1996 Suzuki King Quad 300 - Resurrection, help needed..

[damm315er]

I bought a semi-running 96 king quad 300, it had multiple fuel issues. It's beat up, dirty, and old, but that doesn't matter since it's only going to be dragging dead snowmobiles from trailers to my shop to repair them and put up trail signs for the club.

When I bought it, it would run for about 15 or 20 seconds then quit, no matter what was done to keep it alive. A quick look at the guy's house showed that the choke had come off of the carb, all the vacuum and breather lines were off of it, and the original mechanical fuel pump had been replaced with an electric one that was activated by a switch so you had to turn it on and off.

At home, I discovered that the cob job wiring for the fuel pump was not connecting to the battery any longer, and the switch wasn't actually turning the pump on. Reconnecting the wire to the harness, it would now run and stay running, albeit poorly because of the choke and vacuum lines being off.

Go buy the parts, lube up the frozen choke cable, install the choke, and give the carb a quick cleaning.

Guess where all the hoses go, since they weren't connected and I cannot find a manual for it. Ok at this point I figure I can make educated guesses since I know the difference between the vacuum ports and bowl vents. (i've been wrenching on stuff since I was a kid, but never owned a quad)

Try several different combination, some will rev through all ranges but quickly flood the engine at low rpm, others will give it a good idle but have a horrendous bog getting out of the low RPM range.

I found a 99 manual, but it doesn't give hose routing. It said the turn the air jet 2 5/8 turns out, and i found that the carb is at 5 turns out.

Turn that in to the spec, and it now runs like total crap.

Oh, and along the way I found that the petcock is leaking so that hose is now attached to the bowl vent.

I grabbed a fuel pump from my sled, and hooked that up to replace the electric one that was butchered on there, and used the small white vacuum port from the carb as a pulse line. That works just fine I have plenty of fuel.

It seems to run best with the other vacuum line wide open.

Thoughts?

Does someone know of a place I can download a manual or have a hose routing diagram they can upload and correct carb specs for the year?

Thanks,

[oxidized_black]

i can send you the service manual that covers the years from 1986 to 2006 with all the supplements. you can either put your email on here in this thread or send me a message to my mail here at the site, or email me direct at [email protected]

[damm315er]

Anyone?

The manual offered above wasn't correct, so I'm still on the hunt for help or the correct manual.

[Ajmboy]

I looked and I only have a newer king quad manual. You might just want to find a suzuki atv dealer and see if they can fax/print you a vacuum diagram. I'm not sure if the clymer manual has a vacuum diagram:

Clymer Suzuki LT-4WD, LT-F4WDX and LT-F250 1987-1998

Here's another to try, but who knows on this..

Suzuki Quad Runner 250 / King Quad 280 service manual repair 1987-1998 - Download Technical

That's a tough one, but a nice quad. I'm assuming it has those fancy shift levers...

[oxidized_black]

The manual offered above wasn't correct, so I'm still on the hunt.

yes and i'm very sorry about the mix up, i thought i had it and it was the 300 bayou for that year. that king quad manual has got to be the hardest one to find on the net, but i'm not giving up !!!

[damm315er]

Ok, I bought the digital download for $5, it has 4 more downloads left. Have at it guys!!

http://www.tradebit.com/softlinks/8854542-Suzuki_Quad_Runner_250_King_Quad_280_Service_Manual_Repair_1987-1998.pdf