This is my first post on here so let's jump right in. I just bought my second 250 4WD (the first one has been sold for at least 12 years) and I got it for CHEAP from a buddy's dad. The motor is locked up and it has been in storage for years. This is one of my all time favorite quads and will be making at least a partial restoration project of it.

I have not done any diagnostic work to it as of this time, but I have done a once over to see what I'm working with here. I has 7,000 some odd miles, both front CV shafts are toast, it has practically no upholstery left on the seat (big surprise) and a spider has built himself a mansion on top of the carb. I do know the case is intact so hopefully the seized up motor is a moisture issue and not a broken rod or something. All 15 gears seem to be functional and I'll be performing the diff lock lock-out mod soon since I don't intend on driving very fast with the diff locked, but prefer not to have it limited to functioning in super low only.

I'll be starting clean up and dis-assembly of the top end tomorrow and will keep this post going as I progress. Any help or suggestions will be greatly appreciated since I've been out of the ATV industry for several years.

 

I have a '96 250 4WD that I did a top end on a yr ago. The Clymer's manual I bought several yrs ago was invaluable.
Mike

 

Best $35 you can spend. Clymer - Suzuki LT-4WD LT-F4WDX LT-F250 Quad Runner King Quad

 

Thanks guys. I'll be ordering one tomorrow

 

A little something I learned about in frame top end overhaul: you can't get the exhaust pipe out of the way until the head is removed.
Mike

 

Sorry guys, I've had some things come up and didn't get to touch it till today. First off, upon removing the back plastics and rack, I discovered it's actually a 91. The tag on the frame was tore up and looked like "97" but I wiped it off and scraped on it and found that it said "91". There's no difference but it's nice to know how old it really is.

I went ahead and performed the diff lock mod and noticed my snorkel pipe has some sun exposure rotting going on. This quad is in pretty terrible condition but I think I can spend some time on it and make it like new with a little effort.

 

Edit: It's a 92 (made it 12/91). The stealership had 0 manuals and $35 seems a bit steep for a cheap *** like me. Luckily I scored one off ebay for $20 free shipping

 

Update: Decided to play around with it while I was at work in my down time. I pulled the pull start off and worked the engine back and forth with a pry bar. I found that it turned 180 degrees in each direction with ease but locked up abruptly after that. I stuck some welding wire down the spark plug hole and found that it locked up when the piston was 3/4 way up the stroke. I also discovered that the compression release lever is completely limp and is pretty much flopping in the breeze. Looks like a dropped valve is the diagnosis. Hopefully this is the only problem and after a valve job, it shall be running (fingers crossed)

 

Removal of the valve adjustment caps should tell the tale for you.
Mike

 

Really? Up here in northern Ontario Canada , it cost $35 for a 24 of beer and $35 just to fill a fill up my 500 Sportsman to go for a ride.