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Author Topic: Hey guys, new here and to the Quadracer family.  (Read 2604 times)

Offline Sublunacy

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Re: Hey guys, new here and to the Quadracer family.
« Reply #25 on: October 22, 2015, 08:53:18 pm »
its up to you. makes sense to fix it cheap for now. then later if the bottom end starts making noises hopefully the top end will be ok still. 

 thats where im at right now with a good running top end but 2nd gear needs to be replaced.
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Offline MotorGeek - Jerry Hall

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Re: Hey guys, new here and to the Quadracer family.
« Reply #26 on: October 22, 2015, 09:24:20 pm »
Ok so a broken Piston.

I examined the case and it seems some little metal shavings have made their way. I am going to flush the crank case out real good though when I drain, and re drain. I am hoping it will be enough.


The cylinder looks pretty well. Not chewed up or scored. I want to measure at my parents shop in the coming week to see what size piston to order.


What do you guys think?

Only thing that bothers me is the worn ring.


Draining the transmission oil will not remove broken piston fragments.  The transmission compartment and the crankshaft compartment are not connected.  If they are, your cases are broken and the cases need to be split to evaluate the damage.

Offline Sublunacy

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Re: Hey guys, new here and to the Quadracer family.
« Reply #27 on: October 23, 2015, 07:13:19 am »
itchy trigger finger
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Offline Foxracing500r

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Re: Hey guys, new here and to the Quadracer family.
« Reply #28 on: October 23, 2015, 07:44:12 am »
Draining the transmission oil will not remove broken piston fragments.  The transmission compartment and the crankshaft compartment are not connected.  If they are, your cases are broken and the cases need to be split to evaluate the damage.




Any way to do this without splitting cases?

Like I said, top end I am fine, but anything bottom end is in uncharted territory.
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Offline Foxracing500r

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Re: Hey guys, new here and to the Quadracer family.
« Reply #29 on: October 23, 2015, 09:30:09 am »
I read a story online where a guy had an extremely similar situation with a YZ125.

Piston broke same place, top of piston looked the same etc. He fished busted pieces out, then with the engine out, he 2 cycle gas in the case, swooshed it around and dumped it out upside down. He did this maybe 3 times and he rebuilt and runs the bike again.

Anybody think this would work? By the size of the chunk I fetched out, there is very small pieces left. I did get a few almost shavings out with a rag.
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Offline Sublunacy

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Re: Hey guys, new here and to the Quadracer family.
« Reply #30 on: October 23, 2015, 12:18:23 pm »
your correct it could go both ways. you should hear crunching noises if there is chunks in the crank bearings.

- also remember the cylinder cannot be finished untill the machinist has the new piston in his hands. see if you can decide on a piston size and order it up.
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Offline Foxracing500r

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Re: Hey guys, new here and to the Quadracer family.
« Reply #31 on: October 23, 2015, 01:24:26 pm »
I am almost thinking standard bore. The cylinder is in great shape. I gotta measure first. That's whats holding things up now
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Offline Dutch_Rutter

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Re: Hey guys, new here and to the Quadracer family.
« Reply #32 on: October 24, 2015, 12:04:09 pm »
With my LT I was at this point. I just went in and re did the bottom end. You already have the motor out and the top end off. You might as well take the extra bolts out and split your cases to check for additional damage. It is the only way to know for sure. When I split mine it was my first time but with help from the forum, and those manuals that I posted you should be able to take care of it easily.

I thought that for me at least I would hate to put money into re doing the top end, take it for a ride then have something drastically go wrong with the bottom end, which would cause you to have to purchase whole new cases. when you could of spent the extra $200 and extra week and it could have been prevented. Either way we're here to help.
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03 LTZ 400------> Wife's Boy Friend
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Offline Foxracing500r

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Re: Hey guys, new here and to the Quadracer family.
« Reply #33 on: October 27, 2015, 05:27:32 pm »
Yay! Ok. So my stepdad checked the piston, and the cylinder thoroughly and after a nice measure we determined that the cylinder is perfect for a standard piston. The guy luckily knew what happened and didn't mess it up more by mashing and screwing with it.

He gave me supplies to hone the cylinder, some lube and a couple of tips from his days of riding and I am good to go.

Next is to hone the cylinder, pull the bottom end and re do the frame paint and start rebuilding again.
 
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Offline 92lt250wannabe

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Re: Hey guys, new here and to the Quadracer family.
« Reply #34 on: October 29, 2015, 02:50:34 pm »
Looks like you have a good project quad for a great price! If your piston broke at all, or even the piston ring **** off, more than likely there are chunks in the crank bearings. If you have the motor out, like Dutch said its worth it to replace the crank bearings and seals and check the condition of the crank. Trust me there is nothing more frustrating than strong your engine all together just to have to take it back out and completly apart. I know getting it back up and "running" sounds great but taking it slow and doing it right might have the best outcome.

Even with a flushing of the crank area you most likely will not get everything out, I'm just trying to help you in the long run. These motors are extremely easy to take apart and reassemble. There are also lots of guys on the site here that have already or will answer any questions along the way. If you have any further questions or want to chat pm me I like talking quadracers.

Offline 92lt250wannabe

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Re: Hey guys, new here and to the Quadracer family.
« Reply #35 on: October 29, 2015, 02:56:27 pm »
http://www.suzukiquadracerhq.com/general-discussion/92-lt250r-restoration/

Here is a link to my 92 resto thread. The motor is out of the bike at the moment and apart on my workbench cylinder and head is out to Carl Bartlett.

Also there are lots of companies that make great pipes for the lt250r. Shearer, ftz, dynoport to name a couple of the best, there are also some other names that may be coming up in the future. Aeen also makes a nice pipe.

Your bike has an FMF pipe, it is the correct pipe for the year depending on the exhaust flange that might have been your issue. And yes the lt250 pipes are tricky to get in and out of the frame

Offline Foxracing500r

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Re: Hey guys, new here and to the Quadracer family.
« Reply #36 on: October 31, 2015, 06:54:51 pm »
The biggest problem is space. My workbench has been gravel, the back of the Tahoe and in my living room, which causes a trip to the Doghouse.


My biggest issue now, is I think my swingarm is seized. I got the nut off but the bolt is not moving. I have the motor unbolted except for that. Any tips?
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Offline Sublunacy

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Re: Hey guys, new here and to the Quadracer family.
« Reply #37 on: November 01, 2015, 07:58:46 am »
hit the bolt end while using a breaker bar or an impact gun to gently as possible walk it back and forth till it loosens. once you get it moving a little bit it should start moving easier and easier.  in and out back and forth. tap it around with a hammer and  rotating .back and forth in and out. it should free up.
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Offline 92lt250wannabe

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Re: Hey guys, new here and to the Quadracer family.
« Reply #38 on: November 01, 2015, 08:08:13 am »
I highly doubt it's seized. If your rear ended compresses when you sit or push on it it's not stuck. That is the pivot bolt. Meaning the swingarm pivots there and wouldn't pivot if it was stuck. Don't force it out that's not the way to get it out.! I have had my swingarm off plenty and the bolt never moves until you get pressure off of it.


As for the swingarm, I would disconnect the shock from the linkage. And get it out of the way. You will have to use a jack to raise or lower the frame to reach the "sweet spot." Where there is no pressure or tension on the bolt. You should be able to find this spot by trying to turn the bolt as your raising or lowering the frame. Most likely you won't have to raise the frame but you will probably have to lower it down just a tad lower than it sits with the shock on. When you get it to that spot use a punch that is smaller diameter than the bolt and punch it out.

Offline Foxracing500r

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Re: Hey guys, new here and to the Quadracer family.
« Reply #39 on: November 01, 2015, 09:37:42 am »
Thanks man. I'm going to give it a go on my next day off. I really want this engine out. I am using the jack from the Tahoe now lol. I need to get my tools from my parents house.
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Offline 92lt250wannabe

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Re: Hey guys, new here and to the Quadracer family.
« Reply #40 on: November 01, 2015, 07:55:02 pm »
I might have been a little off on info saying that the swingarm wouldn't pivot if it was seized in there. It could be stuck in the motor but I highly doubt it. I have an aluminum punch that is 10" long and about 12mm diameter. Works perfect to smack that bolt out. Once you get it out it will never be as hard again. But I know for sure that relieving the pressure from the swingarm is key.

Offline Foxracing500r

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Re: Hey guys, new here and to the Quadracer family.
« Reply #41 on: November 02, 2015, 06:58:01 am »
I was going through my Chilton last night seeing how to do it. Looks like only a bolt for the shock bracket to loosen
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Offline 92lt250wannabe

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Re: Hey guys, new here and to the Quadracer family.
« Reply #42 on: November 02, 2015, 06:34:45 pm »
Yah it's only one bolt to take one end of the shock off. You want to disconnect the lower bolt from the linkage.

Offline All American

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Re: Hey guys, new here and to the Quadracer family.
« Reply #43 on: November 03, 2015, 03:27:52 am »
When I took out my swing arm bolt, it was seized also.  I sprayed PB penetrating oil in it, let it sit for a day.  Then I sprayed it again and let it sit for a day.  Then I used my pneumatic air hammer with a tappered punch on it.  That thing wouldn't come off when I tried beating the shiz out of it.  But a couple seconds of an air hammer made that bolt slide out like butter and I didn't remove the shock bolt or lift or lower the quad.  It just needed to soak in PB for a few days and then air hammered free and you should be able to pull it right out.  Letting it soak in PB for a few days was key.  Be sure to hit the cracks between the motor and the swinger.  That was my experience.  Hope it helps.
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Offline Q2W

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Re: Hey guys, new here and to the Quadracer family.
« Reply #44 on: November 03, 2015, 07:34:15 am »
I've removed a bunch of stuck swinger bolts by doing kinda what all american did.  Spray it with penetrating oil and have a friend turn the bolt as you hit it out.  I made a rod tool that fit inside the hole on the threaded end.  I smashed the rod with a hammer and out they come.

Offline Foxracing500r

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Re: Hey guys, new here and to the Quadracer family.
« Reply #45 on: November 04, 2015, 05:00:48 pm »
Well after soaking, moving the motor and swing arm, I got that cruddy bolt turning. My dad let me borrow an impact to get it really free. As of now I am just using a breaker and deep well. I ran out of light so tomorrow after the babies appointment I will give it another go.
"Ride that mother f***** 'til the wheels fall off."

Offline Foxracing500r

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Re: Hey guys, new here and to the Quadracer family.
« Reply #46 on: November 05, 2015, 05:17:12 pm »
Engine out finally. After hours on that swingarm bolt I got it free. Took half a can of pb blaster, a breaker bar, and a electric impact.

The frame is gross. I plan on trailering it to the car wash and get ready for paint.


The frame, foot pegs, bumper sprocket cover and hood are purple.

The engine will be gloss black along with shocks and a arms.

Zombie quad lol. Black seat too. Pics coming in a few. iPhone photos too large
"Ride that mother f***** 'til the wheels fall off."

Offline Q2W

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Re: Hey guys, new here and to the Quadracer family.
« Reply #47 on: November 06, 2015, 10:04:08 am »
Use a hosting site like imgur or photobucket.  Post your pics to those site then use the IMG code to link them to the forum.

You can post better photos and it doesnt eat up space on the site.

Offline Foxracing500r

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Re: Hey guys, new here and to the Quadracer family.
« Reply #48 on: November 06, 2015, 01:59:15 pm »
I've just been sending them through Facebook messenger and saving them on my computer. Then uploading
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Offline Q2W

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Re: Hey guys, new here and to the Quadracer family.
« Reply #49 on: November 09, 2015, 08:08:16 am »
I just got an email saying the site is about out of space so.... It wont be long and you'll be required to use a hosting site or you won't be able to post pics.

 

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