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Hey guys, new here, but haven't found ANY answer to my specific problem on a Suzuki dedicated ATV forum, so here's to hoping!
I acquired a 95' Quadrunner 250, 4x4, (LT4WD) for practically nothing with no spark. The PO had tossed in a used stator which didn't fix the problem... so I went all routes (though cheaply) to narrow down the initial problem of no spark.
Plug, coil, CDI (caltric) and stator w/pickup (caltric) were purchased and installed. And it RAN, but bogged horribly and would not rev past 1/4 throttle.
I checked fuel flow, vacuum lines, all the normal stuff, no issues. I decided to check the valves and cam... well, there was one problem. The cam was 1mm under the lowest spec in the manual. So, in-came a new cam, Stage 1 Hotcams... also threw in a new set of shindy valves, lapped them, replaced the valve seals, and the timing chain.
Back together again (w/stock airbox and new oiled filter). Now it idles even better, still boggs at 1/4 throttle, but will rev past it if you hold the throttle open for a second. Ahaha... success!
So I was able to ride it above 1/4 throttle once I had momentum... could shift through the gears, all was good as long as I kept it over 1/2 throttle. Took a long enough ride to break in the cam properly at least so I won't have to worry about that.
Now, I start fiddling with the carb. It's clean as a whistle, stock, with stock jets (new replacement Mikuni jets). Same problem.
I start thinking, maybe this is fuel related and the bike is having an issue transitioning from idle jet to main jet... so I LOWER the needle by raising the clip 1 spot. Now it revvs up in neutral with no bog, but it boggs about the same trying to ride it. So I move the needle down again with the clip on the top slot. Better, but still has a bit of bog at 1/4 throttle.
The last bit of advice I got was to ditch the CV carb... so I sprung for a brand new Mikuni VM30-83 round-slide. Bolted it up, blew into the vacuum tube to fill it with fuel (no vacuum port on this one) and she fired right up... but there is still a bit of bog, it's just masked by the fact that I'm not waiting for the vacuum diaphragm to open.
So I feel like each little step brings me closer, but not perfect. I'm now wondering if this is still in-fact a carb tuning issue (I have some jets I can fiddle with and maybe lean-out the idle jet a little.) OR if the cheap-a** Caltric Stator/Pickup is what's causing these issues.
I have a 95' KingQuad with 400 miles on it... like new.. runs like a top... I've tried both the stock QR and the Caltric CDI boxes on it, and it revvs up and runs like a champ.
The only unknowns between the two systems are the carb, and the stator/pickup. My next step in troubleshooting is to rip apart the King Quad and test it's CDI on the Quadrunner... but considering there is no change to how it runs I doubt it will lead to a solution.
HOWEVER... I tried the stock CDI just recently after running the Caltric this whole time, and the bike runs like garbage. Hardly idles, and won't rev up at all. So, that is my one smoking gun telling me that it's either the pickup coil or the stator itself.
Has anyone had a problem even CLOSE to this? I can't image the carb would be causing this many issues, especially going to 2 different ones, both with stock jetting to OEM, and exhibiting the identical symptoms... the only change is when different CDI's are plugged in, or when the needle valve leans out the mixture.
Also, I checked the piston, rings and bore when I had it apart and they're like-new... no scoring, rings are loose, cylinder is still round and has honing marks still int he bore. Stock piston, stock bore size and it has 160psi compression. Battery is brand new, and I've tried 3 different R/R's, none of which change any symptoms, but slightly vary the charging voltage by .2-.5 of a volt depending on which unit. Also tried a new coil which changed nothing.
ANY help would be appreciated. Too much invested to not get it running right.
By crochet homemade
I have bought a 1996 suzuki king quad 300 and I have noticed that it smokes but I have put oil in it and plenty of gas had to fix shifter bc the nuts and bolts came out somewhere. I have had to replace the wire for the starter but now when I try to start it it wont idle at all and when it does run it smokes really bad like a whitish blue I guess, and it likes to stall a lot. So anybody can help me out please and thank you
By Ed Zeppeli
The play on my KQ 300 (1998) choke doesn't allow for the full movement downward on the thumb lever. So it goes about halfway down and if I push a little too far the cable pops out of the plastic setting it sits inside of. Then of course I have to take the control unit apart and put it back into position.
Is it normal for the thumb lever to not go all the way down?
I have no play left in the adjustment screw on the cable in the correct direction. The only play I have left would make it worse.
It'a a new-to-me quad so I'm not sure if it's a replacement cable or OEM.
Problem: The ATV starts and runs at idle perfectly. But as soon as I open the throttle, the engine starts to slow down until it stops. On the attached video you can hear the sound of how it works: see video below
Prehistory: there is a Polaris Sportsman 500 1998, which for about 1.5 years stood in repair, including also replacing CDI with one taken from the same ATV. Finally, the vehicles were on wheels, traveled several kilometers and overheated - forgot to fill the antifreeze Came back home in small moves. The next trip started well, but after 10 km there was a feeling of a small drop in power (even as the vehicle got warm completely) but still drives. Next trip - the situation is repeated. The next test of ATV through time and a huge loss of power from the very beginning. The engine sneezes, does not want to go more than 5 mph.
What has been done: the carburetor has been replaced with a new one (inexpensive, $ 40), a new spark plug, a new ignition coil, the engine head has been removed, the piston is in good condition, valves were corrected - but the problem was definitely not in them.
Ignition control unit is suspected. Who faced similar? Please help in solving the problem.
Thanks in advance.
It's been a while since I posted. Fan trouble and the replacement I sourced on amazon is still working great on my 2005 Suzuki KQ700.
Unfortunately this year I lost my outdoor best friend. He's that go to guy for everything … the day run, may walleye opener, last minute hey my boat's at work get your a$$ over here with your rod and let's go kinda buddy. I bought the quad last year in March and with him gave it the once over and prepped it for fall hunting season, but cancer took him before we could enjoy this new aspect of outdoor life. We planned an October trip into the bush with our quads guns and tent trailer. It never happened. A tribute to our fallen and lost.... But in their memory take the opportunity to grasp every minute of the outdoors you can, life is short... you can sleep at the end...
I've curious what everyone has been doing to prep for the spring season. I mounted my battery and the quad started up straight and easy, just powered it up once or twice to juice the injectors and it fired up after a couple of seconds. I let it run, confirmed fan started, checked charge voltage. all good. I did all my oils in the fall to make sure no water was present anywhere so skipped that this spring.
So what have I done over the winter to prep for quadding? I've been researching. This year I am going to cross over quading with brook trout fishing. So I have been pouring over my old maps from my youth, google maps... looking for those faint markings of trails I can't travel in my F150 (well not yet, paint still looks pretty good ).
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