The Ugly Duckling Quad

[Buckmark]

This will be kinda long,  6 posts and kinda pic heavy, so please wait till the end to comment.
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I picked up this old Suzuki quad back in April knowing it was not a looker but was told it ran and the price was right so figured what the heck, how bad can it be 

When i went to pick it up it was hiding in a dark covered carport which did not hide its ugliness, but like the seller said it ran and it did so in my truck it went, during a pouring down rain storm!!!!

When i left in the morning to get it i did not tell my wife, only said i had to run an errand. When i got home she took one look at, shook her head and went inside, whew shes not mad. My step daughter took one look at it and said "can i ride it?", i said "well the tires need air, the battery is dead but i can pull start it, the brakes don't work and im not sure what else is wrong.....so sure run it around the house" 

As you can see it had not had a bath since about the mid 90's and obviously was very well loved.

[Buckmark]

So the first order of business was to give her a bath to see what i really had to work with, and after that it was not as bad as it looked 
I started making a list of what i could see needed fixing and how much it might cost, the object was to spend as little as possible, set budget was $100.00 and that had to include the battery, lucky for me i had alot of stuff already in my cabinets to use/reuse.

[Buckmark]

Next order of business was to strip her down and give her a good spa treatment (power wash), it amazing how many bolts hold these things together, how many you cant see and after 25+ years how many are not original sizes, pretty sure i used every metric and standard socket i own 
I have a sign in my shop that says "Every 20 minute job is 1 broken bolt away from becoming a 3 day ordeal"
I had 7 broken bolts after taking her apart 

I think i had 5lbs of dirt on the floor after removing the plastic

After pressure washing her, removing the muffler for repairs i was pleased to find not anything else major to repair
Got every bolt drilled out and threads cleaned up

Had to do the best i could to straighten out the front and rear racks, pretty sure this quad had rolled over once or twice 
Repaired the front rack best i could, and the front grill.

[Buckmark]

I recovered the seat myself using a shirt i had that was a polyester/nylon, i think it turned out pretty good 

The shocks were all set to different stiffness so set them all to there max and got the muffler welded back up and made a connector for the rotted one that someone had wrapped a soup can around with hose clamps.

I got to cleaning plastic, repairing cracked/broken plastic, painting etc.

[Buckmark]

After cleaning, painting and painting some more i was ready to put her back together, due to the fact that it was ridden so tender during its years before i got it  , nothing lined up to bolt back together, prybars, ratchet straps, beer and swear words along with a plethora of new fasteners i got her back together 
I still have some stuff to finish, the headlights i am rebuilding along with the rear brake light and the rear brakes still need some help but its able to be ridden.
When i started this project i figured it would take me 2 weeks.......i took it apart on May 9th, the finished pics i took November 11th  Eh 2 weeks, 6 months, close enough    

Suzuki had a King Quad  back in the day that i kinda copied the color scheme of, i am close.
I think it turned out OK?

Check out that articulation 

Thats it for now, thanks for reading/looking 

[Buckmark]

Last

[Curly]

Quality work right there. Good job.

[Birdguy]

I would say well done!! Quite the  improvement for sure.

[C-Money]

Looks ready for some trails!!

[emac]

Wow that is impressive great work

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[Timberstalker]

She's a beaut, Clark!

Nice work for sure.

[J.Brower]

Doesn’t even look like the same beast!


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[Boss .300 winmag]

And people say you can’t polish a turd.👍

Probably tripled it value, nice work.

[syoungs]

Nice job! I've got the same quad sitting in the garage that needs the same love, thanks for the inspiration to get started 

[greenhead_killer]

That’s awesome! And did you stay under $100?

[Southpole]

I have a late 90's Suzuki 250 just like that one. I love the little thing. I don't think any ATV manufacturer has made a 250 with 4 wheel drive for many years. Mine even has high, low and super duper low. Cool little bikes for sure.

[CAMPMEAT]

6 ply tires and you're good to go.

[Buckmark]

@syoungs  If you decide to get rid of it PM me, i need another one

@greenhead_killer  Technically yes i am under budget, but i did have some of the stuff i needed/used in my shop and the seat cover material was free, if i cant get the front lights repaired like i want to i will buy a small LED light bar and that will get me close

@Southpole  Yeah these are cool little machines, 2wd, 4wd, high, Low, super low and Differential lock. Pretty sure they can climb a tree if you wanted

@CAMPMEAT  Send me some i will put them on

[Buckmark]

I still have the front lights to repair if i can and install, if not than a small LED light bar might be installed
I am going to make a padded cover for the handle bar cross brace and cover it with some of the left over material i used on the seat and i may hang a rear rack bag on it if i can find one cheap

[syoungs]

I still have the front lights to repair if i can and install, if not than a small LED light bar might be installed
I am going to make a padded cover for the handle bar cross brace and cover it with some of the left over material i used on the seat and i may hang a rear rack bag on it if i can find one cheap

Mines getting a small led light bar, the original lights aren't that great to begin with, and my wiring is trashed anyhow.
I cant bring myself to get rid of it, it's a little tank when in the low ranges and locked up in 4x4, itll go anywhere, and possibly more places, as my sportsman 600 will.

[Mudman]

Just dumped my RZR for new quads.  Back to em.  Hey good job on that sweet ol ride.   Its cool and fun to do that.  I have resurrected old bike before and really enjoyed it as hobby!  Rivet or stitches, the million $ question!

[CAMPMEAT]

Just dumped my RZR for new quads.  Back to em.  Hey good job on that sweet ol ride.   Its cool and fun to do that.  I have resurrected old bike before and really enjoyed it as hobby!  Rivet or stitches, the million $ question!

Have you gone mad ? I just bought a new 2018 RZR XP 1000, WOW is all I can say.

[Widgeondeke]

And people say you can’t polish a turd.👍

Probably tripled it value, nice work.

                  

[Mudman]

Just dumped my RZR for new quads.  Back to em.  Hey good job on that sweet ol ride.   Its cool and fun to do that.  I have resurrected old bike before and really enjoyed it as hobby!  Rivet or stitches, the million $ question!

Have you gone mad ? I just bought a new 2018 RZR XP 1000, WOW is all I can say.

Well, yeah I did!  So frustrated with Wetside restrictions on utv's.  And I was getting bored.  Im a guy with need for speed so got a faster one!  We will get another UTV in few years when Wa is in our past. Quads are fun and usefull, been riding em a long time.  Buckys old dog in thread is really cool.  brings back good memories!!  The XP is a great choice for ya down there!  Tusk windshield has good vents.  had on my lil rzr and loved it.

[Sandberm]

Awesome!

Its nice to see someone rebuild something in a practical, low budget way.

Love the seat cover. Had a buddy that recovered a seat on his old Yamaha IT125 with a pair of Levis 501's. Looked funky but at least it matched colorwise. 

And WELL DONE on getting all the twisted off bolts drilled out. I pride myself on this skill. 

[CAMPMEAT]

@syoungs  If you decide to get rid of it PM me, i need another one

@greenhead_killer  Technically yes i am under budget, but i did have some of the stuff i needed/used in my shop and the seat cover material was free, if i cant get the front lights repaired like i want to i will buy a small LED light bar and that will get me close

@Southpole  Yeah these are cool little machines, 2wd, 4wd, high, Low, super low and Differential lock. Pretty sure they can climb a tree if you wanted

@CAMPMEAT  Send me some i will put them on

Sorry, already on mine.