Jump to content

  • Do you own an ATV or UTV? Join our Forum!

    Join QUADCRAZY ATV Forum today for FREE! We keep these forums clean and user friendly. All first posters will have to wait to have their content reviewed and approved. Once your first post is approved, you will no longer need to got through an approval process. To gain immediate approval and a NO ADS experience, consider subsribing to our Premium Membership.

1992 Suzuki King Quad 300 Help

Recommended Posts

Hi All,

I have a 1992 Suzuki King Quad 300. I got it in rough, picked apart condition on Facebook marketplace. The previous owner was not mechanically inclined and threw parts, and deleted parts to get this to "run". To give you an idea of what I am dealing with he put a non vacuum carb on with a separate fuel bladder mounted on the rear rack. I live in CT and things are a bit high here so I got the atv with a plow for $400. The atv came with (3) Carbs, 1 OEM, (2) petcocks 1 OEM. What I have done / found is the neutral safety switch was ate by mice (probably the original problem), fixed that, reinstalled (cleaned and put in a new needle and seat) OEM carb, the diaphragm is a little clapped out but still flexible, installed new Fuel pump, cleaned and reinstalled OEM petcock (non vacuum) has slight drip every now and again as I did not replace the tank side gasket when I installed and installed a brand new battery.  doing all that the quad fires and runs but briefly.  On the handle bar the choke paddle is broke off, I ordered that and looks like you need to remove the grip to install so haven't done yet and If i can get some direction on that as well, So that is "floating" in  the carb as I do not have the correct choke cable connector, I took the one off the Chinese carb and it somewhat holds it in place. The air box and system are gone and it has a stubby K&N cone filter on it currently.  So the way I start it is pop off the air filer, hold my hand over the carb to get a good enough vacuum to get to the bowl, then it will run for a few seconds. The tank is filled to the top, to help it out. Does anyone think I am missing anything before purchasing the entire air box system (If I can find it). This will be a yard machine for work and will not be taken out recreationally, cool little machine I would like to keep it, but unsure if I will spend the money on a airbox system as it for sure seems I am not pulling a good enough vacuum with out it. 

Link to comment
Share on other sites

Good job getting it running, I would be looking at compression and intake manifold leak ,possibly make sure vacuum slide is working properly. I may be wrong but I don't think the air box missing is causing suction problems .

Link to comment
Share on other sites

I did take a look at the intake manifold boot, no signs of dry rot and looks well seated. I would say the vacuum slide is working because when I get the bowl full the quad will idle decent and rev up and down with out any bog, nice and smooth. I did pull the vacuum line off the fuel pump and held my finger over it and can feel it suck. I do have a cheap fuel pump on it from amazon and the elbow where the vacuum line goes on can be pulled out of the socket and rotates like its on a bearing. Maybe I will try rebuilding the OEM one. 

Link to comment
Share on other sites

The fuel pump vacuum has to be pulsating. If it's got a steady vacuum then you have a restriction in the hose somewhere or the hose is too thinner walled.

If the carb is full of fuel, then it should run. Check the fuel is getting to, and into the carb by undoing the drain screw on the bottom and checking fuel keeps coming out after the bowl has emptied. It should flow by gravity if the tank is full.

Then, if you take the fuel hose off the carb and lay it in a bottle it should be pulsing out fuel when it's idling.

Link to comment
Share on other sites

I think you might be running  lean after you check to make sure your fuel pump is pumping gas as Mech suggested, try enriching your mixture a little bit see if that helps, you can also check for manifold leaks with it running spray wd 40 carb cleaner what ever you have right where manifold meets the engine and where carb meets manifold if idle increases you have an air leak. As far as getting hand grips off I pry up the rubber a little and squirt a little lubricant around the grip and use compressed air to blow it loose from the handlebar. 

Link to comment
Share on other sites

If it runs ok when the bowl is full then you need to figure why the bowl isn't staying full.. 

When the tank is full the fuel will/should flow out the carbs fuel hose if you pull it off.. You should check that happens first. 

If there is fuel getting to the carb then use the drain bung to check it's flowing through the float needle and into the carb fast enough.

If there was no fuel to the carb then check for restrictions or vacuum in the tank. That new pump might restrict the fuel when it's not getting vacuum.

To test the fuel pump you lay the fuel hose from the carb into a bottle. Lay it on it's side with the hose laying flat. If the hose is dangling down you won't see the fuel pumping out properly. Then suck hard two or three times on the vacuum hose going to the pump, and then let the vacuum off suddenly. You should see a single slug of fuel come out of the fuel hose. The slug should be full diameter of the hose and about ten mills long. If that works then your pump is ok and will work if it's getting good pulsating vacuum.

To test the vacuum you reattach the vacuum hose and start the motor and let it idle. It should pump fuel out of the fuel hose into the bottle at full diameter of the hose and slugs about eight mils long. If that works then the pump is working and it should start and idle at east.

Then you need to check the vacuum is still strong enough when the motor is under load. To check that you leave it all as is but sit on the bike, put the brakes on hard, engage first gear and open the throttle until the motor starts straining against the centrifugal clutch. As the motor starts to labour the pump will likely slow down it's delivery of fuel, but it should keep pumping some. If it stops pumping then you have weak vacuum or a malfunctioning pump.

The vacuum has to be strong, and pulsating when it gets to the pump. If the vacuum hose has been swapped with some soft thin walled stuff the pulsations can get lost as they suck the vacuum hose flat and then let it out again. Low vacuum can be caused by low compression, tight valves, or air leaks.

Edited by Mech
Link to comment
Share on other sites


I did not even think about the vacuum line being non oem and folding on itself, as I had to use my heat gun and warm the end up real good to get it to fit on the aftermarket fuel pump, however it was on the previous one and it looked OEM. I will check that later this week. Do you know what size it is supposed to be? I can not find it online.


Thank you

Link to comment
Share on other sites

I think it's eight mill/five sixteenths. Fuel hose works.

Also, some aftermarket carbs don't have the large sized vacuum port on the carb, the brass fitting. The originals had a hole in it about five mills but I've seen aftermarket with a smaller hole, about,,er..  a bit over two mills I think it was from memory..  That didn't work and I swapped brass fittings.

Link to comment
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

  • Similar Topics

    • By Filthy_Mule777
      I'm currently pulling my hair out over a customers 98  bayou 2x4 KLF300b. I've changed every electrical component on it twice and in a couple instances three times. Still no spark, I am baffled. Initially customer brought it to me complaining of a hard start no start situation and in fact, it wouldn't start. I changed the starter relay, spark plug,  CDI box, and starter circuit relay after which it fired right up ran very well but then started having issues with the neutral switch/light where it wouldn't come on and wouldn't allow it start or even turn over. I found in the wiring harness a loose connection, I got it taken care of and secured and that solved the problem. So now that it would crank up again and run fine I called the customer over to test it out see what he thought as I've never heard it run before and I wanted to get his opinion on how it was running. Customer ride it around a little bit pulled it back on my carport and turned the key off and said it was great, and had never ran better or started so easily, then we set up a time for him to come pick it up the following day and he left. Well where he pulled it on my carport and shut it off was in the middle of the carport so I jumped back on it to park it off to the side,  crank it up no problems put it in reverse went about maybe 18 inches and it stalled and ever since that point it has not had spark or run. I replaced the CDI box again with a better brand, I replaced the ignition coil twice put another starter relay on it and I've also changed out the stater and the pick up coil (pick up coil twice) and I'm just I'm lost I don't know what else to do to it. I've had this customers  four wheeler for four months now whereas he's a patient guy I need to get it out of here so I can move on to something else. I've seen dozens of threads across  different sites for off-road, 4 wheelers, ATVs, UTV's, whatever and they are all experiencing the same sort of issue but they never ever post hear the problem was or  the fix. So I'm hoping somebody here has a little bit of knowledge on this particular issue sent since it seems to be so widespread.  Thanks in advance for any help or suggestions.
    • By Wrye Pipeworks
      Picked up a 2000 prairie 300 4x4. It is leaking out of the rear output seal where the driveshaft contacts to the engine. I'm havi g a really hard time finding out how to remove the driveshaft online, finding a service manual, and finding the seal on a parts diagram. Anyone know how to remove the driveshaft or know where a service manual is for it?
    • By Jim Denton
      I was gifted four King Quad 300's, they were used to tow portable snow guns around the slopes. All of the plastics are trashed and racks bent up from rolling down the mountain. The lone Quadrunner is a 98, and will be the initial point of focus, as it reportedly ran before being parked in the field of lost dreams. 

    • By Mikey69
      Heres my story. Kinda long. I guess I was a late bloomer when it comes to quads. I had never ridden a quad in my life. Rode Dirt Bikes as a kid growing up. Back in Oct of '06 I found a Mustang on craigslist. Took it for a test drive one morning before work. Fast car. 351 Cleveland. I had planned on meeting the guy again after work. For some strange reason thats still to this day beyond me, I stopped in Hillsboro MotoSports on the way home from work. I had 6 Grand on me. There was a left over '05 sitting by the front door. It was on sale for $4999. It was $5499 OTD. I didnt even look at anything else. I knew nothing about quads accept I thought it really looked coool and I had the money in my pocket to buy it. I was sitting on it when the salesman walked up and asked... "Can I help you?" Without hestitation I pulled 60 Ben Franklins outta my front pocket and said "I want this Quad. Load it up in my truck." It was just about dark by the time I drove away from the shop. BTW, I didnt bother to ask my ol lady if I could buy it. LOL. Anyway, I took it by the house and showed her. She was kinda stunned but not mad. We drove over to a friend of mines house and unloaded it. I took it to the field across the street from his house. HOLY CHIT!!!!! I was surprised by the power. I had it for about 2 weeks and took it to Sand Lake. I was there a few hours and rolled it on a banked turn at the top of the bowl right before you get to the one-ways. When it rolled, I flew off and landed on my belly. The quad came bouncing and landed on my back. For a month I couldnt even walk. I was scared of it. I considered trading it for a 250EX. Went back to the shop. The salesman said..."Dude!!! You dont want a 250EX!!! Trust me. Just get used to it" I still wasnt convinced. I put it on craigslist for $4000. Calls were coming in. I had a guy that wanted to come look at it that evening. I decided to take it for one last ride at Browns Camp before I sold it. I was still afraid of it. After about 5 minutes I started feeling comfortable on it again. I decided right then, I loved my Honda 450 and would learn how to ride it instead of selling it. That was late Nov of '06. Work was slow for a Painter in Oregon. My new job everyday? Going to Browns Camp and ridding my Quad. I bought my Girl Friend an '02 Blaster. I rode my 450 for 4-6 hours almost every single day for 3 months. And yes, I know my way around Browns Camp pretty well. LOL. In March I bought her an '06 TRX250EX (Thank God I didnt trade my 450 for one of those) LOL Since then, I have become totally addicted to quads. I love them. Couldnt imagine not owning at least one quad. Luckily I have two. My "07 was $6500 OTD in July of '07. Bought it for my Girlfriend. Traded in her 250 EX. A month later we broke up. So, I wound up with two Honda 450's.
    • DIY like a pro! Shop from over 1,000,000 Repair Manuals at eManualOnline.com! As low as $14.99 per manual. Shop now.
    • By JohnKramer
      I replace everything involving fuel and it still won’t work. 
  • Similar Tagged Content

  • Gallery Images

  • Recently Browsing   0 members

    • No registered users viewing this page.
  • Create New...