OK, so what all is involved on my end?

Do I have to completely tear the quad apart, or can I remove the fairings and get access to the head that way? Sorry, I can work with tools, but working in the area of quads is new to me.


While I am on this subject, I would like to rant about this quad, or the person who sold it to me. Feel free to skip this part if you want.

The guy I bought this from I have known all my life. We grew up together, went to the same church together, and graduated in the same class together from high school. Now, I had not been around him in a little over 20 years, but you know, with childhood friends like this, you can just pickup where you left off.

So I am disappointed in this entire situation. I got this quad for my son's birthday as an early present. His birthday is tomorrow and he will not get to ride it. He rode it all of one week, him and his sister both, and not since. That was weeks ago. Although he's pretty tough, when I told him about the compression test, he was disappointed when he wasn't going to have it to ride tomorrow with his cousins and whatnot.

The fact that a lifelong friend not only told me on Facebook that he would work with me, and that it ran great, but then told me to my face that it was fine, only to be in this situation right now, infuriates me. I would like to review what all I've done with it.

*Replaced spark plug that was hideously fouled.
*Replaced air filter that literally was disintegrated in the air box.
*Cleaned out the carb that was filthy.

In short, while I am a neophyte when it comes to quads, I know how to work on cars to a degree and I know lack of preventative maintenance when I see it. Yes, carbs get dirty I get that, but it's clear the spark plug and air filter was never changed. Now I'm looking at an engine with 30 PSI compression. Correct me if I am wrong, but doesn't that scream abuse or lack of care?

Anyway, I'm stuck with it, and the logical question, at least to me, is, is it worth fixing, or should I sell it? He loves it, and I like Suzuki, but I do not want to sink money down a potential moneypit. Thanks for the feedback.

 

Is it worth it? Sure! Once repaired it will run a long time and give miles of smiles.
Top end: remove the bolt from the Coil/cdi and let them hang, remove the spark plug and motor cover (it's tight but it will pull out). Remove the pipe. Remove the 4 head nuts and you are ready to pull it apart.
I use a small sharp pokey type thing to get the cir-clip out of the piston. Push the pin out and the piston will come off.

You can either send it to me (or a local shop) for cylinder boring ($125 w/gaskets) or you can get a Cheapo kit off of ebay(50 bucks).
If you send it to me, I only use Suzuki parts.
It's easy. You'll have no problem I'm sure.

 

Just pack a clean rag around the connecting rod when removing the piston...don't want anything and I mean anything getting into bottom end...

 

Well, I took the quad into a shop, and the guy running it, a Marine vet, told me, another Marine vet, that the labor would kill me on this. He asked if I knew how to work with tools, and I told him I did. He said like you guys, I would be better off doing it myself.

So today I'll roll it out of the bed of the truck and start getting to work.

 

We'll help.

 

OMG! This was super easy to tear down!

Had a little bit of trouble getting the exhaust off the head. Once that was off, then it was to figure out how to get the piston off the arm. Figured that out, and got it off. the head and the piston are pretty well scored up.

My question is, you said you can get a cheap one off eBay. Is there a concern about that, in terms of performance?

 

I do have a question about installing the circlips once I get my parts.

I know how to install them, but do I have to install them with the cylinder back on the arm, or do I install one off the arm, put the pin in and then put in the other circlip? Thanks for the help!

 

The cheapo kit off ebay is a ok option for a stock machine. Pay attention to the ring gap and all should be well.
"do I install one off the arm, put the pin in and then put in the other circlip"
Put the pin in the piston, then put one clip in (the pin helps keep the clip straight imo), Remove the pin, stick the piston over the connecting rod (arm), install the pin and other clip.
ARROW toward exhaust. Make sure the rings are aligned with the lil pins in the ring grooves and wiggle the cylinder on. It should wiggle right on with little pressure.
Also, the cheapo kit will have cylinder studs included. Don't use them...
Need any help, just ask.

 

Don't get the cheapo kit...just installed one in my neighbor's LT80 and it was a project (and I'm kinda experienced at this stuff)...the machining sucked and there was zero ring gap as delivered. Let Jack handle the hard stuff so when you re-assemble it'll be smooth as butter...

 

Well Jack, how much would a new piston kit cost me, OEM?