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1991 Yamaha Moto 4 Service Manual

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I just got a 1991 Yamaha Moto 4 for my son and I am looking for a service repair manual. I know that the timing chain needs replaced.

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    • By pokolbinguy
      Hi All,
      Following on from the brief interlude in the "introducing myself" thread....
       
      In a nutshell, I acquired a YFM250 Moto 4 (1991) for cheap recently with the previous owner citing "no spark, needs a new magneto coil and I don't have time to fix it"... anyway I am dubious that the magneto/generator is the issue and thinking more along the line of ignition coil as after a clean up of the magneto I was able to get a rather decent voltage reading off the magneto with pull start and resistence readings seem to check out that the magneto is all ok (all 3 x phases = 1.2 ohms and no run to ground)
      None the less I ordered a new Ignition coil and Magneto/generator coil and am waiting for them to arrive.
       
      In the mean time I cleaned up the current Magneto, popped in a new battery and sparkplug, checked out all the wiring harness, all seemed good except I came across the "neutral switch" wire was broken.
       
      After wiring up a new neutral switch wire, the neutral light now comes on  (small win) and the starter relay (attached to rectifier) now clicks. If I hit the starter switch on handle bar the starter motor spins and if I  pull the cord starter I get a spark on pull....YAY!! I'll try and attach a video below if possible.
       
      So onto the starter motor. Starter solenoid seems to work A-ok, even if it looks crappy and starter motor spins as it should when I hit the start switch....but here is my issue.
       
      When the starter motor runs it turns Cog #1 and Cog #2 (see photo below)....but the chain in the back of the starter which I assume is the timing chain, does not move and there is no apparent movement of the piston in the cylinder.
       
      If I turn it by hand (per photo) or with the pull starter however the chain moves and the engine turns. However cog #2 rotates but not fluidly with the "Crank" (part I turn by hand) for the lack of a better word to use if that makes sense?
       
       
      Is there a grub screw or similar on Cog #2 that fixes it to the center shaft to make it all turn when the starter motor is run? Could there be a part missing? Previous owner had the starter apart so could be possible?
       
      The outer/front part seems to be on a key-way so not sure how to remove this easily to check how Cog #2 is attached.
       
      What am I missing here?
       
       
       
       
       

      spark_baby.mpg


    • By Brer Wilson
      I got this almost a year ago for $500.00 it was covered in a garage and owned by a 57 year old lady.  She said she didn't need it anymore and wanted me to have it for my kids 1 of which is level 3 autistic.   Ritual oil changes and yearly service.  This was barely driven and when it was it wasn't beat on.  All in all I got a killer deal on this wheeler and nothing is wrong with it.  Starts and drives like its brand new. 

    • By Arby911
      I can't for the life of me find the correct service manual for this unit. It's air cooled, not liquid (oil cooler tho) and every manual I find has the wrong front differential diagram (it does NOT have a 2wd/4wd shifter).
      I'd be eternally grateful if someone could point me in the right direction. I can probably slog it out from some of the exploded diagrams I've found, but a good "do this, do NOT do that" manual would be a godsend.
      Regards,
      Ross
    • By Barry Wilford
      got a 350 big bear 4x4 about a 1988 not sure. need upper ball joint, but wales atv say only available with suspension arm . any thoughts appreciated.
       
    • By STEP MONSTER
      as soon as key is turned on 30 amp fuse blows. replaced battery & starter relay. no luck.
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