1995 Suzuki King Quad Electrical Issue

[FastJimmy]

Hey all and thanks for the welcome.

I bought a Suzuki King Quad 300 new in 1995 for use on the farm.

We used it several years without it hardly missing a beat. Then about twelve years or so ago it started acting like a loaded up two-stroke, blubbering and spitting.

At that time I had owned motorcycles for about thirty-six years. I had worked for pretty good sized dealer, raced bikes and later I had two bike shops so I had a little mechanical experience.

First thing I did was disassemble and clean the carb, which made no difference at all. After trying everything in my bag of tricks I broke down and took it to a “professional” who assured me that it was a worn needle and seat. I doubted that to be the case but approved the $125 or so “repairs”. It was of little consolation to me that the “professional” couldn’t figure it out either for his “repairs” made absolutely no difference whatsoever.

Reluctantly I carried it to another shop. As soon as I started it to unload it off the truck the mechanic said, “That’s an electrical problem.” Well this “professional” knew what he was talking about and after replacing an electrical part it ran great again for another five or six years before it started doing the same thing.

I discovered that if I turned on the light that it would smooth right out run normal.

By that time we had bought a Kawasaki 610 Mule and the Suzuki didn’t get used much. A few years ago the blubbering and spitting came back even with the lights on. I kept meaning to track down its electrical issue and fix it but other things took precedence. It has been a year or more I suppose since I even started it.

I tried to find the paperwork from the original repair to see what was replaced but couldn’t.

Although I can hold my own on mechanical issues I have never been very proficient at electrical issues (if they were very complex).

I have had the Clymer’s repair manual for any years and I’m sure there is an electrical trouble shooting section I just need to take time to check it out.

My thoughts are that it is the rectifier regulator but before I spring for $100 or so I need to do some checking.

I have a fencing project through the woods coming up and the Mule is just too big to go through some areas so I need to get the Quad back in service.

I have rebuilt the starter a couple of times over the years and will do that again and get a new battery for it.

I noticed that in another recent post a King Quad owner had a similar issue.

I welcome any thoughts.

Thanks again

FJ

[oxidized_black]

i have read on some suzuki forums that it is the regulator right down to turning the lights on ... and to have a fresh battery too. some suggested to clean the ignition switch also. i will look thru the service manual for troubleshooting and post it up if i find anything ...

[FastJimmy]

oxidized_black,

Thanks for seconding my assumption.

I actually dug out the Clymer's service manual and it does have a section on checking the voltage rectifier regulator.

One VOM check and another check if you have a special Suzuki tester.

It calls for a steady 5,000 RPM using a portable tach. I don't have one and at my age it's getting unwise to invest in more tools but I may have to spring for one. I have had need of one a few times in the last few years.

Thanks again

FJ

[FastJimmy]

I'm assuming that the starters and voltage rectifier regulators were common on all the 1995 Suzuki 250 / 300 (actually 280) models.

I contacted an ebay seller who had a starter rebuild kit listed for a 1995 King Quad 250.

When I inquired if he meant King Quad 300 he took offense, said his listing was 100% correct and doubted if I really knew what I had.

Perhaps scans of the 1995 Suzuki ATV brochure and my MSO will make him aware that Suzuki didn't know what they were selling either.

Anyway, I need to order a starter rebuild kit and possibly the voltage rectifier regulator and can't imagine that there is a difference on those two parts for the 250 / 300 models.

Thanks

FJ

[oxidized_black]

Correct on both, i checked the micro fiche @ bike bandit and same regulator/rectifier & starter on the king quad and 250 quad runners 2W and 4WD

[FastJimmy]

oxidized_black,

Thanks again for taking time to respond to my inquiries.

FJ