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  1. I have a 1989 quadrunner LT160. I am looking to replace the plastics. I can't find them for the 89 specifically but I do see plastics for a 91 - 01. Is there a difference in the 89 to the 91 - 01 plastics? From the photos, they appear to be the same with the exception of the holes for the front and rear racks. Please help clarify if you can. Thanks!
  2. I have been rebuilding some ATVs in my spare time and teaching myself along with the help from the internet how an engine works and getting bikes running again is quite enjoyable. I even built an arctic cat 300 4x4 from two parts bikes the had seized motors and missing parts. It was pretty enjoyable. So I am now working on a sazuki quadrunner 300 1992 which had a whole list of issues when I got it. I have fixed almost everything I need to in order to get this bike running. But something is going on inside the head or crankcase. I had to replace the timing chain because it was very stretched due to the previous owner. What the issue was, the timing chain was off the sprocket inside the engine due to it being stretched it slipped off. So the previous owner rebuilt the top end thinking it would fix it which it may have temporarily, but when doing so they welded an extra inch onto the tensioner to hold the chain tight. Which as you can imagine caused a dozen other issues. So that stretched the chain to the point where I could remove the cam with the tensioner in. It beat the sliders all to hell. Destroyed the cylinder housing and obviously ruined the tensioner. I didn't realise all of this until after I rebuilt the engine. I noticed wear where the timing chain runs through the cylinder. I found the cam had no retaining chair, or clip whatever you want to call it so the cam was beat to sh** also. It had almost an inch of play side to side. So I pulled the head off of my parts bike and fixed all of it. Then put it together and went to pull it over and found it was not on the sprocket (this is when I realised that all that damage and the welded tensioner was because the timing chain had been off the sprocket) So I pulled the stator cover off and pulled the flywheel (which I should add to get at the stator cover I have to remove the rear tire and a arm as well as remove the bolt through the front of the engine. And the exhaust system has to be removed to pull the cylinder as the exhaust guard is bolted to the side of the timing chain tensioner. Stupid setup. Glad the king quad doesn't have that. So I got everything apart and the flywheel off. New timing chain (nice and tight now) put the head back together and flywheel but it is quite hard to turn the engine over. I can but with difficulty. When the valve cover was off it seemed to spin much more freely. Before I tear everything back apart and start again any ideas on what it is?
  3. I recently purchased a 1998 Suzuki Quadrunner 160. It is very clean and in good condition for it's age. I am rebuilding the carburetor and looking to do some maintenance. I am going to change the oil, which is simple enough, but after reading the manual there are many adjustments that are needed when the oil is drained. Does anyone have any advice on the valve clearance or clutch adjustments? Both require the oil to be drained and the engine at top-dead-center. Anything else that I should do while it is in this configuration?
  4. ok so i have been searching for a 12 inch rim for my quad but with the lug pattern on the quad (4/140 mm) I haven't been able to find them so i decided to look at tires but with the size of the tires (25/12/10) and (22/8/10) they are a hard tire to find and when yo do find them they are either to cheap to be a decent tire or to expensive to afford does anyone have any suggestions or just tell me what you did for yours
  5. Does anyone know of a good place to get decent priced wheels?
  6. I’ve been working on my old 1988 Suzuki qaudrunner LT300E and I can’t find anywhere the specs for the valve clearance. Was hoping someone could help me as I don’t have the service manual, thanks.
  7. View File 1999-2002 Suzuki Quadrunner 250 Service Repair Manual A complete repair manual for 1999-2002 Suzuki Quadrunner 250 Service Repair Manual Submitter JohnR Submitted 05/12/2023 Category Suzuki ATV  
  8. 8 downloads

    A complete repair manual for 1999-2002 Suzuki Quadrunner 250 Service Repair Manual
  9. One 1998 Quadrunner 250 4x4, two 90's King Quad 300's worth of parts. Fenders are garbage..
  10. Looking for some tips and tricks for a 2006 yfm450 4x4 wolverine quad runner
  11. Hey, this is just an FYI post. After getting my quadrunner going again (voltage regulator issue in other posts), it ran well, but a couple of times I had trouble getting it started. I suspected the fuel petcock because I was shutting the fuel off when I wasn't using it, and I knew the filter/stems in the tank were looking rough last time I shone a flashlight into an empty tank. So I went on amazon.ca and bought the cheapest petcock I could find, like $13.99. But when it arrived, I realized it was different than the original. It had on/res/pri as the level selections, and along with fuel out, had a connection for (I discovered) vacuum in. Wheras the original petcock only had on/off/res and just fuel out. So I read up on it, sounded cool, the vacuum connection means that you just leave the lever set to on, and it automatically cuts fuel when the engine is off. So I found a splitter, and I split vacuum off my fuel pump to the new pet cock, and it seems to work well. I'm not sure if I've made a mistake here, but I like the idea of an automatic fuel shutoff, and if there's an issue, I can just set it to Pri, and it bypasses the vacuum shut off and just allows fuel to drain through the lower Res stem. Only thing was setting the lever to Res, I expected it to work the same as On, but fuel coming from the lower Res stem, but it doesn't seem to allow fuel at all, but not a big deal since Pri will serve that purpose.
  12. Hello everyone! Just joined up. As an introduction, I've had a Kawaski Bayou KLF300 2x4 since my Dad bought it new in '86 (nearly as old as I am), done a lot to keep it running through the years, especially with starter motor and carburetor work. I'm also working on a 1993 Suzuki QuadRunner 300 for a friend. Seems original carb was MIA so he bought one online, put a 120 main jet in and then asked if I could help - still running bad. So I'm here asking if anyone has the specs for idle screw turns, float height and valve adjustment specs. Looking to download the service manual soon from here when I'm able to. I've cleaned out the carb and reassembled it, it had some assembly errors, and so far got it to start and idle fairly well, bit unstable, and it drives good but tends to stumble when starting out with light throttle, and then when releasing the throttle sometimes it dies. Think I'm getting close to having it dialed in. Also have to look at the rear brakes, pedal goes through the floor and no braking at all. Everything else appears pretty good, even the speedometer works. Thanks in advance to everyone, cheers!~ Bellarmine
  13. Im looking for a frame for my 1999 Suzuki LTF 500, or a used 4 wheeler to buy to swap parts. Thank you
  14. I have a 86 LT quadrunner 230 GE I had a post about high idle i couldnt fix well it was the boot so now its fixed but im bogging out on full throtle I think it may be throtle cable as i had to make adjustments to it because it was getting high revs when turning handle bars but now may have to much slack though it seems like its going up and down good on carb . Do you guys think its a carb issue or a throtle cable ? Idles perfectly but I will say i did put a carb on i had in shop OEM for this quad but i honestly dont know how clean it is I do have a chineese carb thats brand new i dont know why i just didnt use it but thats neither here or there Thanks in advance its been a few weeks of hell with this quad and its so close to being a beast again
  15. Hello ! Does anyone know why when I start my quad the idle go very fast ? The only thing I did is change the fuel line and the fuel filter.
  16. New to the quads my neighbor just gave me an old Suzuki quadrunner 230. It has been sitting on his trailer in the back 40 for 7 years since it last ran so I figured it would be a good winter project. Not sure of the year I believe late 80’s I am sure I will have lots of questions but for now just searching the forums for info.
  17. 2000 Suzuki Quadrunner 500 In repairing what I thought was a front differential failure I've come to realize its time for new tires. I bought this thing new, when I was in 8th grade (via an agreement with my dad and being the groundskeeper at our church). By far, the most reliable machine I've ever owned. It's had a "bigfoot" kit since its first winter. It's time to replace the original 23 year old Highlifter Outlaw tires. I want something close in capability but a little smoother, easier to steer and less slippery on dry, hard trails. I don't seek out mud holes anymore but I will hit them if I find one. The current tires are 28x10.5-12 up front and 28x12.5-12 in the rear. I want to stay close to that size and I'm looking for opinions. I've got it narrowed down to: ITP Mega Mayhem 28x9-12 & 28x11-12 @ $724 Maxxis Zilla 28x10-12 & 28x12-12 @ $648 ITP Mud Lite XL 28x10-12 & 28x12-12 @ $702 SunF A050 Mud & Trail 28x10-12 & 28x12-12 @ $592 I like the look of the Mega Mayhem but they come in at 1" narrower all around. Do you guys feel like this different would be a big deal? Any experience with the SunF? The are almost identical in appearance to the Mud Lite. Looking for any help in narrowing this down. Thanks
  18. I've got an 88 suzuki quadrunner lt4wd 250 . I'm rebuilding the top end and can't find anywhere how to set the timing. Does anyone know where I can find this information or know how to set it ?
  19. Hello, Does anyone have a service manual for a 1986 Suzuki lt230s quadrunner? I have replaced the top end and cannot get it to run which i am having a major problem with timing.
  20. Are the rear axel nit's left handed threads I've been 3 weeks on n off trying to replace the tires on this thing do to bolts being rounded off that holds rim to spindle those 4 bolts i just need to know if the axel threads are bastard threaded thank you i bed to know
  21. Background on this Quad. Over the past year or so I have been teaching my 7 year old Niece to ride. She loves it, I even went as far as buying her a 2012 Arctic Cat 90cc and getting it up and running. We have a bond, her dad (my cousin) is a deadbeat junkie who abandoned her mother as soon as he found out she was pregnant, so my family has all been helping her over the years. I didn't have a dad or a father figure growing up. That hurts and I didn't want her to feel that way, so I have been taking her fishing, to ball games, aquarium etc etc and now it has progressed into riding four wheelers. So after stopping by the family farm and observing and seeing what I was doing and watch us ride one of our old retired farm hands approached me with something interesting. It seems a few years ago he was making his rounds around his old family farm and came across an abandoned four wheeler in the creek bed on his property. He called the Sheriff, they came and got it and took it. A few weeks later they bring it back to him. They ran the serial numbers, it has/had never been reported stolen. Since it was never reported stolen and it was on his property, as far as they were concerned it was his. He put it in his barn and its been there for 4/5 years now. It was mine if I wanted it. Naturally I jumped at it and picked it up.. Turns out it was a 1997 Suzuki Quad Runner 250 4x4. A bike exactly like the one I had as a teenager. I have decided I want to rebuild and restore it as much as possible to what it was rolling off the factory floor. Maybe I am a little bias but I think these were some of the best quads ever built. The four wheel drive transmission has always been cool as hell to me. Anyway this is going to be my rebuild thread on the bike. These photos are from the day I brought it home. The front half of the plastic is in great shape. The back, has been destroyed, I am looking for a replacement. Since the day I have brought it home I have ordered a replacement stock airbox system, a cover for the battery box and a rebuild kit for the carb.
  22. So I have a 86 Quadrunner LT 230GE machine runs great for its age so I know I have to clean my carb witch im prob going to just rebuild with a Shiny rebuild kit that ill do this week .But I started quad 2 days ago after not starting for about 10 days and it was running real bad it was pretty cold out about 45 degrees F so I did some carb adjustments to pilot screw and pilot needle ( air and fuel screw and idle screw ) and got it running pretty good ,I also put the winter summer knob to winter position per manual. So now quad keeps stalling when fuel petcock is in on position but when in reserve position works fine I topped off tank with True Fuel its all I use (no ethanol) so I guess the fuel filter in the tank is most likely clogged or the fuel petcock may be clogged or not working correctly. My question is do the fuel filters come right out of the tank i see in manual that they are right in tank off the rubber bushing do they pull right out or does the rubber busing grommet have to come out ?And do you think I can blow the line out with air witch im not sure ill do because the filters are very thin and may break or tear any one ever change these filters ?Any help would be greatly appreciated .Im also going to clean and possibly replace fuel valve as I ordered one on Partzilla. Can quad run on reserve? Beside picking up bottom of tank gunk can any harm come from running on reserve as im waiting for fuel cock to be delivered .Thanks again
  23. So I recently cleaned my carb on my 1986 Quadrunner 230GE and had to replace my fuel pump and now it seems im getting to much air and I can not use carb to adjust it I believe its coming in from either my air box or one of the air ducts or possibly the clear air container that is under front of quad that runs into the air filter bag but im not sure. Has anyone have any experience with this happening quad will idle super high and nothing can lower it except blocking off a air duct that leads to main air box i also have to check again for any cracks or leaks in air lines and box and ducts any advice will help im stumped ! What else can cause to much air coming in ? Could it be a leak from engine or top end ?
  24. Well, I seem to have picked up the Quadrunner bug. I bought a second one, a much older and physically smaller 230. 2WD, semi-auto, pull button reverse. The fellow got it to run, but certainly the carb is blocked up as it only ran on full choke. Controls are much different, and I'll have to look into the clutch/transmission as I can't seem to get it in neutral, though the previous owner was able to while loading??? I may be missing something. Does anybody know if the early Quadrunners were still "5 gears up" with neutral at the bottom? I should be able to knock it into neutral without the motor running, correct? Expect lots of questions, as this one needs a ton of work, lol.
  25. Hi everyone, this is my first post so bear with me. I recently purchased a late 80's suzuki quadrunner 250 4x4 (so i am told at least). The guy i bought it from was riding it when i showed up to look at it so i know it runs. He needed to use starting fluid and had to pull start it because the starter would just whirl when you hit the start button. He said he thinks the flywheel is bad. I dont think that is the issue. So i purchased it and took it home and was tinkering with it and i could get it started but only with starting fluid and the pull starter(which by the way is incredibly hard to pull) and when started it would run only while i kept throttling it. So i figure its a fuel problem. So i proceed to clean the petcock and give her new gas and clean the carb and spark plug. When taking off the petcock i noticed the rubber gasket was in bad condition and would need replaced. I decided to go to local autoparts store and get gas resistant gasket maker. when i get back to the quad my neighbor who was helping me(15 year old kid) had decided to take the repairs into his own hands and put it back together and get it started. That kid dogged me. Not on purpose but none the less screwed me pretty good. I didnt lose my temper and i just asked him what all he did. He said nothing just put it back together. Well kids dont always tell the truth. He kinda dropped a screw out of the carb and didnt tell me. He said he stripped the petcock screw and now couldnt remove it. He did drop the stripped screw earlier before i went to store and i found it on the skid plate. well he dropped another screw as well ive come to find out. So i tried to start it and couldnt get it to fire over at all and the starting fluid can seemed to have lost all its propellant magically when i was gone. i decide to take it back apart to where i had it before i left and see that the petcock is missing one of the filters now and that the port on it is blocked with this rusty pebble stuff. Drain out my new gas and take flashlight to the tank and see more of that crud in the bottom. i try to rinse it out but cannot do it. Then i try taking the tank off and cant. its seems i may have to remove the entire motor for that. i also see a spring and o ring on the skid plate when i remove it. very shiny spring and a clean o-ring. Notice the screw next to the idle screw is missing on the carb. checked the parts diagram and see its missing the air fuel adjustment screw. I also see why i couldnt remove the petcock screw as well. the nut that is recessed in the tank where it mounts at is pulled out a little and spins now when i try tightening it up. I could really use a manual guys. can anyone help me or give me advice on how to repair this machine? Any advice on how to operate it as well would be appreciated. I dont have any experience with this type of quad. Dont understand the decompression thingy and dont understand the starter just whirling.
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