Uglyside38

Hey! So, I got back on the project this week. I've started up a part time small engine repair gig and it's been keeping me busy! Anyhow, I got the ol girl running pretty good. I cleaned out the fuel tank and while doing so, realized that was 90% of my problem all along.🤦🏼‍♂️ Can't believe I overlooked that. Tank was FILTHY! Pretty much was mud at the bottom and once I got that flushed and added fresh gas, she fired right away. Now to buy some front tires and she'll be ready to have some fun and be put to work. Painting the racks and front bumper also. Will have them put back on next week. (Busy this weekend 🥵)

Well...the cdi seems to be doing ok. Need to do some carb work/tuning...and I need a new fuel petcock and clean out fuel tank. However... project will be on hold for a bit (couple weeks probably) due to some family emergencies and just a lot going on in life at the moment.🤙

Has anyone had any luck converting an older quad from a 7 wire CDI to the newer (and cheaper) 5 wire CDI? I have a 1988 Suzuki Quadrunner and I believe the CDI is on it's way out...🤦🏼‍♂️ A used CDI from 1988 goes for $250-$300 on the bay...and that's when you find them. The Chinese CDIs for the 1990 and up quadrunner are only about $40. I have read a blog from a guy who says it's possible and that 2 of the wires can be omitted if the rectifier is a newer one also. Any experience with this would be greatly appreciated!!!🤙

Got it all buttoned back up and everything is good in the case now. Sealed up and shifting from low to high🤙. However...still having to tap the cdi to get spark...and it will run as long as I leave it on, but after it's been shut off a few minutes, have to tap the cdi again...🤦🏼‍♂️. So, it's probably on its way out. So, we go back to the "7 wire cdi to 5 wire cdi" discussion... because I really have a hard time bringing myself to spend $250-$300 on a 1988 cdi off eBay... perhaps I can get with Ricks or something and see what they'd charge to build me one.🤷🏼‍♂️She runs great when it fires though!!!!

Just found out it's the hi/low shift mechanism that's causing the issues. It's in a bind somehow. Ran it through the gears to be sure everything was working properly but couldn't get it into high. 🤦🏼‍♂️ I'll pull it back apart this week and get it figured out 🤙. I did find a rogue washer when I picked it up off the blocks...🤦🏼‍♂️ Learning the hard way!!!😬🤣 I'll let ya know what I find

It's ALIIVVEEE!!!😀 Got everything back together and it still had the "intermittent" spark issue🤦🏼‍♂️. But, I tapped on the rectifier and the cdi and Bam... consistent spark. Went over all the connections and one from CDI had a bit of corrosion. So hopefully that was the issue. It sat for so long before I got it. Maybe just using it more often will keep her in better condition. Still gotta do some tuning on the carb (air/fuel and idle)...but she sounds great. One other issue...on the top right hand side of the stator cover, the corner closet to the rear on top of it, is not sealed properly at the gasket. Bolts are torqued properly but the gasket isn't tight at that point. Wondering if there was a reason that washer I put in wasn't there...not sure. But I'll look into that. If it says it needs the washer then it must need it...🤷🏼‍♂️ VID_20240129_184119537.mp4

Well, it's been a rough couple weeks here on the home front. After my last post, I was waiting on the stator cover gasket to arrive, and once it did I was looking over the manual to make sure everything was in it's correct place before closing her up, I realized I was missing a washer on the reverse shift linkage. I looked everywhere and couldn't find it, nor could I recall there ever being one in there. So, unsure if someone had been in it before, I ordered up a new washer. $1.81 part. $8 shipping...😬🤦🏼‍♂️ So, after about a week, it arrived and I was able to get the stator cover back on. Just need to add oil and put everything back together to do some more troubleshooting. However, my entire household tested positive for the flu!!!🤧🤒 So, been waiting it out. Been a rough several days here. Excited to get it put back together though. Hopefully this week I can feel well enough to get out to the shop.

Just a bit more info on these CDIs... In comparing the 2 CDIs, 1987-99 to1990+, I was trying to determine what the 2 extra wires coming from the stator assembly were for. I was assuming ground. After some research, it appears I may have been correct about one of the wires. And the other should be for the style of rectifier used prior to 1990. So, if I ground the one wire and use a 1990+rectifier, I could possibly use the 6 pin CDI... I'm jumping ahead of myself with this CDI as I'm not entirely sure yet if the one I have is even faulty...😜🤦🏼‍♂️. But, I do find all of this very interesting to note. Wish my stator gasket would hurry up and get here so I can test everything!!! Working on exhaust tonight. Prepping for paint. I had to cut it off, so I'll get it welded back up when I re-fit it.🤙

Mine does have a ground...I suppose the 6 wire one could ground itself?🤔🤔

This is why I need y'all's help!!!!😜 Lol. Do you know of a way at all to use a 6 wire cdi then?

So, obtained a manual. Stator assembly ohms out in spec. Stator cover gasket ordered. So when I get that I'll put it all back together and see what we've got. Fixed ignition coil wire so hopefully that gets us somewhere. At least I know the stator is good so I can start diagnosing from there up. 🤙 Looked into CDI box just in case. Mine has 7 wires coming out of cdi. Most aftermarket ones are 6 wires, but I think I can wire the kill switch to the coil and it should be able to shut it off?🤔 That's how my mind is working anyways...lol. OEM cdi is about $300. So hopefully it's not that, but I'm worried if the rectifier is bad, it may have fried the cdi...🤷🏼‍♂️🤦🏼‍♂️ We shall see!

Here you can see the back plastics...😬 Pic from back in September when we played in the mud a bit when it was running. Pretty rough condition lol 😆. I have some tin formed and riveted underneath the broken parts to just maintain the shape for the time being. Aftermarket plastics will be on the agenda down the road. Although, used ones do come up from time to time on the Bay...🤷🏼‍♂️ Also, I keep an eye out on marketplace for a used quad. Have seen a few on there I'd like to pick up for parts.

I believe the starter I purchased a few months ago was a Niche starter... seems to be holding up ok so far!

Front really not too bad...back is terrible 🤦🏼‍♂️. I'll get a pic of it tomorrow

The frame really is in good shape considering it's age. Surface rust on front bumper assembly, both racks, and the hitch. But I'll address those once I get it running again. I did the torch trick for the plastics... since they were so chalky white and flaking. Here's a pic of while I was doing that awhile back. I was pretty impressed!

They definitely don't make them like they used to! I figure I'll be about $1k deep if I go all the way with this thing... aftermarket plastics are probably the most expensive part of the entire build...🤦🏼‍♂️ Plastics on this thing are pretty rough 😬 I have them patched together at the moment

There are definitely a few wires throughout that have been chewed on...one at the rectifier, a couple at the pulse coil/stator and a few more minor ones that I'll address while I've got it all opened up. I'm learning a lot about these things. I'm a "get in there and just do it" type of learner...lol. But it definitely helps to have all this advice! Here's some pics of the current state of it and some of the wiring issues. Might just get some of these open insulation areas taped/sealed off and see what I've got. The pulse coil and stator tests out ok...so I think if I get them sealed up I may be ok there until I can get a new one.

Anyone have experience using Meier aftermarket plastics? OEM ones are shot on my quad I'm restoring and I have them "Frankenstein'd" for now...🤦🏼‍♂️😬 Just curious on opinions on Meier as that seems to be the only place I can find any type of replacements. (And they're pretty pricey!)

I know this post is a couple months old, but have you had good luck with these carbs? I had bought a cheap one on Amazon awhile back for a mower, and it seemed ok for the short time I had it...🤷🏼‍♂️

Lol. Even if I didn't do anything else to this quad, the few times my son was on it when we had it running was definitely worth $20! Smiling ear to ear the whole time. But, since I'm this deep into it, I'm gonna take it all the way and get it somewhat restored 🤙

Thanks Mech, I will get a hold of manual. Working on my requirements on here...lol. Last night I did find that the black wire coming to the ignition coil only has about 50% of the strands connected.🤦🏼‍♂️ So, that could very well be the problem. Once I get ahold of the manual I will look into all the testing procedures.

I have a 1988 Quadrunner 250 2wd. My brother in law sold it to my son for $20...had been sitting outside for several years. Got it home and had it running in about 30 mins. Ran it a bit and then went to looking at the carb as it was having trouble idling. Was getting it pretty close, then started losing spark...Also, it wouldn't start up every time...only about 1 in 5 tries. Anyway...now, it has what I can only describe as "intermittent" spark. I can get 1 light spark right when the start button is pressed and sometimes one when it's released...but none while cranking. 🤷‍♂️ I have replaced the spark plug, ignition coil/wire, and traced wires best I can. I noticed a couple frayed wires at the pickup coil where it enters the case. So, now I have the cover off, stator and pickup coil out and trying to test the coil. I do have about 114 ohms resistance for pickup best I can tell. And I can read minute voltage when I drag a magnet across it. Could it still be bad? Can a bad ignition switch/button cause this? (I did have the switch off to oil the choke cable)...pulling rope makes no difference though...any ideas or help would be greatly appreciated!!! It's the intermittent part that's throwing me off!