Mudflap64

I'm looking for some advice on re-building my front axles on a 2002 Suzuki Quadrunner (ltf500f) My left front outer joint sounds like a popcorn machine when I make a sharp turn. I looked on Ronnies and they want $429 each for a complete shaft so that is out of the question! Has anyone here fixed their shafts on an "as needed" basis? I generally use the quad to plow snow and for yard clean-up in good weather. I just recently put a set of ITP Mudlite XTR's on for plowing, so I'm sure they "helped" the shaft fail due to the extra stress from the added traction. I'd like to hear your story about re-building your axles. Thanks.

Just got a set of Mudlite XTR's for my 02 Suzuki Quadrunner. Stock size 25's . Any suggestions to keep the rims from leaking when I mount them? Tips or tricks to mounting on a tabletop tire machine. I've changed thousands of car tires but never done ATV tires on a tabletop machine. Should I look out for anything specific with the radials? Any help or suggestions would be appreciated. I really hope these tires make a difference on my quad. Share your experience with these tires if you have time. Thanks.

The tires on my 2002 Quadrunner 500 are getting worn enough that I'd like to replace them or find a set of rims so I have "summer" and "winter" tires. Does anyone have any suggestions for good plowing tires? My driveway is gravel and I live in the snowbelt of northeast Ohio. Would a nice mud tire be fine or is that too much? Thanks for any suggestions. If you have a spare set of rims...let me know. I like the idea of swapping wheels and not messing with changing tires every season. I didn't look for a classified section here yet......oops.

I'm no expert, but I have some background in automotive. I'd suggest leaving the cap off of the master and opening the bleeder. That will allow the air to "burp" it's way UP........a quick cycle of the brake handle may help it if it's doing nothing. It should self bleed with the bleeder open and a constant supply of fluid. I may be totallly wrong, but the fluid dynamics still apply. I've seen some situations when the caliper has to be bled while it's above the master resevoir, but that was on a snowmobile.

I just put an RT-15 on mine and it was a pretty simple job. Once I got the plate mounted the winch fit just fine. The only Issue I had was finding a proper place for the controller box. On my machine the best place was under the gas tank to keep it as dry as possible. The switch wiring on mine was a bit short but I'm sure that varies by model. The best suggestion I can give if you are plowing is to mount the switch sideways so that the "out" faces forward and the "in" faces backwards. That way it's like a normal plow control to raise and lower your plow.

I'm happy to hear that suggestion!!! I was thinking that it's a guide rod problem as well. I know this machine spent most of its life in a low speed high load environment. Alot of the time it was in Low range as well. Knowing how mechanically un-inclined the previous owner is, it makes sense. He's one to shift up and down for no real reason other than for more torque @ the wheels. ( I let him borrow it to get his pigs to slaughter and he said it shifted GREAT for him, then he proceded to spiderweb the hell out of my winch cable! ) If I'm plowing I HAVE to get it to second gear before I make the long run down the driveway or it will NOT shift to second by foot. If I reach down and grab it with my hand it will go but it takes effort. It also has problems downshifting from second to first. Other than the 1-2/2-1 it shifts just fine. I really think the rattle noise was old fluid, maybe some shaft endplay somewhere. It is quiet now ( I understand it's cold and the fuids are alot thicker) I guess I'll wait till spring breaks and I get it tore apart. Hopefully it's something I can just weld up and re-grind the guide rods. (or replace with a nitride coated rod) depending on the diameter. My other thought was the shift control cam may be worn or have a burr that is making it difficult to get past. Either way it's coming apart and will be 100% before it plows next year. It might just be some dremel work on the cam and shift forks. [ame=http://www.youtube.com/watch?v=I9o4rQ2w0CI]YouTube - Quad LED Strobes[/ame]

UPDATE.......I did all the lube service and cleaned her up quite a bit. I need to check the front bearings in spring but that can wait. It's still picky getting to second gear but not nearly as bad as it was. I'm preparing to pull it apart this spring and go through the transmission while I have it apart. It runs good and seems reliable enough so I put a Warn Rt15 winch and a Moose 55" plow on it and let me just say........This thing can push some snow!!!! I had over 49" of static snow on my back deck with last months storm. I had HUGE piles from my old plow driver not pushing it where I wanted and was able to clean the driveway very nicely and push the meduim pile back to make room.....all with this quad!!! I'M AMAZED!!!

Well thank you. I did end up with a nice plow for the new toy. I got a Moose 55" plow and a Warn #1500 winch to lift it. With the the push tube, plow, plow mount, winch, and winch plate was just under $800.......I guess I could've done it a little cheaper but right now it is WELL worth the $$$$. This thing can move some snow!!!!!

Thanks Josh, I'll keep this post updated. I hauled some stuff back to the barn with the trailer and it seems to be getting better as I use it. (lightly) The front diff makes some noise in 4WD and the rear diff fluid looks like mud. I'm going to do a full fluid service and adjustments per the owners manual. Trying to find a good service manual for an 02 is harder than I thought it would be.(without spending a fortune) Clymers only lists 1998-2000. I'm just going to keep things simple right now, at least till after the holdays. This may just be a case of ridden hard and put away wet. I'm not buying a plow until it rides better.

If I don't have to split it.......then by all means I will check it out. I don't want to tear it all apart and have it dead all winter. I also don't want to run it with a plow and bust a case! I messed with it a bit today and it shifts really easy when it's in low range. I'm suspecting it may have something to do with the HI-LOW area of the transmission. I need to wait to get the manual to see how it relates to the internals. Shift fork sounds right but i guess i'm reluctant because of the cold. It's my luck. It does seem to be fine in low range......just no full speed runs down the driveway.

I'm not surprised, I'd rather not tear it down till spring. I was hoping to get a "quick fix" or "baby it" suggestion. I'm looking for a full service manual now and noticed that it does rattle quite a bit in third gear. Having just bought it I was NOT planning on getting so friendly with it so soon. My instincts say it needs to be looked into as well. SIGH..........

Ok, I'm new to this forum and the 4 wheeler world. I have a 2002 LTF500F 4X4. The problem is this thing is VERY difficult to get it to shift from 1st to 2nd gear. It seems hard to downshift sometimes but it's usually during upshift. Upshifting past 2nd seems to be ok. How can I help this issue or is it going to turn into a teardown issue? Is this common? Could using a lighter weight oil help? Any guidance is appreciated.

AJMboy, No I have not decided on a plow set-up yet. I'm open for suggestions. I'm thinking a plow that is tiltable would be better for my long driveway. I've been looking at some of the set-ups out there but I'm just not sure what will be best.

Just stopping in to introduce myself and my machine. I'm Kevin and am a first time quad owner. I've been riding snowmobiles for many years and am quite familiar with off road equipment and tractors. I am a Machinist/Toolmaker. My new quad is a 2002 Suzuki LT-F500F Quadrunner 4x4 with 950 miles. I bought it from my girlfriends brother because he blew the tranny in his truck and needed the cash! We just moved into a house this past summer with a 450 ft long driveway so I figured I'd help him out with some $$$ and maybe put a plow on the quad for our driveway , so I have the new quad. It needed a battery right from the start and some TLC just to make it look more like a usefull machine. It runs good but does have some problems I will be asking about once I get to know it, and once I get to know this forum. I welcome any insight as to what I might look for on this machine. ( Common problems, fixes, etc. ) Thanks for looking :seeyac: