Suzuki LT230S Quad Sport (aka Lil Suzie) build thread

[2000]

Yes I know this isnt a warrior but this forum is one of the best and I figured you's wouldnt mind seeing this.

So lets start with a brief history on this quad:

My brother bought it around 8 years ago for $50 I think its an 87. He later bought a 1985 parts quad for it for $150. It has sat outside ever since he bought it and hast ran good in atleast 2 yrs.

So long story short I bought them both for $100

Here is the parts bike (in pieces):

The better plastics: are on the back of the zuk I like the blue with the red/orange.

After an hour of detailed carb cleaning it runs like new:

https://vimeo.com/130246412

More to come!



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[Gen1Pat]

They are a great little quad. I had an '87 when I was in my teens. I still have the Clymer repair manual. That sideways kicker sucks monkey nuts! Other then that, I had no complaints. Keep the oil and filter changed regularly. I have heard that the oiling system isn't the more efficient. Be glad you have good fenders (they are getting hard to find).

 

[Gen1Pat]

You may want to do some internet searching for a-arm threads. I ran into a guy on 3wheelerworld that says YFZ arms are a common swap. How? I don't have a ******* clue. But, worth looking into.

 

[2000]

They are a great little quad. I had an '87 when I was in my teens. I still have the Clymer repair manual. That sideways kicker sucks monkey nuts! Other then that, I had no complaints. Keep the oil and filter changed regularly. I have heard that the oiling system isn't the more efficient. Be glad you have good fenders (they are getting hard to find).

They are great. Good for wheelies lo and pretty nimble. I do hate that sideways kick start lol


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[2000]

You may want to do some internet searching for a-arm threads. I ran into a guy on 3wheelerworld that says YFZ arms are a common swap. How? I don't have a ******* clue. But, worth looking into.

Never heard of that but will do. Thanks for letting me know


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[2000]

****Updates****

Speaking of oil genonepat:

I changed the oil on it and I talked to my brother and he said the last time he changed the oil was when he got it around 6-8 yrs ago. It was very nasty lol

Incase anyone was wondering I put shell rotella diesel 15-40w conventional in it. (It leaks a little otherwise it would have got synthetic) and rotella is jaso-ma approved so it works in wet clutch machines.

I also mocked up the the good plastics and painted the parts frame and Im going to put everything on that frame instead of taking everything off the one it has and painting it and putting everything back on.

Before:

After:

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[hammy7734]

my dad had one of these it was bored out to a 250 i think but it was stolen about 16 -18 years ago and my friend has the utility one of this and it sucks ass it has no rear suspension and the choke sticks and it smokes like crazy


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[Gen1Pat]

This is what mine looked like over 10 years ago. Hard to believe it's been over a decade since I owned it. Engine was in pieces, in a box, with a bad crank. After owning it for 2-3 years I had the engine rebuilt (was not capable of doing that at 14-15ish), it had a cam and valve springs (that I can't remember the profile of cam) modified air box lid, and she flew!!! Did not have stock carb either. It was a nasty little bike.



Another thing to do is ditch the most sloppiest shift linkage ever installed on a quad!

 

[2000]

my dad had one of these it was bored out to a 250 i think but it was stolen about 16 -18 years ago and my friend has the utility one of this and it sucks ass it has no rear suspension and the choke sticks and it smokes like crazy


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Those are nicer, wider, more power, better oil system, better suspension. Did they ever find it?


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[2000]

This is what mine looked like over 10 years ago. Hard to believe it's been over a decade since I owned it. Engine was in pieces, in a box, with a bad crank. After owning it for 2-3 years I had the engine rebuilt (was not capable of doing that at 14-15ish), it had a cam and valve springs (that I can't remember the profile of cam) modified air box lid, and she flew!!! Did not have stock carb either. It was a nasty little bike.



Another thing to do is ditch the most sloppiest shift linkage ever installed on a quad!

Thats cool man. It looks good. Web cams makes cams for the 250s, do you think they interchange?

One of the first thing I did was fix the shifter lol


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[2000]

Updates:

I wire wheeled the exhaust and painted it with hight temp black it was still pitted though but turned out alright.

I me and some friends pulled everything from the other frame and started transferring things. We got the steering stem on, the a arms/shocks, the electrical and just mocked up the plastics.

And then I got a little caried away and decided to inspect the valve train/cylinder and it looked good just some minor scratches in the cylinder. Im going to replace the valve stem seals well im in there two as it smokes when I first start it.

I also decided im going to paint the motor and sand the fins like this. I just have to fix the oil leak from the stator cover first.

Not a fan of the gold:

I did however start doing the head:

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[hammy7734]

no they never found it my dad had bought is almost new then sold it to his brother who bored it out and then sold it back to my dad

 

[Gen1Pat]

Oil leak from the stator cover was common. Mine had the same issue. The crankcases aren't that thick, and the one bolt hole pretty much broke in half. If I were to guess, you're leak is directly in front of the sprocket.

 

[2000]

Oil leak from the stator cover was common. Mine had the same issue. The crankcases aren't that thick, and the one bolt hole pretty much broke in half. If I were to guess, you're leak is directly in front of the sprocket.

The leak was actually rite on the bottom. Yeah the cases are pretty thin.


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[2000]

no they never found it my dad had bought is almost new then sold it to his brother who bored it out and then sold it back to my dad

That sucks. Sounds like it was a fun bike.


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[2000]

****Updates****

So I installed new valve stem seals and lapped the valves and started re assembling the motor. I decided to fix the oil leak so I installed a new seal on the shifter shaft and took off the stator cover and put some rtv on it.

I had the timing chain tied up so it wouldn't fall in to the bottom of the motor and while putting the head on I dropped the timing chain in the the bottom end lol

The metal coat hanger saves the day again lol

So After that I finally got it all together and timed.

After that I sprayed the motor down with degreaser and pressure washed it then painted it black.

I also painted the airbox flat black

The swing arm bearings fell apart when I took it off the frame so it was time for new ones. I heated the swing arm up and tried pounding them out with a socket and that didn't work so then I tried cutting them with a sawzall and that didn't cut them so I tried the Dremel and it worked so I cut them into smaller pieces and pounded them out.

While I was doing this I had the new bearings in the freezer for a couple of hours and they went right in.

After installing the swing arm onto the frame I installed the motor, exhaust, airbox, etc.

Im also going to mod this old bumper from my warrior 350 to fit this Suzuki.

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[Gen1Pat]

I like it.

Oh, use a strong telescoping magnet to retrieve a dropped timing chain.

 

[jimmyde78]

Nice job so far man

 

[Warriorrider20]

Nice job and I was wondering what paint you used on the motor because it looks great

 

[2000]

I like it.

Oh, use a strong telescoping magnet to retrieve a dropped timing chain.

Thanks! I would have used one but I didnt have one on hand.


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