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Hello all. Happy to be on this site. The information is priceless. Quick background on me, I have built hot rod cars from 1920's to 70's for many years.
I currently have a 1991 Yamaha Moto4 250 2wd quad. The bike is in great shape. I bought it from an older guy who used it around his farm until it decided to stop running. He figured it was an electronic issue since it was a "crank no start" situation. He replaced the original CDI with a cheap Chinese unit and a stator with a cheap amazon part. What was happening, as you started it, with the spark plug grounded, it would spark on the the push of the starter button - then no spark as it turned over - then spark when the button was released. When I got the bike, he did give me the oem cdi and stator.
Fast forwarding, I picked up a manual. I started to check all the electronic specs.
~The original stator, falls in spec per the troubleshooting methods as described by Yamaha. I swapped out the china stator for the original.
~The china cdi box was removed and i put the original cdi back in. What I discovered was the original cdi did not give off any spark. I picked up another original 'good used' cdi as I dont know if it is possible to test.
~new DK coil pack, spark plug and spark plug cover and swapped it in. ( I tested spark plug cover, the manual says it should be 10 ohms but the plug cover is showing 5 ohms. Not sure if this is vital issue)
Now I am getting spark consistently out of the plug, grounded to head/fins.
I have 2 china carbs. One that came on the bike and a 2nd new in box. Fuel is flowing from the tank to carb.
When I try to start, the bike just turns over. Fuel appears to be flowing from the carb (clear yellow fuel line), notably when I put my hand over the carb, I get fuel on my hand from the vacuum. Every now and again, it does burp or 'fire' a few quick cylinder cycles (like "3-4 fires in cylinder" (boom, boom, boom)). It burps back through the carb more than it does to try to start. I tried starting fluid, it does pop, but nothing consistent to want to run or even go vroom!.
I have checked the timing and it "appears" to be spot on. I even check to make sure piston is all the way up on the firing cycle. Without over thinking this, I did notice as the flywheel is at TDC, the cam gear was off a little to the right, not completely straight up and down to timing mark as per the manual. With all that I have done, I feel like the timing chain off, and timing is the main issue (replace timing chain), am I wrong?
I have adjusted the rockers per cold values in manual. I did a compression check and with the throttle closed, im getting 114 psi roughly. I did see some posts saying that the throttle should be open to get the correct value, Ill perform this and update my post.
Unfortunately, its still not starting/running.
I'm at a loss and about to replace the timing chain. I dont think it is a mechanical issue, but I need some fresh perspective....
Any help is greatly appreciated.
New to the quads my neighbor just gave me an old Suzuki quadrunner 230. It has been sitting on his trailer in the back 40 for 7 years since it last ran so I figured it would be a good winter project. Not sure of the year I believe late 80’s
I am sure I will have lots of questions but for now just searching the forums for info.
Background on this Quad.
Over the past year or so I have been teaching my 7 year old Niece to ride. She loves it, I even went as far as buying her a 2012 Arctic Cat 90cc and getting it up and running. We have a bond, her dad (my cousin) is a deadbeat junkie who abandoned her mother as soon as he found out she was pregnant, so my family has all been helping her over the years. I didn't have a dad or a father figure growing up. That hurts and I didn't want her to feel that way, so I have been taking her fishing, to ball games, aquarium etc etc and now it has progressed into riding four wheelers. So after stopping by the family farm and observing and seeing what I was doing and watch us ride one of our old retired farm hands approached me with something interesting. It seems a few years ago he was making his rounds around his old family farm and came across an abandoned four wheeler in the creek bed on his property. He called the Sheriff, they came and got it and took it. A few weeks later they bring it back to him. They ran the serial numbers, it has/had never been reported stolen. Since it was never reported stolen and it was on his property, as far as they were concerned it was his. He put it in his barn and its been there for 4/5 years now. It was mine if I wanted it. Naturally I jumped at it and picked it up..
Turns out it was a 1997 Suzuki Quad Runner 250 4x4. A bike exactly like the one I had as a teenager. I have decided I want to rebuild and restore it as much as possible to what it was rolling off the factory floor. Maybe I am a little bias but I think these were some of the best quads ever built. The four wheel drive transmission has always been cool as hell to me. Anyway this is going to be my rebuild thread on the bike.
These photos are from the day I brought it home. The front half of the plastic is in great shape. The back, has been destroyed, I am looking for a replacement. Since the day I have brought it home I have ordered a replacement stock airbox system, a cover for the battery box and a rebuild kit for the carb.
Hello - Quick introduction. I live in Arkansas on a farm. Built hot rods and customs for over 20 years. I love to wrench and toy with machines. I have 3 different quads (92' LT4WD Suzuki 250 Quadrunner, 91' Yamaha Moto4, 01' Honda Rancher ES) and 1 82' Honda ATC.
Gotta love Facebook Marketplace, and the crackheads that you can buy things from on there...
Naturally, I'm like "Hook up the trailer, let's go get this pile of eBay parts!" and hauled as* to this dude's house with 3 crisp Benjamins to wave under his nose. Showed up about 20 minutes early to find him and his buddy hastily reassembling the pile of plastics into a semi-presentable quad, using some real sweet bulk bin galvanized hex bolts from Tractor Supply Racing Co.
Looked it over and handed him the three bills in exchange for a transferrable registration from 11 years ago, and a STACK of handwritten bills of sale from the last 11 years, since apparently no one has gotten it functional (for long). Average ownership period ranges from 6 months to 2 years. Fingers crossed, lads!
Got it home, and hit it with a healthy dose of bike wash and the pressure washer, more bike wash, a lot of scrubbing, and more pressure washing to get years worth of crud off of it. The entire left side of the crankcase was covered in an eighth inch of caked oil mud, as though there had been a catastrophic loss of oil at some point in the past, because it was nowhere near the drain or fill holes. Totally opposite side. Managed to find the VIN hiding in there and ran it for giggles.
PO mentioned that he "had it running at the beginning of the season, but it was 'rough' " and that he had cleaned the carb, but it didn't help much. And now it just plain wouldn't fire at all. Kind of threw his hands up and shrugged. So, after cleaning it up enough to turn wrenches without looking like a Texas oilman, I took off the plastics and started poking around. Found a few fishy spots in the harness where previous attempts at repairs had been shoddily made and hidden with black tape. Sorted those out, drained and filled with fresh oil and a filter, and hooked up a battery. Turned the key, got a green light, hit the starter switch and got a little grunt and squeak out of it, then nada. No light, no nothing. Pulled out the DeOxIt D5 and started pulling apart all the connectors and giving them the business. put everything back together again, turned the key, got green light, and starter cranked! Then nothing again. Started fiddling with the wiring and connections while watching the green light, and saw a flicker when I bumped the 25A fuse holder. Gave it a squeeze, and sure enough, the light came on. Thing was full of powdered remains of spade terminals, so I installed a NOS replacement model from RADIO SHACK that had been swimming around in my toolbox for nigh a decade. Sure of my fix, I tried the starter again, and NOTHING again. More fiddling revealed that the OTHER fuse holder (15A) was the same. Homebrewed another fuse holder from spade connectors and shrink tubing, hooked it all up and everything was good.
Now that I could crank it, I poured a couple cups of gas in the tank and pulled the plug to check for spark. Good blue spark, once I cleaned up the theretofore fouled plug and gapped it. Screwed it back in, with a healthy dose of ether, and gave it a crank. Not even a wheeze or a sputter. Off with the carb!
So, I think our old friend PO has a drastically different definition of "carb cleaning" than I do. I'm thinking maybe he wiped down the OUTSIDE of the thing, and was shocked that it had little to no result. That white stuff is a combination of powdered aluminum oxide and near-varnish fuel. Has the consistency of slight dried mayonnaise or white library paste, but no pleasant wintergreen aroma to match. A quick perusal of the Amazon bargain bin turned up a carb (BST31SS) and non-vacuum petcock for $25, with a caveat that the carb required minor modifications to fit. Four days and a lot of sandblasting and surface prep on the plastics while I waited, the carb arrived today and I drilled out the ferrules for the choke and throttle cables to accept slip-fit cables instead of thread-ins. Other than that, the only difference was a lack of one vacuum port for the petcock, which I had anticipated and purchased a regular old one with no vac diaphragm in it. Safety first, amirite?
Now with definite spark, and reliable fuel delivery, I started cranking and fiddling with the idle and air screws, managed to get it to fire up - almost literally~ There was a LOT of smoke coming from near the exhaust port on the head, thought I had loose header studs for a minute, then realized it was just more of the old oil mud I had missed while cleaning, burning off between the fins on the head and the exhaust heat shield.
First fire up - lots of smoke
While I was changing the oil, I took the opportunity to pull off the access covers and adjust the clutch and valve lash, so I was feeling OK about running it a little more. Got the idle and mixture set a bit better and decided to test out the transmission and shifting a little.
Realized I left the parking brake set, so it stalled out. Oops. Another thing I did while waiting for Brown Suit Santa to bring my carb was to remove the diff lockout pin from the shifting mechanism and I wanted to see if it worked. Here's the quad, up on the lift, minus the LF wheel (due to a seized cylinder I've since replaced) with range set to HIGH, and Differential Lock engaged. Worked like a charm. Had to holler at the dog who was camped out below the rear tire Dog under the tire. Again. I think she has a death wish. Or perhaps aspirations of being a jackstand in the pro-leagues.
Testing Diff Lock in High Range
Put the wheel cylinder in, (Dorman w38750 for a 1991 Geo Metro/Suzuki Swift was a precise fit and only $10) to replace this crusty POS:
put the wheel and hub back together, put seat back on and fired it up. Made sure it would start again after turning it off.
Long Live The King
All the repairs appear to have been successful all around! I took it out for a quick rip up the street and back, needs a little bigger main jet (it came with a 145 installed, which I swapped out for the 120 OEM spec, but it feels boggy at WOT, so I'm going to experiment a little after I get the airbox back together, but 145 seems like a big jump.
I'll try to post an update once I have the plastics all refinished and installed next week. Pretty sure it's going to be yellow, no camo or green bullshit for me thanks Hope you didn't hate my post.
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