Got a new toy, and its orange.... [ATV restore project] [Archive]

poser

10-24-2009, 02:59 PM

....but its of the devil :twisted:

EDIT: I guess I should fix the title since this is a proper project thread and all.

Oh and so you don't have to read too far down, I picked up a '98 Suzuki Quadrunner 500 for cheap and I'm having fun "restoring" it.

EDIT 3/6: Project complete! Its not orange anymore, and I'd say it looks good. It runs great and is a blast to ride. It is a beast though.
See post #74 for pics of finished product.

M38A1

10-24-2009, 03:37 PM

No pics - never happened.

You know the rulz...... :deal:

.

poser

10-24-2009, 05:35 PM

I'll get some teaser pics up soon

poser

10-24-2009, 05:55 PM

about to take the wife out to dinner, I'll get some more pics tomorrow, but for now...

http://i25.photobucket.com/albums/c52/jlbohac/S5030050.jpg

Rman of 237

10-24-2009, 08:12 PM

about to take the wife out to dinner, I'll get some more pics tomorrow, but for now...

http://i25.photobucket.com/albums/c52/jlbohac/S5030050.jpgMmmmHmmmm.:ponder: Shouldn't this be in the "Prayer Request" forum?

Loyd

10-24-2009, 10:28 PM

"man gets awesome new devilish toy...wife gets dinner" Story @10. :mrgreen::-P

greengoose

10-24-2009, 10:39 PM

Kubota

jar675

10-25-2009, 07:21 AM

Very ugly from that picture!

JTM

10-25-2009, 09:02 AM

Very ugly from that picture!

Careful you may have to help him work on it now.

poser

10-25-2009, 09:14 AM

Very ugly from that picture!

I told you it was ugly, but ATVs aren't suposed to be pretty

Careful you may have to help him work on it now.

not as much as you'd think, it fired up yesterday :thumb:

JTM

10-25-2009, 09:20 AM

So it was just the carb, like you mentioned it might be?

poser

10-25-2009, 09:23 AM

Dunno yet, all I did was hook jumnper cables to it, to get juice to the battery, and for kick and giggles tried to start it. After just a bit it fired and died. The it started and stayed running. I drove it about 5 feet and turned it off, the oil in it is BLACK, and there's WAY too much. The sight window [or whatever you call it] is completely full.
I'm going to put fresh fluids in it and a spark plug before I ride it.
So far I know its going to need a vavle adjustment as they were pretty loud.

M38A1

10-25-2009, 09:59 AM

So WHAT is it?

....still waiting..... :ponder:

.

1TallTXn

10-25-2009, 02:55 PM

Kubota
+1

poser

10-25-2009, 03:58 PM

Not a Kubota.
Its a '98 Suzuki Quadrunner 500 4x4. I bought it cheap, under the impression that it didn't run and needed work. I'm always up for a challenge and have been wanting a cheap project ATV for about a month or so now.
Its missing a few parts for the 4wd to work, but the motor is good. It'll need some paint on metal parts, there's not much I can do about the plastics.
The carb probably needs a tune up, and so does the motor. I'll probably put a few hundred dollars into it, but should make a decent profit on it.
My intention is to flip it, after all part of the fun is getting it running and in good shape like I did the XR400.

http://i25.photobucket.com/albums/c52/jlbohac/S5030052.jpg

http://i25.photobucket.com/albums/c52/jlbohac/S5030051.jpg

I may post some pics of the fix up, or just when I'm done. Like I said I plan to flip it eventually, but I'll have some fun with it first :trust:

RedPill

10-25-2009, 07:34 PM

Just don't flip it on top of yourself.

gixxerjasen

10-25-2009, 07:43 PM

Install some cupholders, cover the plastics with cammo vinyl and swap some chrome rims onto it, then bring it up to Muenster and sell it for a tidy profit in a very short amount of time. :mrgreen:

You had me all ready to hate you when you said it was orange and the devil. But....it's an ATV, not what I thought you had gotten. :mrgreen: Though, I don't doubt it'll be long before I will be hating you for that very reason.

poser

10-25-2009, 08:48 PM

well I said it was of the devil because of a thread a while back asking if ATVs were of the devil.
What did you think I had? KTM ATV? HAHA :lol2: I wish! Those things are SWEET!!

Jack Giesecke

10-25-2009, 09:51 PM

It very much needs camo paint. And, no gun rack? :mrgreen:

wdw

10-26-2009, 09:21 AM

And, no gun rack? :mrgreen:

+1

gixxerjasen

10-26-2009, 10:12 AM

well I said it was of the devil because of a thread a while back asking if ATVs were of the devil.
What did you think I had? KTM ATV? HAHA :lol2: I wish! Those things are SWEET!!Nah, I hadn't figured the ATV route yet, but I thought you'd finally picked up a KTM SM. And I would truly hate you for that.

poser

10-26-2009, 10:24 AM

Nah, I hadn't figured the ATV route yet, but I thought you'd finally picked up a KTM SM. And I would truly hate you for that.

I wish, maybe someday [like when the kid graduates college :rofl:]

gixxerjasen

10-26-2009, 10:29 AM

I wish, maybe someday [like when the kid graduates college :rofl:]I hear ya, I hear ya for sure.

Of course, then you'll have all the parent loans to pay off. :rofl:

poser

10-26-2009, 01:05 PM

Hmmm... moved to the projects section.
Guess I have to fix it and post pics now :mrgreen:

If anyone has a few extra hours in the day they're not using can I have them :lol2:

Hemibee

10-26-2009, 01:51 PM

I hear ya, I hear ya for sure.

Of course, then you'll have all the parent loans to pay off. :rofl:

Ain't that the truth...anyone want to adopt a Baylor Sophomore? I sure would like a new set of wheels...heck I'd like to be able to afford a day at Muenster..so how about it? He only eats as much as the yearly cost of school!

You are messing in the devil's playground with that wretched kwad.

Tracker

10-26-2009, 05:58 PM

it didn't take a swim in Hurricane Ike, did it?

poser

10-26-2009, 06:37 PM

it didn't take a swim in Hurricane Ike, did it?

I don't think so, it came from the Brenham area
and while there's eveidence of being in the elements on the plastics and the racks, the frame is good shape, very little rust if any

gixxerjasen

10-26-2009, 08:58 PM

That evidence is most likely spilt beer.

stinky93071

10-26-2009, 08:59 PM

Just don't flip it on top of yourself.

trust me it hurts,

DFW_Warrior

10-26-2009, 09:00 PM

trust me it hurts,

:rofl::rofl::rofl:

I was there.... it was scary and funny.

poser

10-29-2009, 11:23 PM

Started tearing it down tonight.
Got all the plastics off and the racks. IT really looks mean w/o the plastics, looks like something out of Mad Maxx :lol2:
Got to looking at it, and I guess the guy was right, that he had messed with it some and was tired of it. The battery looks fairly new, as does the air filter. Also the radiator looks like it has fresh anti-freeze in it.
It looked like there was an oil leak, but the sight glass for the oil level is completely full and no telling how much over that he had in there. In talking to Justin the other night at bike night, he mentioned the oil may just be coming out of the crank vent. So fingers crossed on that one.
Tomorrow or Saturday morning (since my planned trip to the track is going to be rained out) i'm going to change the oil (with the correct amount), and the spark plug.
Since its already apart I'll probably pull the carb and give it a good once over.
If I can get it back together in a reasonable amount of time, I'm going to go test it out before lunch on Saturday.

I'll post some pics of the Mad Maxx mobile later

poser

11-30-2009, 08:30 AM

Been pretty busy and haven't had much time to work on it. I did pull the carb and rebuild it on Saturday afternoon. I cleaned it as best I could, but decided to go with a carb rebuild kit, and boy am i glad I did. The previous owner, I guess attempted it, but didn't put everything back, and certainly not back correclty. It was a good thing the kit came with new jets and other things, and a good thing I picked up the clymer manual for it.

I got it started but it will only run if you're giving it gas, it will not idle. Looking through the clymer manual I have the idle pilot screw way out of adjustment. It is suposed to be 2-3/8 turns out and I only have it 1/2 turn out. Haven't gotten back out there to fix that.

The petcock is going to need to be replaced. Its leaking gas through it like a siv. Its definately leaking through the vent line, and in turn running through the carb and into the motor. Looking at the site glass, there is now gas in the oil (how bad is that, and no I haven't run it since). Not only is the petcock leaking into the carb, but its also leaking out, so theres a puddle of gas under the quad and the garage wreaks. I took the tank off yesterday, and tonight I'm going to clean the mess up.

I looked around for a petcock rebuild kit, but I can only find one for old street bikes, looks like I may have to drop the $75 on an OEM replacement. An ebay search also turned up negative.

Tracker

11-30-2009, 09:20 PM

please tell me you don't have a gas hot water heater in your garage....

poser

12-01-2009, 12:12 PM

please tell me you don't have a gas hot water heater in your garage....

ok I won't :giveup: but I did leave the garage doors cracked open about 6" to get some ventalation.
Cleaned up the mess last night. Drained the gas/oil from the engine, had to practically turn the quad on its side to get it all to drain out, and there was a bunch. I figure I'll add fresh oil to it, run it for a few minutes and then change the oil and filter to get any last remains out.
Not it too big of a hurry, as I need to order the new petcock, so it'll be put on hold until that gets ordered. my potential profit margin is shrinking :lol2:. Even if I don't make that much off it, its still fun taking something from junk to not-junk

poser

01-06-2010, 04:17 PM

Petcock issue solved, thanks to some ingenuity and gasket maker stuff, and an o-ring from Ace Hardware.
Got the pilot screw and idle screw adjusted well, It'll fire right up and run no problems. I'm kinda surprised how easily it starts and how well it runs.

But like any other project, you alway find more than you bargained for, and this one is no exception. The rear diff is worn or something, but it will not reverse. The shaft spins, but it just makes a terrible grinding noise :doh:.
Opened up the oil cap and it was DRY :eek2:. The guy I picked it up off of, said something about the reverse and gave some rear end oil, and I guess thats why. Filled it up, and it helped, but still no dice, its going to need a new rear diff or gears :doh:. And yes that is as expensive as it sounds if you look on OEM parts sites. Luckily I have found one on ebay thats cheap right now, and hopefully it'll stay that way untill the auction ends.

Its still in Mad Maxx form in the garage, so maybe I'll finally get some pics up this weekend. I hope to start painting on some of it Saturday. Nothing fancy, just spray can stuff.

On a side note, I don't know if I've mentioned it, but I LOVE Ace hardware. I have found bolts, screws, and even an o-ring for the petcock there. That place is great for little DIY fixer jobs.

poser

01-09-2010, 10:31 PM

Took some pics of the Mad Maxx mobile today, and finished blowing out the rear end :lol2:, I knew I needed one amd I'm watcing ebay, but I put it in the low gears, gave it a bunch of and hear a clunch and then grinding. So the rear diff is officially toast, luckily there's one on ebay right now.

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0094/761133135_ah3ey-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0093/761132384_F7nbA-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0092/761133983_6GX7C-L.jpg

Rman of 237

01-10-2010, 06:35 PM

Are you absolutely sure that crunch and grind is the differential? It might just be a simple U-joint.:shrug:

CT90RR

01-10-2010, 08:03 PM

Love the seat! So simple and functional.

poser

01-10-2010, 08:30 PM

Are you absolutely sure that crunch and grind is the differential? It might just be a simple U-joint.:shrug:

yeah, because at first reverse was only affected. The drive shaft would turn, and all you'd hear was grinding. Now the drive shaft turns for foward, and you hear the same grinding noise.

M38A1

01-10-2010, 08:48 PM

Have you given thought to cracking the case on the rear diff just for a peek? Might be something you can fix?????? If you think you'll have to replace it, why not crack it first anyway?

poser

01-10-2010, 08:53 PM

Have you given thought to cracking the case on the rear diff just for a peek? Might be something you can fix?????? If you think you'll have to replace it, why not crack it first anyway?

Yeah, I'll probably crack it open, but the auction I'm watching ends tonight so I'm going to go ahead and grab it just in case I can't fix it, so I'll have a back up plan.

Rman of 237

01-10-2010, 11:25 PM

The symptoms you described could be a number of things but it sounds like a bad bearing. Could be a wheel bearing(which are incorporated into the differential housing by the way) or it could be a U-joint(which is nothing but a bunch of bearings). Either one will cause the drive shaft to hang up in one direction one minute and then hang up the other direction the next making all kinds of noise in the process.
It's hard to see from the pics but does it have drum brakes? It could very well be a broken brake shoe as well. A broken shoe will do the exact same thing, noise and all.

poser

01-10-2010, 11:48 PM

Looks like I'll be pulling it apart and hoping for the best (didn't win the auction).
It does have drum brakes on the rear right, but it doesn't work. It needs to be adjusted.
I hope you're right aout it being a bearing.

On-Off

01-10-2010, 11:56 PM

Just from looking at the tires chances are is that it has been really deep in mud on more than one accation and the bearings are the first to go, which if your lucky will be an easy fix. you find some helpfull info on .www.atvnation.com good luck

poser

01-11-2010, 12:02 AM

thanks for the link. I hadn't come across that site yet.
This saturday I'll be working in the garage, and I'll take some time to pull the rear off and apart

Rman of 237

01-11-2010, 12:14 AM

Love the seat! So simple and functional.Yeah, all he needs now is a Nerf football for a cushion!!:rofl: Don't ask!:mrgreen::doh:

poser

01-11-2010, 12:27 PM

JTM

01-11-2010, 12:46 PM

Yes, a bearing can lock up the entire axle.

poser

01-11-2010, 12:53 PM

you guys have me very hopeful, I sure hope thats it. I may go out there tonight and see if I can pull it apart.
thanks for the input, differentials are new teritorry for me

JTM

01-11-2010, 12:57 PM

If you want I can bring some cold beverages by and lend a hand.

poser

01-11-2010, 12:58 PM

If you want I can bring some cold beverages by and lend a hand.

lemme see what the wife has planned. I was going to go out there after the kid goes to bed

poser

01-11-2010, 04:29 PM

If you want I can bring some cold beverages by and lend a hand.

nothing going on tonight, if you wanted to swing by. I'll buy the beverages, what's your flavor?

JTM

01-11-2010, 05:30 PM

Free

Rman of 237

01-11-2010, 08:57 PM

Free:lol2:...:chug:

poser

01-11-2010, 09:48 PM

M38A1

01-11-2010, 10:08 PM

Well that's good news on the driveshaft!

Brakes? Just drag your feet like Fred Flintstone. :rofl:

.

poser

01-11-2010, 10:12 PM

:doh: but that worn out part is $100 :thumbd:

Rman of 237

01-11-2010, 10:30 PM

I'm just curious, which part is it? Here's Bike Bandit's exploded views.

http://www.bikebandit.com/1998-suzuki-motorcycle-ltf500fw/o/m6498

poser

01-11-2010, 10:58 PM

I'm pretty sure its.....

2: SHAFT,REAR FINA 490319-001

its cheaper here than mrcycles

DaveC

01-11-2010, 11:20 PM

They are of the devil, every time I took the Artic Cat out it ended up with me under it!:eek2: It is not like I am some type of wack-o speed demon, it just a solid axle rear drive and it turns upside down as quick as you please. I hate the thing and now it is broken, tranny , an automatic?:giveup::angryfire Still owe on it. Should have bought a couple of used dirt bikes! where is the kick yourself smiley?

On-Off

01-11-2010, 11:23 PM

Well big thanks to JTM, he came over and we pulled the rear end and took apart the rear diff. Good news everything looks great, the problem is the end of the drive shaft. It looks as though it wasn't all the way up in, and the teeth are ground down. More good news, the recieving end of the rear diff, those teeth look good, so I just need that one part.

Oh and there was no rear brakes :lol:, no pads, springs, nuth'n :doh:

Win one, loose another

Thanks again Justin :thumb:

Rear drum brakes are a waste of time on a 4wd atv, you will spend more time adjusting then riding that is probably why everything is missing. if it has frt disc brakes then you will be good.

I have had several atv's prior to the 2 wheeled exp. the last on was a Can Am 800 max it would do 75mph on the dirt.and it was a spec.two up machine.good luck.

poser

01-11-2010, 11:37 PM

looking at the parts fishe online, all I'm missing are the pads and 2 springs.
pads can be found on ebay fore reasonable and the springs are cheap. getting it all to work properly, may be another challenge.

Barring any other problems I'll have it in tip top shape soon, and listed for sale. With any luck I'll make a little profit on it, as frustrating as some things can be, I'm actually enjoying tearing into it and learning new stuff and testing my abilities.
Next I may jump on the cafe racer bandwagon :dude:

JTM

01-12-2010, 08:15 AM

I'm pretty sure its.....

2: SHAFT,REAR FINA 490319-001

its cheaper here than mrcycles

I would go ahead and order a new spring as well

37: FLTR RETAINER S
473782-001

They are of the devil, every time I took the Artic Cat out it ended up with me under it!:eek2: It is not like I am some type of wack-o speed demon, it just a solid axle rear drive and it turns upside down as quick as you please. I hate the thing and now it is broken, tranny , an automatic?:giveup::angryfire Still owe on it. Should have bought a couple of used dirt bikes! where is the kick yourself smiley?

this is why I like the smaller ATVs, I have seen a few people get lifeflighted.

I am still determind that I am going to build a 4wd go-cart out of an old 4wd ATV.

poser

01-16-2010, 09:04 PM

Rear brakes and shaft piece should be in this week.
Sanded off the rust adn painted the rear wheels black today. Its amazing the difference a little rattle can makes.
I'm going to try and get the plastics painted this week.
Oh and I need a seat cover, this one is jacked

poser

01-20-2010, 09:58 PM

Brown Santa dropped off some presents today, so I messed with it tonight, and snapped a few shots.

The teeth on the shaft were very worn compaired to the new one, and I don't know why it wore out, other than its designed to be the weak point so other more expensive parts don't break. Also the spring that goes between the shaft and where it goes in, the new one is about half as tall.

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0145/769669848_AANnm-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0153/769669200_4Tiys-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0149/769670951_7pXxo-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0152/769668543_Uq64x-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/DSC0151/769667949_fQ3FU-L.jpg

Maverick

01-20-2010, 10:37 PM

poser

01-20-2010, 10:45 PM

Well, looks to me like it should get that way when it's :rider:

But hey, the rims look nice, and I'd stand that EZ-UP against the wall, it's not good for them to lay flat. :lol2:

And I hope that you didn't put any of that rotella into one of your bikes. Geez, haven't you read all the threads? :rofl:

Looks like it's coming along nicely, when we going to go play in the mud?

Maverick

The e-z-up is acting as a make shift wall to keep bolts on the ground from being kicked.

I only use the rotella for cooking :lol2:
On a side note, all those jugs down there are full of old oil, I need to take it down to O'Reillys or something.

As soon as I'm done I'll be testing it out somewhere :trust:

poser

01-23-2010, 09:50 PM

Got the rear end put back together and installed.
Tested it out and everything works great :thumb:
all thats left is to give the plastics a coat of paint, and new cover for the seat

Squeaky

01-24-2010, 08:03 AM

I'd have to look for it, but I think I have some marine-grade vinyl somewhere around here that you could use to recover the seat. It's a blue-ish turquoise though...

poser

01-24-2010, 03:53 PM

I've got a new seat cover on order via ebay :thumb:

poser

03-03-2010, 10:25 PM

Stay tuned :mrgreen:

jar675

03-04-2010, 07:09 AM

So what's the next project? :trust:

poser

03-04-2010, 09:59 PM

So what's the next project? :trust:

besides the other orange toy in the garage.... not sure

poser

03-06-2010, 01:59 PM

Well I'm happy to say its finally finished!
Took it ou for it's maide voyage today and got pretty dirty, and even stuck. I will say for just being 2wd it will go thru some STUFF.
Had a blast riding today, heck I had a blast getting to this point.
I'm going to list it for sale today on craigs list and start the search for the next project.

here's some pics of the final product and some of todays ride...

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/S5030159/803665993_dYMVn-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/S5030160/803666514_7DLFg-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/S5030157/803665042_hdDYg-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/S5030162/803664525_3oSfz-XL-1.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/S5030139/803660893_P8SgS-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/S5030141/803661533_9aQqu-L.jpg

http://thebohacpage.smugmug.com/Motorcycle-Stuff/Projects/S5030149/803663237_fTtAv-L.jpg