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Unread 05-15-2013, 06:24 PM   #1
JeepnBlake
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ATV guys help me pick a quad

So long story short we had a 98 Suzuki King Quad 300cc.

It had 2wd, 4wd, diff lock 4wd, it had high, low and super low ranges, and it was also a 5 speed semi automatic.

Basically I'm looking for an ATV that shares all of those characteristics, but with a bigger engine.

The nitty gritty

Choice between 2wd and 4wd no AWD full time 4x4
Semi Automatic
Differential Lock(s) Front rear or both.
Preferably larger than a 300cc.


I'm not expecting to find an ATV with all of those things, but I am looking for one that has as many of those things as possible.


Here's some pics showing the goodness that is a fully locking ATV.
I drove it to where it sits in all of these pictures, set the park brake jumped off took the pics and jumped back on and drove away.







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Build Thread: http://www.jeepforum.com/forum/f22/j...thread-985907/
Dad's Build Thread: http://www.jeepforum.com/forum/f22/d...build-1474170/
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Last edited by JeepnBlake; 05-15-2013 at 06:38 PM.. Reason: Pictures always make threads better
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Unread 05-16-2013, 08:00 AM   #2
Indy
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I had an 03 kawi prairie 650, had all those items except a semi auto tranny, not sure what that is. It was a cv style transmission.
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Unread 05-16-2013, 04:25 PM   #3
JeepnBlake
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Quote:
Originally Posted by Indy View Post
I had an 03 kawi prairie 650, had all those items except a semi auto tranny, not sure what that is. It was a cv style transmission.
That's sounds like a good option I'll look into them thanks.
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Build Thread: http://www.jeepforum.com/forum/f22/j...thread-985907/
Dad's Build Thread: http://www.jeepforum.com/forum/f22/d...build-1474170/
OEM Fog Light Connectors, Conversions, and Extension Info:http://www.jeepforum.com/forum/f20/o...ngler-1008928/
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Unread 05-21-2013, 04:34 PM   #4
bmxer0122
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I have an artic cat 650 which has lockers, semi automatic, 4wd, big beefy tires and is a beast for riding trails and yard work. The only complaint that I have is that the fuel pump cracked this winter which sucks to replace.
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Unread 05-22-2013, 06:00 PM   #5
JeepnBlake
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Quote:
Originally Posted by bmxer0122 View Post
I have an artic cat 650 which has lockers, semi automatic, 4wd, big beefy tires and is a beast for riding trails and yard work. The only complaint that I have is that the fuel pump cracked this winter which sucks to replace.
What year is it?
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Build Thread: http://www.jeepforum.com/forum/f22/j...thread-985907/
Dad's Build Thread: http://www.jeepforum.com/forum/f22/d...build-1474170/
OEM Fog Light Connectors, Conversions, and Extension Info:http://www.jeepforum.com/forum/f20/o...ngler-1008928/
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Unread 05-22-2013, 08:29 PM   #6
bmxer0122
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It is a 2006. This is the only pic I have of it
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Unread 06-07-2013, 11:26 AM   #7
JeepnBlake
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I'd like to change the thread title to Rubicon Reconstructions or something similar.

I ended up finding something I can work with. Here are some pics:

2001 Honda Foreman Rubicon It's missing the front diff, cv axles, front driveshaft, a arms, wheels and tires, shifter and many of the bolts to hold it all on, oh and the rear diff is in pieces.



First thing I did was put the rear diff back together.



Here is a better view of what we're working with.











After thinking it over and deciding that we're going to keep this machine, we decided to rebuild it. A few searches on eBay and the like was showing that buying the front end parts was going to be very cost prohibitive, the other option was to buy a salvage bike. I just happened to be so lucky.

The parts donor. This one is a 2003 with a blown cylinder/head.






I stripped them both down.

Red one:



Green one:




I found the fuse block was cut out of the red one so I sectioned in the one from the green one.




Then I carted over an optima red top to test the electrical system. Note the official work attire.




Hooked up the battery, and cranked it over, and I kid you not after sitting for like 3 years due to some "electrical issues" it fired right up with the help of starting fluid. The only issues I found was the handle bar head light was unplugged, the "lights" hot wires were grounding out were they wore through the insulation right by where I spliced on the fuse block. The fuse block was missing, and the oil temp sensor was knocked off by a corn stalk. Fixed all of those, and the electrical system works great.

The rear axle is in, I drained the fuel and put in fresh and it runs like a top. Waiting for a few parts to swap all the rest of the parts back in.

front drive shaft seals and o-rings
upper a arm washers/bushings
front wheel bearings
front brake cylinder rebuild kits
wheels and tires
shifter lever
overflow bottle
seat cover
battery
all new fluids all around
oil filter
spark plug
front brake lines from green one to the red one


Current pics as of today.

Green one.



Red one.



Red one running, without a battery, only takes 1 pull of pull starter.




The good news is, I'll be driving the red one around by the end of the month. The problem is however I have about a million parts left over from the green one, some of which will be saved, others scrapped, and others will be used else where.


Stay tuned for updates
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Build Thread: http://www.jeepforum.com/forum/f22/j...thread-985907/
Dad's Build Thread: http://www.jeepforum.com/forum/f22/d...build-1474170/
OEM Fog Light Connectors, Conversions, and Extension Info:http://www.jeepforum.com/forum/f20/o...ngler-1008928/
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Unread 07-07-2013, 12:29 AM   #8
JeepnBlake
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Updates:

Overflow tank was bad so it was replaced:





Good as new:



Seat needed some help too:





Also got a shifter:



Front driveshaft got all new seals and the front diff was installed:





Put some wheels on the rear:

Note: these were later found out to be the 05+ style rubicon wheels and the back spacing wasn't right.



Bearings in the knuckles were toast:

Note: Later found out these knuckles were also bad since the destroyed bearings were left in so long the outer races began spinning inside the knuckle. Change your bearings!





We have arms:



Left side brake cylinder was leaking a bit:



Brakes hooked up:



The upper arms needed bushing kits bad, check the pics above they're already removed.



Installed



Picked up a glove box too



Got the correct rear rims for it



Front plastics on




About this time, we decided to get a few more to do


Kawasaki Prairie 650







The Kawi, and a 2003 Honda Rubicon in Yellow.



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Build Thread: http://www.jeepforum.com/forum/f22/j...thread-985907/
Dad's Build Thread: http://www.jeepforum.com/forum/f22/d...build-1474170/
OEM Fog Light Connectors, Conversions, and Extension Info:http://www.jeepforum.com/forum/f20/o...ngler-1008928/
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Unread 07-07-2013, 12:45 AM   #9
JeepnBlake
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The rest of the parts:






The Red 2001 got a new ball joint:





This is how it currently looks





Not bad considering the original condition.




So the plan is to take the transmission out of the green one pictured above, and use the engine from the yellow one. The green one threw a rod, the yellow one blew up the "hondamatic" unit.


Green one:



Yellow one:





The usable parts



First cover off, nasty stuff everywhere but the gears look good.



These are just some pics I used for reference when swapping the transmission gears.




















First thing after cleaning the case for the yellow one was to swap this bearing good for bad.

Good:


Bad:


The only thing I don't like about the yellow one so far is this fancy crank milling job. It works just fine though, and the threads are good.



Green transmission inside yellow case, as well as the "hondamatic" on the back side.




This is where I'm currently at. I need to get a crank bearing, some "hondabond" case sealant stuff, clean up the case halves and reassemble some more engine. More pics to come.
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Build Thread: http://www.jeepforum.com/forum/f22/j...thread-985907/
Dad's Build Thread: http://www.jeepforum.com/forum/f22/d...build-1474170/
OEM Fog Light Connectors, Conversions, and Extension Info:http://www.jeepforum.com/forum/f20/o...ngler-1008928/
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Unread 08-27-2013, 08:05 PM   #10
JeepnBlake
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Location: Lincoln Nebraska
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Trans cover:



Sensors:




Stator/cover:



Rear half complete.

Front central cover before:



After:



More parts added:



Front cover on:



At this point I kind of forgot to take pics for awhile.

The jug is on and the internals etc.



At this point 8-27-13

The engine is fully assembled and in the bike. It's been fired up and runs fairly well. It needs a valve adjustment and it should purr like a kitten.

I'll try to get more of the intermediate pics between the way it sits in the garage today, up until it's complete.
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-Blake-

Build Thread: http://www.jeepforum.com/forum/f22/j...thread-985907/
Dad's Build Thread: http://www.jeepforum.com/forum/f22/d...build-1474170/
OEM Fog Light Connectors, Conversions, and Extension Info:http://www.jeepforum.com/forum/f20/o...ngler-1008928/
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