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I have a 2004 Yamaha Bear Tracker in the shop for repair. I have the service manual but it doesn't have all the information I need to fix the problem. I need to know the voltage output of the stator charge coil and pulse or trigger coil at cranking speed. The wiring diagram color code doesn't seem to match and that is compounded by the fact that the wiring harness CDI connector is missing so I have 7 wires that need to be connected to the CDI. I can not find a circuit diagram of the CDI which tells me where the pulse/trigger coil connects or the charge coil connects. The other 3 wires (black ground, orange ignition coil, and r/b ignition kill sw) also need to be connected. The CDI has a single 8 pin connector and has a P/N 4XE-00 F8T19871 -1122 number on it and I believe it to be OEM. However I think the Stator and pulse coil are aftermarket items. I have resistance tested everything and it all seems to be in spec. but I don't want to miss wire anything and cause damage. Any help would be greatly appreciated.
By Bruce Sawyer
1987 YFM350FWTB 350 4x4 Big Bear when going uphill will sometimes act like the clutch realeases then re-engauge all at once.
Seems to maybe be little more often if the engine is at about 1/2 throttle instead of at lower rpms.
I have the Factory Service manual and checked the external clutch adjustment screw as ok and the H/L/reverse shifter lever linkage as adjusted correctly. It appears to be maybe a internal (inside the case) clutch issue or ??
This is the type Big Bear that has the manual shift lever on the left front fender and has the manual foot shifter lever with 5 speeds forward.
Can someone tell me how the primary and secondary clutch operates?
I assume one is mechanical and one is centrifugal. (what I'm asking is one clutch for the higher rpms and one for the lower rpms or ???. (the clutch appears to only momentarily release at the higher rpms is why I ask. The cycle has about 3000 miles of low speed through the brush hunting and has been well maintained, oil changed, etc and no deep water or mud useage.
Anyone been into a similar issue with the big Bear ATV????
By Dwight Williams
Ok, so I bought this scream of a deal the other day - a 94 King Quad 300 for $40.00. It's been sitting outside with no carburetor on it for about a year. Its rusty, missing some parts, wiring is all cut up and spliced etc. No seat, no racks but the plastic is all there minus the headlight housing. Anyway, who can pass up a $40.00 quad right? I get it home and looked at the sight glass for oil level, it's about 1/2 oil and 1/2 water. I drain it, refill it and turn the motor by hand (recoil starter is missing) and it turns over just fine. I worked on the wiring for about an hour and got it to turn over with the electric starter and got enough of it sorted out to get a spark. Did a quick compression test, 70 lbs. Wet test bumped it up to 90. Ok, so rings and cylinder washed out with water for a year, not too surprised. I thought 'what the hell' and sprayed some starting fluid in it and it ran for about 2 seconds - enough to show it's got life. Since then the compression has gotten worse, I can't get enough pressure to activate the carb diaphragm, therefore no fuel pump either. The compression is now around 60.
Anyway, my question is....is it worth it to try to get this thing going? I tore the top end down today and the cam and one of the rockers is pretty worn. I figured a top end job would be about $100 or so, depending on the condition of the cylinder but I'll probably have to put a cam and rockers in it as well. Doing some research on ebay I figure I'll have to spend about $500-$700 to make the whole machine right again. Much less just to make it run and use as-is but I won't really like it until it's right. I don't mind doing the work, I actually enjoy it but I'm concerned about what all that water did to the rest of the internals, I can't really test it all out until I can make it run.
I know it's a basket case but I'm not into it much at all, even if I do the top end and find something else wrong I'm still not out much. I'm leaning toward ordering the top end parts and going from there unless you can convince me otherwise - any way to check the rest of the internals without tearing it down? I plan on flushing the oil cooler before I do another oil change, I've drained it twice now and it gets milky almost immediately just turning the starter - I suspect the oil cooler is polluted badly.
I'll get some pictures today if anyone want to see them.
By Ellery Zandt
I have no idea where the antifreeze line coming off the thermostat goes too. The carb two nipples in the pic create a vacumme. Can someone help me on this please....!!! my email direct is [email protected]!!!!
got 7 atvs off CL recently for a good price. one of which is a yamaha warrior. anyone know where the vin is printed on this bike? Haha good place to start as I do not know year or size yet. The former owner says needs exhaust ans and clutch work. he said it ran fine until the clutch cable broke and then I couldn't get the new cable adjusted right and it would grind gears. things I see: clutch cable locked up again, no brakes, carb leaking (green with algae around the bowl and has gelled gas stalagtights on it), aftermarket exhaust melted the airbox so I need something different and a new air box. I would like the use the current exhaust if I can but I have a feeling its a redneck fix as it looks like there is an ace bandage holding it to the exhaust pipe (its an aftermarket slip-on exhaust), so I'm not sure about that- lets get the bike running first. also, battery (looks brand new, what a shame) is dead, 0 volts. Otherwise, bike looks to have not been wrecked, and plastics are ok (it sat outside under a 'tarp' for 3+ years since it was run last). any tips and advise on where to start first would be awesome as this is my first clutched bike (manual).
the clutch is my main concern- I've never rode a clutched bike so I dont even know what its supposed to feel like. lol I'm spoiled on my automatic polaris
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Howdy y'all. Just bought myself a 2004? Yamaha 400 with electrical Gremlins aplenty. Runs good (after jumping the starter solenoid relay terminals with the helpfully included with the sale pliers) but no fan when my wife's 03 Kodiak 400 had fan and the starter button makes it to the starter solenoid but the ECU side isn't happy. This seems to be a lively forum with manual downloads being supported so hi.
Oh yah, and you can get two Kodiak 400s on a 5x8 trailer... I bought a nice 14' trailer as soon as possible after this.
By Ellery Zandt
Does anyone have a redcat 250 or falcon 250cc that they can share where the two vacuum lines on the carburetor that you run antifreeze through I honestly have no idea where the lines are suppose to go to circulate the antifreeze.
Any help is greatly appreciated.
By Nate Hanson
I am a new atv owner...I bought a used atv this summer (pretty sure it is a wolverine but reg card from last owner didnt actually say that so idk for sure). It ran great for most the summer and early fall but one day I tried starting it and it turned over a while without starting and then suddenly it quit turning over at all. No click or anything.
I charged battery and light turns on showing neutral and heatlight can go on.
A few other things that may be pertinent: The pull start is missing, I have a fluke multimeter but not many other advanced tools (or relevant experience), there is an extra aftermarket led light attached to front but it doesnt work either... never looked into why since I didnt need it.
I looked for a fuse box and didnt find one.
Please recommend some easier things to try first as I really want to avoid taking it in if I can (having one income and 4 kids can keep out extra cash, plus I want to learn). Pictures would be awesome if possible. Thanks!
By Kanyon Pershing
I have recently rebuilt my Yamaha warrior 350 engine and when I got it all back together with no “spare parts” i went to start it and realized it’s in reverse. I went to put it in drive and the shifter won’t budge, I took the linkage off and tried to use vise grips but it won’t budge at all. Any help would be greatly appreciated. I’m hoping it’s not something internal!
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