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First off, I have spent a week browsing your Forum, but now I must join and find answers, please assist.

Soon to be retired US Marine, I live in the woods of Maine, I purchased a used ATV, listed above. I have a Clymers Manual. ( uuhh not real easy to read with out my crayons and Pop-up pictures).

When Purchased, I knew it needed work. This is a father son project ( he is 13), in parts, in the basement..

no brakes, electrical wire dis-allowed the electric starter to work, ( fixed easily) choke frozen, rear bearings shot, close to impossible to start, stop light brake switch electric broken, speedo cable broken.

Description of work done:

1- new rear bearings-purchased "boss bearings"

2-new choke cable and assembly - was stuck in the carb, and cable was frozen

3-new rear bushings on suspension arms- were frozen/seized during the bearings removal

4-new front, rear breaks,- drums being turned this week at local machine shop

5-brake master cylinder-top screw being tapped out- .. was stripped and broken

6-miscilaniouse OEM parts and bolts ordered from Partzilla and Rockymoutnain parts- so far good fits: bushings, bushing bolts, air filter assembly, choke assemble, wheel brake cylinder: springs/gaskets bolts, master cylinder rebuild kit.

to be fixed- ANY AND ALL Advice to all next steps:

1-Wheel Brake Cylinders to be rebuilt- cylinders in local machine shop being "honed"

A- hints and suggestions ? I have new gaskets, bolts, rubber, and springs. OEM

2- I need a New Muffler Exhaust: Hard to find?? any ideas?

3- Speedo Cable assemby on order

4. MOST IMPORTANT QUESTION AND HELP: Carburator engine NOT starting:

below is what I know to be true:

a. reassembled carefully back in place after choke assembly was replaced

b. checked ALL Fuel lines, steady streams !

c. Starter switch works-

d. spark plug is not fouled, blue spark, damp.

e. electric is working

f. tried eather / quick start - NO catching of spark to make engine go "vroom"

g. no visible oil or fuel leaks on engine head or crank case

h. when inspecting air intake at filter, it appears the carb is shooting air back into the filter, NOT into the carb..?? this normal??

Well, I hope this didnt bore you, and you can provide some insight on all or any items? Help this Marine out please?

Frankfort, Maine..USA

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I did a similar job on a 93 a few years back. Detailed here: Suzuki King Quad project - Forums - 907Outdoors

Sounds like the rig was pretty beat up. Do a valve adjustment first per the routine mx section in your manual. Next rebuild the carb and make sure its getting fuel. That its back filling into the carb could mean the timing chain has jumped. To check you have to remove the head cover.

i get most of my parts off used from Ebay. Mufflers are hard to find cheap. Try local salvage yards.

Good rig for a kid to learn on. All the mechanical controls and poor breaking system teaches them to operate the machine rather than just hanging on.

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WOW !! I just glanced at your blog- many thanx for the post! Can you send me a list of special tools I might need to do that? I.e "left handed tent pole" etc etc .. I have basic tools, meteric, ratchets , pliers, but do that..I feel it is coming.. what tools are recommend for easier life..? again..many many thanx! stay warm and stay riding!

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The tools you have are fine. If you get into deeper work like CV joints and crank case separation, the manual will tell you. RTFM right. Or ask me. I might have a work around. Ive been to the bottom of 2 of these.

My blog details the valve adjustment. I think I posted something else there about timing chain. Join that site. Hunting and fishing stuff you might be interested in.

And semper fi. Thank you for your service.

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WOW ! I just read your blog! extremely motivated and gonna hit this up! I am disabled/ lots of titanium in my body ( WIA 13 Nov 2009) ) soo, i try to keep myself occupied, and want this done before Fathers day, when I get my 2 boys for the summer..

I have it in my basement ready to go!! Your blogs were awesome, inspired me to continue to march! I have this feeling timing chain, and valve is next. I will order carb kit, and gasket kit.

and yes, not a lot of room in there! I have the same issue with my struts and wheel cylinder, hopefully fixed by next week! I think I will create a blog post for a re-build of my ATV! very inspiring !

I dont sleep much, So i have read the manual 2X over, and re-read it while watching your blog.! i will order a paper book one. I think it will be necessary.

1- Question : RTV- can I use that instead of gaskets ? or do I need Gaskets? is this a good substitute?

i will be diving into my valves adjustment and chain - what is good to get on order?

Semper Ride!

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Good to hear and glad it helps. Yes, hi-temp RTV is used on the head cover. No gasket here. Do the valves first then give it a crank. Might be all you need.

The wheeler I blogged about is AFU now. My kids sunk it a couple times and sucked mud into it. Rings are shot. Timing chain stretched, clanking noise in rear gear box, and so on. Im tearing into it now to assess damage. Might part it out.


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yeah! on a stand and ready for work- like a 5yr old building a latter to get to the cookies..but safer..

attached photo has what i call extra wires, I found under the odometer housing..I cant figure out what they are for?? any ideas? There is no other wires they "mate" too, I checked the manual, and the diagrams..Am I missing something important? Help?

clean space.jpg

parts board.jpg

extra wires.jpg

left front wheel.jpg





Edited by Whiskey_Bravo
spell check

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1820- sitting by the wood stove, waiting for my bud to bring over chicken wings, beer, for the Bruins Game-

after actions- ( maybe I did this wrong, but it seamed so right)

When I built my lift- I put left over polly down from dry walling, a "catch All"..good idea it was..

current enemy situation:

Air box assembly is off - , all skid plates removed ( broke some bolts, I am thinking of using U bolts to replace hold on to frame), Tool box assembly is off, brakes are off ( waiting for drums, cylinders etc).

I Noticed it had aluminum armor?..I have been blasting it with 409 degreaser and simple green.., muffler heat plate is out too, need to "heat" paint it?? maybe?

My past Defensive Atck Plan:

I for the first time ever, had to fill a battery with acid ( new out of box) and set on charger- over nighter- power test looked good..smile..a little acid on my basement floor..enemy tried to probe the wires..

So, after coffee with the old man,( fire support) I went to Belfast to Auto-zone- ( looks like we are gonna be good buds),

Past Ops:

1-bought the wrong torque wrench !! ahhhh WTF : it says Metric - but was in MM..model number: 79-141

very complicated- will return for a normal one I can read- Any recommendations? yes I am a rookie

2- picked up Feeler gauge valve- got the right one.

3-So While I was using my #17MM wrench, doing my valve inspection, top valve inspection hole wont budge!! Zap with PB Blaster..will wait until tomorrow, don't want to strip it.

So I put everything all back- Valve inspection stopped- Called my buddy- he said-----try the knew battery..

hmmmm....Fuck it..at least I will see the light work..wait..those are taken off..

Ok, remember the new battery??

wait for it...new battery-a little choke- fire ! VROOM VROOM !! it runs !!, exhaust was exhausting, carb was carbing...why is it working? Karma-birthday?..luck..??

Do I continue the valve inspection?? do I dare upset the ATV Gods??

Do I go for a Carb Rebuild? Will this upset the ATV universe?

Lost... Lost...

but I will continue to fire, and continue to re-load with the manual. HP Inks - should have packed more.

Current Ops:

1-today- received mail from cycle express: wheel brake cylinder gaskets, and their respective bolts.

2. ATV fired up..good bad?..not sure..is this a diversion atck from the enemy-

Future Ops

1- Friday- pick up from local machine shop: my machined drums ( 3) , master cylinder ( top screws broken off in) , wheel brake cylinders being honed,

2- Waiting on : Speedo cable- ebay- 30 October

3- waiting on new front brake cylinder springs-

4- Need to order:

Wheel brake cylinder rebuild kits, master cylinder rebuild kit, a shit ton of those #4 suzuki bolts...,

5- saving my big trip this weekend to Bangor- Big City - for Tap /Die Set, torque wrench,

6. Do I dare order a Carb Rebuild kit?

Bruins on in a few..


and the enemy Blue Falcon in the basement..waiting..planning its next attck

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While the enemy was sleeping, I went door to door, doing some Intel and target work ups.Looks like winning the hearts and minds of the local populaces, helped build me a back ground on the Blue Falcon organization . A little more is known on my enemy, took some serious research and high level HUMIT.

But, this is what I cam up with in a VIN identification, wasn't easy, no one particular WWW had all the right info. If Any one has something to Add to this, please by all means..help out.

VIN : JSAAK42A7P2107227










10. P 1993

11. 2 LOCATION OF PLANT – I have no idea where it was born- But must be Japan







Armed with a little more knowledge, I will spend a day, planning and rehearsing my next attck..


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Enemy situation update:


Defense- enemy has provided a serious defense on stuck frozen bolts!

--solution: Trip to Big City for bolt extractor TAP / Die Set

Reinforcements – Again, Blue Falcon chose to not release its upper valve bolt

--counter action- larger , longer wrench 17mm – with rounded edge resistant assistance

Attack- The enemy has chosen to attack me with rust-

--Spent the day repelling the attack with wire spin brush attachment on drill

Withdrawing - so far, he has no sign if withdrawing his strong defensive posture

--solution: bring in bigger guns

Delay- Blue Falcon has a strong delay attack plan

--solution- I can wait- ice fishing doesn't start until Jan 1...

Entrenchment- Old Blue has dug himself into the sq footage of my basement floor

--solution: continuous attack, attack attack, dont lose sight of the goal-

Past Operations:

1- wire brush on rust

2- rustolium rust stopper on a few parts after rust was removed-

3-internet and manual research- parts, tools, and carb

Future Operations planning

1- big box store in big city – torque wrench?

2- TAP/DIE Set

3- Order : Brake rebuild cylinder parts, order carb rebuild kit

4- remove upper valve nut! - Bastard

5- pick up repaired / machined drums and master brake cylinder, wheel brake cylinders Thursday / Friday..cross fingers

Request for information:

1-Where is a good place to order the Carb rebuild kit? What do I know is a good one? I have seen a few for 20$- is that normal

2- Read the Manual- ' if drums are turned “re arch the brakes” WTF ??? huh?? I just bought new brakes front and rear? re- arch them??? huh? .. I cant make that up.. Do I re-arch them?

3- decided to paint Blue Falcon – Hunter Blaze Orange..

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1648- end of day-

its been a long battle today- Blue Falcon and I have both had our lines pushed back and forth- like WW1 trench warfare.

So- As promised lessons learn so far= Keep in mind I am a rookie, but I hope common sense and "murphy" are on my side.

Fail to plan then you will plan to fail-

1- Tools: the right tools- the manual actually tells you what tools you will need before you start the job

CirClip pliers ( master cylinder )/metric anti-stripping ratchet heads/breaker bar/RVT/kitty litter/poly-tarp/pine-sol/red shop towels/DOT 4 / coffee tobacco (lots)/magnet/mirror/small pick/metal punches

2-ATV lift / pully - built mine out of scrap hemlock, but I put it in the wrong spot-wont move it again

3-MAchine Shop- know your local machine shop / they work wonders! and have great advice

4- print off the pages you need, read, re-read, read again the manual- rehearse it in your mind and even work backwards before doing it

5-youtube-blogs- there is some really good advice out there, also some bad-ask then re-ask others confirm

6-right down the tool your looking for, be exact, when you go to a parts store: they have 6 million tools that do almost the same thing your looking for..you will get confused easily! use your smart phone to picture or txt your self what your looking for. it helps.

7- pictures-take lots of pictures, before, during, and after- you cant remember every thing..i am learning this the hard way- took pictures of my carb tear down- i hope it helps

8-organize your new parts, and the parts you take off, a pile of mixed used bolts and screws, gets confusing after a few hours, let alone a few days..i have a mess on my hands...egg cartons, baggies,plastic containers

9-pre-order if possible, some parts take longer to mail than others-expect wait time- rebuild or knew- shop around-ebay?

10- you will be nervous, its normal-attack it slow and smooth..stop take a pict-continue

11-its an old machine, ATV, it has been through the elements, expect rusted parts and bolts to break

12- at the end of the day- clean up your work area- put tools away- you will start to learn what tools you primary use- this will help identify quickly bolt sizes

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Bruins are on..pray for a win..we need it..gonna upload a few picts or atleast tryblue falcon naked.jpg






Plastic is off, did some work earlier on plastic molding repairs..

my home made hemlock lift..sturdy as hell, but i should have put it in different spot- used pullies and floor jacks and blocking to get it there..

just about to remove the dirty carb, notice the frozen idle spring

right now, it is soaking in pine sol, looked at it after 2 hours, looks nothing like this, almost new.

, although i ordered a carb build kit, gonna see how this plays out..

it is about to be soaked..in pin sol for 48 hours

Now, I used my head, I plummed, wired, and dry walled my house, So I used my PEX Expansion Pro tool and 1/2 inch tubing to make a few funnels..and it isnt gonna come off..just saying

organized at the end of day..cleaning it up, allows me to think..


on over watch at ths time..attack!






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