I just got this machine and it seems to run ok. But it won't spin taking off, even if you stand beside it and gun it. I hauls my 8 year old around good once it gets up to 5 mph. If he runs a hill its okbut if he stops on it it can barly get moving again.
This atv does have considerable use on it. The front king pin bushing need change as they are loose.
I looked at the belt, it seem ok, tight, no missing chunks. (have yet to measure width) but I can feel there is wear on the drive and driven shieves, seems it spent alot of time driving in the slower speeds as there is definite grove in the belt surface of he primary.
Top speed is 21 mph (gps) with my 240 lbs on it. it does however seem like it revs out on the top end instead of shifting up.

So with higher mileage units where should I be checking?
I do have a service manual and I'm readng up but I just figured there whould be some common problem places to check.

I was thinking or removing the 2 clutch rollers, which should help bottom end, but does it sound like I'm getting all the top end speed.
I don't think it has been modified in any way, but who knows after all these years.
All I know for sure is the 90 sportsman will has way more bottom and top end.

 

Also who is the best price oem part suplier?
I'm lookin for a front bumper, perhaps a belt, chain and sprocket set, seat cover, decals, rewind starter, etc.
Slow is ok, lookin for cheap.

 

bump

 

Speed is down and grooves are made because::: What has happened is that the grease Suzuki put in the clutchs got rock hard and won't allow the variator to move in and out the full travel.
Get into the clutchs...your going to need some front clutch parts.
You belt prolly is fine. Wore belts run better it seems.
Chain and sporockets:: I like the 87/88 version. 428 chain and sprockets 12/26 I get them from Suzuki (they are good steel and cheap).
motorsportssupercenter.com has fair INTERNET prices. If you call and talk to someone they charge more.

 

I have got to order some king pin bushing to tighten up the front end anyway. So just rollers and oring for the clutch? Or will I likely need other parts? Gaskets for the belt enclosure. Anything for thr driven or just a cleanup and relubed?
I can feel a lowspot in the drive clutch face where the belt has spent alot more time running in low gear then high. Wonder how that will affect the shifting once the clutch is cleaned? Does the drive clutch faces or roller cover commonly wear out?
Do you think the sticky clutch is causing a loss of the low gear ratio as well as the high? As i said before the 90 sportsman has way more jam off the line. The Lt won't spin with a 5 year old on it.
Thx
Ken

 

I feel that you will need rollers and the plate that covers the rollers. Good chance the variator is bad also. The o-ring will be good..LOL
You need to get it apart to know what you need.
I'm unsure of if this is the fix but you need to fix the clutchs first to see.
It's a good chance that it will fix things.

 

When you say "variator" do youmean driven clutch?
What part # from this breakdown of the driven OEM Parts
typically wear out?
Or is that hard to say?
I'm away from home for 2 weeks and was wanting to order the parts.
Likely still never have it all but gonna try.
It s runnng now so I hate to take the kids "new toy" out or service, lol

 

2-3-5 is what wears.
The variator is #2
FYI: you need to look in "transmission 1".
It'll be fine till you get to it.

 

Ok so in the primary or drive clutch = variator

Trans 2 or driven just clean and lube?
Will a cleaning and those parts helpit get into a lower gear ratio as well
Tks

 

Rear clutch:: scuff the contact pads with sandpaper to break the glaze and check the bearings.
Lower ratio: prolly. It will start working as it should again which should be good.