[TUBBYTUBB]

That is the correct oil that AJ recommended according to the manufacturer. The plug is correct also. As far as the rectifier goes there is the easy way or the hard way, The easy way is to pop/break the little vents on the right side of the quad when you are sitting on it that is right below the handlebars on the front right above the battery compartment. You can see what I am talking about right below the hoop bar in this picture:

Or the hard way is to take the front plastics off to get to it, once you gain access to it you will need either a 10mm socket or a big Phillips head screwdriver to take the screws out and then replace the rectifier and reverse the procedure.



THOMAS

 

[TUBBYTUBB]

To check if your timing chain is stretched and to make sure that the chain has the proper tension on it, you will need to locate the timing adjuster on the rear left side of the cylinder. Once you locate this you will see 3 bolts, one in the middle and 2 on the outside edge. If yours is stock the middle bolt will be an Allen head bolt not the standard hex type in the picture below. Once you have the middle bolt out, this will remove pressure from the spring that gives it the self adjusting feature of it, then you will remove the outer 2 bolts and gently lift it out of the cylinder so you can inspect it to see if there is still any adjustment left to keep the chain tight. I also want to add that when you go to reinstall this you will need to put a drop of some kind of Loc-Tite on the threads to keep it from loosening up, that is why I don't have the stock Allen head bolt in the middle any longer mine loosened and flew out going down the road.

THOMAS

 

[timmyd]

Well, I replaced the solenoid and it seems to have solved the problem. What a major pain to replace something so simple. Thank your for your assistance. Now on to the torn CV boot.

 

[TUBBYTUBB]

Cool Deal, at least you were able to get it replaced and it solved your problem. They design everything these days to make it hard so the average Joe doesn't want to work on it so that the factory mechanics will get the business.



THOMAS

 

[ajl719]

Nice write up Thomas, very informative..!!

 

[TUBBYTUBB]

Thank you Sir, I tried.





THOMAS

 

[critter3466]

I am also new to this forum and i have the same problem... i have a 1991 quadrunner 250 and well i took out the whole engine and wiring in order to put it on a gokart frame, i know it sparks because i used a battery charger on the starter to turn it over and there is gas going into the carb... any ideas that can help me out?? thanks

 

[Masshole]

Another thing I wanted to add if you are getting clicking sounds when you are hitting the starter button, there are a couple of things that can cause this as well. First thing is low battery voltage if it is low then you should charge it properly and then retry and see if it will crank. If you still get a clicking sound after the battery is charged then you will need to inspect and clean all of your connections, this includes at the battery, the solenoid, and at the starter itself. After you clean all of the connectors with a wire brush you can keep it from corroding again a couple of ways, the first way is to use die-lectric grease or if you have some spray paint laying around you can spray it enough to cover the entire connector, BUT only do one of these last 2 steps if you have verified that it will crank and are no longer having problems. After you have done these steps and you are still getting the clicking sounds odds are that you will need a new solenoid (First place I would start considering this is cheaper than a starter) you can normally pick one up at an auto parts store for around ten bucks, if you replace the solenoid and still have the clicking then you will more than likely need a starter. Good luck and if you think I should add anything to this let me know.

THOMAS

I've got a lack of starting issue on a 00' Quadrunner 500 w/ 400 miles on it. When i attempt to start it, i get a loud "Buzzing" sound from the solenoid. It started 1 day, the next this! Wires are good, starter bench tested good, even bought a new solenoid, fuses all good, No corrosion anywhere!!... Still the S.O.S. (I would use the pull start, but there's another issue there!) Any idea what I can check next??

 

[farmersteve]

I have a 98 king quad, followed this thread in a troubleshooting effort. The green neutral light does not come on. when i slide the neutral/reverse from rev. to neutral, the green light blinks but does not stay on, i have been successful in starting this way once or twice (a thumb on the start, hand on the shifter and an elbow on the gas, my kids were laughing at me until she turned over). i have taken the back rack and plastic off, so that i can see where the wires go into the transmission in 2 different places. i haven't gone any further, please help if you have heard of it. i can post later.

 

[farmersteve]

I have the wheeler still apart next to my shop, went out to the shop last night, one of my kids turned the key on and guess what, yep the green light came on, what gives, please help, before i put this thing back together.

 

[zukifreak]

Sounds like the neutral safty switch is going bad,its on the left side of the engine and you will need to remove the exhaust heat shield to get access to it.

 

[glennboy66]

Suzuki eiger 4x4 400 starter not engaging how to fix. also can you buy new plastics for this bike aftermarket at reasionable price? I have spare starter motor off drz 400 I was told this is the same starter is this true?

 

[zukifreak]

I answered in your other thread.

 

[higganator]

This machine is known to have exhaust valve problems! The exhaust valve should be set to .010in, If they are to tight it will cause hard starting, worse when machine is hot.

 

[plumber]

This is just what I was looking for! Ive got a 1994 king quad 300 and I started running bad this spring, The spark was all over the place and I had some coroded wires under the speedo, fixed the wires, didnt help much replaced the cdi now ive got spark, fuel, valves checked by qualified guy and wont even pop with starter fluid, Im thinking the timing must have been thrown off with all the coughing and back fires. What do you think? thanks!

 

[higganator]

I have fixed thoes before! Exhaust valves may be to tight they should be set on .010. those things get hotter than most and need the extra clearence. Also I use briggs& stratton vaccume fuel pumps to by pass the petcock, just set it to prime so the gas flowes all the time to the briggs pump. It will only pump when the engine is turning just like the factory one. This is a $20.00 item at the lawnmower shop.

 

[higganator]

The timming! Turn the engine to TDC and line up the mark on the fly wheel. The cam lobes should be faceing down and the marks lined up on the head surface. Be carefull when reinstalling the timming tensioner not to jump a tooth.

 

[CARL]

Useful.
Thanks

 

[shawn]

Hey im new to the site and have been reading some of the issues and most sound like thay have been fixed so heres mine...... I have a suzuki king quad 300 the year 97 it dose start and idle great but if its warm outside it dose not run for long and quits and has no spark untill it cools off. Now about a month ago when the weather cooled off it will run all day with no problems now I was thinking today maybe the oil cooled rad could be plugged or the lines will this cause this to happen I am gonna do an oil change this weekend gonna put royal purple 10w30 in it. But if this is the problem then ill take it all off and clean it g9od. For new parts it has new starter solinoid voltage reg starter and new fuses and it did this before the new stuff was put on the bike.... hope to hear back on this problem asap thanx shawn

 

[mla2ofus]

You need to have a known good spark plug w/ you when it quits. Attach the good plug to the plug wire, ground it on the head and see if it still has spark. If not then I'd point a finger at the coil.
HTH,
Mike