75.)
U4XE65.book Page 17 Tuesday, May 6, 2003 1:38 PM

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.
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

8-69 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)
EBU00379
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.
U4XE65.book Page 69 Tuesday, May 6, 2003 1:38 PM

8-71
WARNING
Battery electrolyte is poisonous and danger-
ous, causing severe burns, etc. It contains sul-
furic acid. Avoid contact with skin, eyes or
clothing.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg
or vegetable oil. Call a physician immediately.
EYES: Flush with water for 15 minutes and get
prompt medical attention. Batteries produce
explosive gases. Keep sparks, flame, ciga-
rettes or other sources of ignition away. Venti-
late when charging or using in an enclosed
space. Always shield your eyes when working
near batteries. KEEP OUT OF REACH OF CHIL-
DREN.
U4XE65.book Page 71 Tuesday, May 6, 2003 1:38 PM