Suzuki 500

[Gizmo36]

I have a Suzuki Quad Master 500 4X4 it only has 800 miles on it . it stop pulling I thought it was the belt. Pull the cover off the belt looks new .what would be the next thing that would brake .It is going to be in the transmission.I need all the help I can get.I have never work on one before.

 

[graybeard451]

I've never worked on one, but it looks like the same kind of drive as a snowmobile which I have repaired. The belt can "look" good but if it's narrower that it's standard it will not pull from a start. The other thing that can mess up with snowmobiles would be if one of the pulleys is sticking and doesn't change size like it's designed. I don't think there would be anything in the transmission that could keep it from pulling unless it had no oil and it was getting ready to lock up. One last thing to check would be to make sure the brakes are not dragging. Good luck and let us know how you made out.

Richard

 

[crazylare1]

Hey there, behind the clutch there is another centrifical clutch, the problem is more than likely there. Make sure that there isn't anything going to get into the moving belt clutches, attach the ground lead to a good ground ( you should have had to disconnect it to remove the cover and put it out of the way of the moving pulleys) then make sure the quad is in neutral, start it up and give it some throttle and see if the belt pulleys are doing their thing. The pulley in the front should squeeze together and the larger one in the back should go apart to let the belt lower itself into it. If this is happening then hold the brake (someone to assist would be recommeded) and put it in gear then give it some throttle see if it also works the same way, if not or if it doesn't work as stated above then the centrifical clutch isn't working, if everything works that you can see then something may be wrong inside the trans itself. If it is the clutch behind the outer clutch then you may want to purchase a repair manual from your local dealer or online. I hope this helps alittle. Have a great week! Let us know what you find. And most of all good luck with your repairs I hope it is simple and easy.
Lar

 

[Gizmo36]

I started it up put it in gear and ever thing works right. there is a big spring behide the big one in the back .I think i will have to take the transmission apart .has any one ever had one apart.

 

[ovrszd]

I started it up put it in gear and ever thing works right. there is a big spring behide the big one in the back .I think i will have to take the transmission apart .has any one ever had one apart.

I like to apply the K.I.S.S. principle, are you sure the transmission selector is in fact putting the transmission in gear?? Maybe unhook the linkage and mover the selector lever on the transmission by hand to make sure it is working??? I would try anything to prevent taking the tranny apart. Good Luck.

 

[Gizmo36]

I have not , but I will that may be what it is.

 

[kenmac]

I have a polaris 400 auto. This happened to me & I found out the problem was in the rear or secondary clutch I made the repairs for around $30.00.Hey Gizmo, Check out fourms.atvconnection.com & click on the sizuki link ask these guys .That's how I found what was wrong with my polaris. I looked at your picture. With the back wheels off the ground, Put it in gear with the belt cover off . Give it gas & watch the belt it should start to climb the front clutch. while, the rear clutch should open up & the belt will fall lower into the groove. BEE CAREFULL WITH THAT CLUTCH COVER OFF !!!!! Don't let it grab your clothing or body parts

 

[Gizmo36]

The belts and the rear clutch all work right.it just don't move the wheels.thinks for the web site i am look at it.

 

[kenmac]

can you hear any noises like it's trying to move ?Mabe it's not going into gear

 

[Gizmo36]

It sounds like it allways did .When I hit the gas it made a pop sound and did not move .I has not made any more sounds the clutchs turn the belt gose up and down on the Clutch's.The Suzuki place wants 85$ and hour to work on it .I give it to some one for parts before I will pay that.

 

[ovrszd]

It sounds like it allways did .When I hit the gas it made a pop sound and did not move .I has not made any more sounds the clutchs turn the belt gose up and down on the Clutch's.The Suzuki place wants 85$ and hour to work on it .I give it to some one for parts before I will pay that.

Sounds like it has a physical break inside the transmission. If checking the linkage like I suggested doesn't help, then plan on taking the transmission apart. One last KISS principle item would be to ensure the rear clutch is turning the transmission shaft?? That clutch is keyed onto the trans shaft with a taper and a halfmoon key. There is a small chance that it has sheared that key and the clutch is spinning on the shaft. Still grabbing at straws here, but anything to keep from tearing the tranny apart. So if the clutch is truly turning the tranny shaft, next stop is opening the tranny. If you are even moderately mechnical, you can accomplish this task. Get yourself a big working area where you can lay out each piece as it's removed. Go slow. Have a clean area, including a very clean floor so when that spring or checkball gets away from you it's not lost in floor debris. The kitchen table is an idea that pops in my head but unfortunately is not seen in the wife's vision!!!! Good Luck and keep us posted!!!!

 

[Gizmo36]

halfmoon key, Man I hope that is what it is .I will look and let you know.

 

[Gizmo36]

That was not it ,it's going to be in the transmission .maybe I can find some one that wants to do some good deer hunting and do some trading on some work.

 

[ovrszd]

That was not it ,it's going to be in the transmission .maybe I can find some one that wants to do some good deer hunting and do some trading on some work.

Bummer Gizmo. Good Luck my friend!!!

 

[dsb5610]

Gizmo36,

Did you verify the transmission selector is actually working? A poster mentioned that but I didn't see your reply, maybe I missed it.

If the trans selector is working, with the clutch off, if you put the transmission selector in each forward and reverse position and turn the trans input shaft by hand the wheels should start to turn. One poster mentioned jacking the rear end up. This would make it easier assuming you can switch from 4x4 to 2x4. If the trans input shaft turns without the wheels moving then I don't see any option other than opening the trans.

dsb

 

[Gizmo36]

the transmission selector is working ,I forgot to post that .I need to go get me a Service Manuals .

 

[TOMMYHPX4X4]

That was not it ,it's going to be in the transmission .maybe I can find some one that wants to do some good deer hunting and do some trading on some work.

when you turn that rear shaft does it turn freely when in gear or does it turn the wheels. did you check the splines on the clutch pulley itself?

 

[Gizmo36]

When I turn the rear shaft it does turn freely when in gear and out of gear.

 

[TOMMYHPX4X4]

internal gear is shot. get a manual for about $40.00 i had a honda 125 four trax and the gear went out sorta like that and it cost like 65 bucks. but with a manual it was a piece of cake to change. if your machanicly inclined guy it should be about 3 hours worth of work at the most.