1989-1991 Yamaha YFM250W Moto-4 ATV Service Manual

Comprehensive diagnostics, removal, and maintenance for the Yamaha YFM250W Moto-4 and Big Bear 250. Includes engine, chassis, and electrical systems. Part # 3GN-21740-00-00.

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Document Details

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Document Number / Seller:
28754 / Brian Wright
File Size:
60.66 MB
File Type:
PDF
Language:
English
Pages:
320
Printable:
Yes
Category:
ATV
Last updated / verified
Dec 26, 2025

Models Covered & Key Technical Specifications

Applied Assembly Workshop Manual: ATV Yamaha YFM250W Moto-4 ATV Service Manual - Precision Maintenance, Diagnostics & Repairs, 1989-1991 Engineering-Archive

Procedure-Type: Workshop Manual | Series-Validation: YFM250W | Procedure-Type: Repair Manual.

  • Designated Size Parameters: 11 L (2.42 Imp gal, 2.91 US gal) defines the total fuel tank capacity.
  • Verified Installation Footprint: 732 mm (28.8 in) is the overall height for standard operation.
  • Nominal Coupling Torques: 8.8 N·m (0.9 kgf•m, 128 psi) signifies the maximum compression pressure limit.
  • Defined System Fill: Yamalube 4 (10W30) or SAE 10W30 type SE/SF oil is recommended for the engine and final gear, with a capacity of 2.1 L (1.8 Imp qt, 2.2 US qt).
  • Key Power Framework: 12V, 25W/25W x 2 pcs. indicates the headlight bulb wattage for optimal illumination.
  • Essential Mass Specs: 216 kg (476 lb) is the basic weight with full fuel tank for stable handling.

Professional Workshop Service Manual & Technical Specifications

Applied Assembly Workshop Manual: ATV Yamaha YFM250W Moto-4 ATV Service Manual - Precision Maintenance, Diagnostics & Repairs, 1989-1991 Engineering-Archive

Procedure-Type: Workshop Manual // Series-Validation: YFM250W // Procedure-Type: Repair Manual.

Performance-Element Value Context
Model Code 3GH Engine starting information.
Front Tire AT22 x 8 - 10 Tubeless tire specifications for optimal grip.
Rear Brake Type Drum Brake Provides reliable stopping power.
Ignition System C.D.I. Manages spark delivery for combustion.
Basic Weight 216 kg (476 lb) Dry weight for handling assessment.

The repository is divided into chapters covering general information, specifications, periodic inspection and adjustment, engine overhaul, carburetion, drive train, chassis, electrical systems, and troubleshooting. Procedures are clearly outlined with supporting diagrams.

Testing requirements are specified for engine components, including valve clearance and ignition timing, to ensure optimal performance and longevity.

Clearance measurements are addressed for critical engine parts like pistons, rings, and camshafts, providing detailed specifications for wear limits and allowable tolerances.

Fundamentally requiring proper component alignment retention, this manual documents torque specifications for various fasteners throughout the ATV to ensure secure and reliable assembly.

Special procedures are addressed for tasks such as carburetor adjustment and drive shaft lubrication, guiding technicians through complex maintenance routines.

Verification procedures are included for systems like the electrical and drive train, ensuring all components function correctly after service.

Repair information is provided for common issues and component overhauls, offering step-by-step guidance for effective repairs.

FAQ

Reference the **specified** tool requirements for engine service. keyboard_arrow_down

P/N YU-08036 for the Inductive Tachometer and P/N YM-01312-A for the Fuel Level Gauge are required for engine service tune-ups.

What are the **essential** electrical values for the YFM250W? keyboard_arrow_down

12V is the standard voltage for the electrical system, with a 15A rating for the rectifier and a 12V, 14AH battery.

Specify the **correct** calibration settings for the carburetor. keyboard_arrow_down

1 and 3/4 turns out is the standard setting for the pilot screw; the float height should be between 21.0 - 22.0 mm (0.83 - 0.87 in).

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Reviews (4)

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The illustrations are clear, and the troubleshooting section is incredibly helpful. Download process was smooth too!
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Rated 4 out of 5 stars
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I love how comprehensive this manual is. The email support was quick and professional when I had questions about the download. Thank you!
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This manual is a lifesaver! The detailed breakdown of each chapter helps me tackle maintenance tasks with ease. Highly recommend!