ATV with a fully manual transmission?

js5020 · May 28, 2019

One thing I haven't gotten around to is to see if its capable of modifying the 4wd shifter to get 4wd lock like the zuki. I have seen 01 and earlier it is possible, 02 maybe, 03 and later not possible.

timswi · May 28, 2019

My 2cents..I had a Yamaha Big Bear 4x4 that had the semi-auto trans..The machine was indestructible but after plowing with it for a few seasons I found the full automatics much more efficient...Also, hill climbing is better with the auto--A few times I didn't have the RPMs perfect and missed a gear, that isn't fun.

General trail riding though, the manuals are fun.

I have a Polaris Sportsman 570 efi 2-up. I'm very happy with it.

dfkrug · May 28, 2019

js5020 said:
Yes it has 3 ranges, we bought it new so its not a swap from a zuki king quad.View attachment 606703

Interesting....maybe some short-lived features of '02-'03. All your other ACs had only 2 ranges, correct?

Suzuki is my favorite brand, based on quality and features. Also, my first ATV experience, back in '83 with the new LT185 semi-auto quad. First serious production maker of 4-wheelers. Also, Suzy uses painted bolts thoughout. (I was into motocross bikes back then.)

Currently have a top-of-line 2000 Suzuki Quadmaster 500 4x4 Auto, a 650# monster.

I also had an AC DVX400, a sporty quad with manual trans, which was a joint effort with Suzuki and Kawasaki. I was going to lower the final drive ratio for utility use, like I did for the Warrior, but the parts were harder to find. Super-quick ATV...more power than anyone should want, who is not racing.

bullbreaker · May 28, 2019

Been along time but another good feature about the AC/Suzuki was the toe heal shifter where you would kick your gears up with your heal .

dfkrug · May 28, 2019

bullbreaker said:
Been along time but another good feature about the AC/Suzuki was the toe heal shifter where you would kick your gears up with your heal .

An unusual feature that I kinda liked, which allows you to ride around in sandals, since you always pushed down to shift. The ACs had it, but the Suzukis did not. The longer AC wheelbase was probably why.

Oldpath05 · May 29, 2019

I had a 94 Suzuki King Quad, it was king of gears but wasn't liquid cooled and when I parked it in gear on an incline/decline, needed a stick of dynamite to get it out of gear so I could start it up. The 96 AC Bearcat was the best atv, I could park that on a bank in gear, shut it off, then step back on the rocker shifter and it would slide right out of gear. The ride was good to with that unique stile walking linkage hooked on the rear axle, the only big draw back was the front end didn;t lock and unlock to a poss tract, when atv-ing I like a true 4x4.

dfkrug · May 30, 2019

Oldpath05 said:
I had a 94 Suzuki King Quad, it was king of gears but wasn't liquid cooled and when I parked it in gear on an incline/decline, needed a stick of dynamite to get it out of gear so I could start it up.

I would say most semi-auto ATVs are hard to shift into neutral with the engine off on a slope. That is why you need a good parking brake. Turning engine off in gear...no bueno.

You had the Bearcat 454 4x4? Two-range trans, correct? No full auto trans offered?

Oldpath05 · May 30, 2019

dfkrug said:
I would say most semi-auto ATVs are hard to shift into neutral with the engine off on a slope. That is why you need a good parking brake. Turning engine off in gear...no bueno.

You had the Bearcat 454 4x4? Two-range trans, correct? No full auto trans offered?

Yup and I liked the rocker shifter on it to, noval idea, wished they still made them, now there all belt drive auto, but maybe someday I'll fix the old one back up if I can still get parts for the motor and transmission.

js5020 · May 30, 2019

I needed to juggle some equipment around today which involved getting all the quads out of the shed. Took notice the cat 300 now has 778 miles on it, even with the low miles time is taking its toll on things like hoses, seals, and such so it's waiting it's turn to be run through the shop. One of the things I was doing some research on was an overbore kit to get some more ccs out of the engine, but although I have read about the kits I cannot seem to find one easily. The 300 is mostly used as a work quad and does the majority of snow removal and doubles as a spare trail machine so I would like to keep it around.

Oaktree · Jun 7, 2019

js5020 said:
I suppose my question would be why a full manual transmission? As I said I have a semi manual and honestly it's a pita once you have used an "automatic". No one and I do mean no one wants to ride the 5 speed all day long on the trails, they will take any of the auto machines over shifting all day long.

I was thinking the same thing. A lot of my riding is over some pretty rough trails that can be enough of a handful without the hassle of shifting. The two ATVs I've had...a late 80s-vintage Polaris and my current CanAM both had the CVT and I wouldn't trade it. Yeah, dirt bikes are manual (or at least any I've had were), but they're not a work vehicle where you've carrying tools, equipment, etc.

dfkrug said:
AC was late to the ATV world, so they partnered up with Suzuki on the drivetrain, starting with the AC 300/KingQuad300.

AC uses Suzuki engines in some of their snowmobiles too, my 660 4 stroke has one. Smooth and very quiet, biggest problem is that cooling is barely adequate in loose snow, tends to overheat if trails are icy.