If you have no manual like me & haven't found these yet, they may help.

front: h**p://images.powersportsnetwork.com/fiche/images/Suzuki/2002/ATVs/1813_12.gif

rear: h**p://images.powersportsnetwork.com/fiche/images/Suzuki/2002/ATVs/1813_13.gif

On the front clean out old grease & dirt. Check rollers (6 parts #5) for flat spots & wear.

On rear clean and check for wear & glaze on shoes (#13) & drum (#12).

I'm no expert but if you inspect these parts someone can help.

I'm not sure about live links on this forum so you need to change h**p to http to view the pictures.

 

Hey thanks for the reply, I'll check those part out. We're going camping this weekend at Spinreel, I blew out the case and the clutch and it see a little better; it'll get me by for the weekend and then I'll have more time and take it apart again and inspect the parts you suggested. I got a littl pissed today hen I pout it back together, I forgot to put the skid plate back on before the foot pegs...so you can guess what I had to take back apart again.....

Anyway, thos split fot pegs I read about earlier ar sounding better and better every minute....Any other posts with more info on what needs to be checked out and replaced would be great, I just need to know what the wear clearances are or how to tell if it's time to replace things. If anyone has instructions, please let me know, tha would be great as well.

Thanks again for all your help everyone

 

I'll add to the reply ofYZotis::
The rollers may be flat or grooved. the contact surfaces of the rollers may be bad also (hub and roller plate) if grooved or wore uneven. When re-installing the rollers, I use a q-tip of high temp grease. I'd only install 4 of the 6 rollers.
You can lightly scuff the rear shoes, they get glazed. Also in the rear clutch there are bearings. Stick your finger in the bearings and turn. Any bumps or grinding and a new bearing is in order.

OK, next is to ditch the FMF pipe and re-install the stock pipe. We need to eliminate that aspect.
I'd also like to know what jets are in it.
The paddles are tough to start out with. For a stock motor, I'm wondering if the stock rears may be OK in the dunes.