check engine 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
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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
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4-11 1. Throttle lever
1. Levier d’accélération
1. Palanca de aceleración
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Throttle lever
Once the engine is running, movement of the
throttle lever will increase the engine speed.
Regulate the speed of the machine by varying the
throttle position. Because the throttle is spring-
loaded, the machine will decelerate, and the en-
gine will return to an idle any time the hand is re-
moved from the throttle lever.
Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.
WARNING
Malfunction of the throttle could make it diffi-
cult to speed up or slow down when you need
to. This could cause an accident. Check the
operation of the throttle lever before you start
the engine. If the throttle does not work
smoothly, check for the cause. Correct the
problem before riding the ATV or consult a
Yamaha dealer.
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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
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6-9
EBU00180
Starting a warm engine
To start a warm engine, refer to the “Starting a cold
engine” section. The starter (choke) should not be
used. The throttle should be opened slightly.
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Warming up
To get maximum engine life, always warm up the
engine before starting off. Never accelerate hard
with a cold engine! To see whether or not the en-
gine is warm, check if it responds to the throttle
normally with the starter (choke) turned off.
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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

8-13 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
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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:
Without oil filter element removal:
1.5 L
With oil filter element removal:
1.6 L
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8-33 1. Air filter element
1.Élément du filtre à air
1. Elemento del filtro de aire
1. Air filter element 2. Foam cover
1.Élément du filtre à air 2. Cache en mousse
1. Elemento del filtro de aire 2. Forro de espuma
3. Pull the air filter element out.
4. Remove the foam cover from the air filter ele-
ment.
5. Tap the air filter element lightly to remove
most of the dust and dirt. Blow out the re-
maining dirt with compressed air as shown. If
the air filter element is damaged, replace it.
6. Wash the foam cover gently but thoroughly in
water or solvent.
WARNING
_ When using solvent to clean the foam cover,
always use parts cleaning solvent. Never use
low flash point solvents or gasoline to clean
the foam cover because the engine could
catch fire or explode. _7. Squeeze the excess solvent out of the foam
cover and let it dry.CAUTION:_

Do not twist the foam cover when squeez-
ing it.


Do not apply oil to the foam cover.
_8. Check the foam cover. If damaged, replace it.
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8-35
9. Install the foam cover onto the air filter ele-
ment.
10. Install the air filter element.
11. Install the air filter case cover by fastening the
holders.
12. Install the seat.NOTE:_ The air filter element should be cleaned every 20–
40 hours. It should be cleaned more often if the
ATV is operated in extremely dusty areas. Each
time air filter element maintenance is performed,
check the air inlet to the air filter case for obstruc-
tions. Check the air filter element rubber joint to the
carburetor and manifold fittings for an airtight seal.
Tighten all fittings securely to avoid the possibility
of unfiltered air entering the engine. _CAUTION:_ Never operate the engine with the air filter ele-
ment removed. This will allow unfiltered air to
enter, causing rapid engine wear and possible
engine damage. Additionally, operation with-
out the air filter element will affect carburetor
jetting with subsequent poor performance and
possible engine overheating. _
U4XE65.book Page 35 Tuesday, May 6, 2003 1:38 PM