Just was wondering if someone could help me out with a diagnosis. Long story short, today I was making some stream passes and some of the streams had very steep decline/inclines as banks. I HAVE NO BRAKES. I KNOW I KNOW< GET THEM FIXED. Anyway, usually using differential lock in first gear/super low keeps the quad really slow and steady down these banks. So I did this probably up and down and through streams three times when all of a sudden the quad made a couple clicking noises, then locked up. Engine was still running, no problem. I put it in neurtal, pushed it back and forth from the back and finally it broke free. So all is good then, and I proceed to the next stream. While going down the decline loud clicking noises came from the differential lock, it still slowed me down the same. I checked to see if all four wheels were spining when throttled, and they were, no problem there. So I try to ignore the clicking and once past all of the water I pulled it out of Differential lock/super low and changed into high/4x4. First of all it was a real hassle trying to get it out of differential lock, then after changing to 4x4 it now clicks except in reverse???? Everything is working properly, but that clicking is really loud and sounds like it could be doing some damage to the engine braking "system". Someone please help if you have ever expereinced this.

P.S.- The clicking goes away when put into 2wd. Is there a differential fluid level I am supposed to be checking???? Sorry I am pretty new at this.

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1995 KQ 300 - OLDSCHOOLQUAD

The differenical oil in the front diff might be contaimated with water, but without a manual to show you where the plug's are located i wouldn't be much help ; there's 2 plug's in the front diff where you drain the old gear oil and one up high is the filler plug !

Is your 95 KQ the 300 ? I had a 1993 Suzuki LT4WD 300 KQ that my Late Cousin bought 2 week's before the Blizzard of 93' ; we didn't ride creek's as much on the KQ as we did with his first Quad a 1989 Suzuki LT4WD 250 Quad Runner !

After we sank his 89' LT4WD 250 Quad Runner the beaver Damed up the creek where it was to deep to go up and down it in later years , i would drain the diff and refill it with new gear oil ; you need to fill it with SAE 80 W 90 Hypoid gear oil !

This maybe what is causing the clicking noise , if you've never changed the gear oil before this could be the problem ; you can use the gear oil from the dealer or get it at most any Auto Parts Stores !

I would get a shop manual it will pay for itself in no time , i have a service manual that cover's the Suzuki LT4WD 250 Quad Runner it's basically the same Quad only the 300 has a little more CC's and larger tire's and wheel's !

If you ride in creek's alot most likely the differenical oil has gotta water in it contaminating the gear oil , there's 2 plug's in the front diff they're located in the front near the right front tire on the 250 ; one above and one below they are in the part painted black !

I have no way to scan the page , the diff oil should be changed annually ; more if you ride creek's alot i would change the gear oil most likely it's contaimated with water !

The front differenical on the LT4WD 250 held 5.1 oz of SAE 90 Hypoid gear oil , the 300 KQ held about the same as the 250 you can find this info on one of the Parts schematics on line like bikebandit.com ; or the many site's that sell Suzuki Parts there are some better than bikebandit.com this is just the first one that come's to mind !

I wish i could be of more help , but i don't have a way to scan the page that show's where the drain plug and fill plug are located ; this manual i have doesn't go into great detail because it cover's so many makes and model's of ATV's sorry i couldn't be of more help !.......

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williebee

Sure sounds like it's contained to the front drive system. Possibly U-joint on the front drive shaft? Maybe if you put the quad up on blocks and run it in 4wd you'll be able to hear and see what's going on.

Jaybee

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'07 Outlander 800 XT Camo
'02 Eiger 5-sp
'02 Ozark
'96 TRX90

Old rides: '89 Warrior, '93 KQ 300, '97 Warrior, '84 LT50, '98 LT80

'07 GMC Sierra 2500HD DMax
25' six-place flatbed trailer

Thanks jaybeecon55, I will probably be putting it up and trying to locate the problem. I did not know that the 95 KQ 300 took differential fluid. I was told just alot of oil and that it took care of everything (minus the brake cylinder). I will definately have to look into that on the microfiche to try to locate where to drain and where to fill the differential fluid. Is it possible to put to much pressure on the differential to cause it to slip? It makes the loud pop when going down a steep decline only, not while going up. I really need to get that manual being that I am so mechanically declined or nieve anyway. I just hope I haven't damaged anything by cruising terrain that I probably shouldn't have without the aid of brakes. Will using the engine to slow me down until I get my brakes fixed hurt the engine or lessen it's life? I am thinking that any strain of any kind could hurt an engine, am I right?

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1995 KQ 300 - OLDSCHOOLQUAD

I don't think it's a matter of strain on the engine, more of a strain on the drive train. I would expect that the weak link in the KQ drive system would be the U-joints. I know that the rear tend to wear out - symptoms are a knocking or clicking noise that varies depending on uphill/downhill travel or if using 2wd or 4wd.

Jaybee

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'07 Outlander 800 XT Camo
'02 Eiger 5-sp
'02 Ozark
'96 TRX90

Old rides: '89 Warrior, '93 KQ 300, '97 Warrior, '84 LT50, '98 LT80

'07 GMC Sierra 2500HD DMax
25' six-place flatbed trailer

From what I can see, my '97 has a drain plug in the bottom, a fill plug on the top and a fill indicator plug in the right hand side of the casing (when sitting on the atv). Pull the bottom plug and drain the oil and then replace the plug. Next, take out the top and side plugs, pour oil into the top plug until you see it start to run out of the side plug. You will need a funnel with a hose on the end to get the oil into the differential. I would do this with mine but I have to get the input shaft seal replaced due to a slow leak.


EDIT:

I changed my diff oil last night and took the top 'plug' out, it turns out what I said above about three plugs in the diff is wrong, the 'plug' on the top left of the pumkin is actually the differential lock stopper, see # 9, 10 , 11, & 12 of this diagram:
http://images.powersportsnetwo...1996/ATVs/1858_22.gif

Don't take it out because it's a bit tricky to line the parts up and get it all back in, I had to use some hard grease to get parts 9 & 11 to stop falling out of the plug and stopping the plug from going in. It's a good thing I did take it out thought because it was falling out, only finger tight. Not sure what would have happened if it had fallen out on the trail, if you're down there might as well check to see if it's tight.

To change your diff oil remove the front skid plate, take out the bottom drain plug and let the oil drain. Next take out the plug in the side of the diff (on the same side as the front brake handle) and fill it with 80w 90 hypo until it starts to come back out. You will need to get a bottle with a small tip on it and a piece of hose that will fit over the tip and into the filler hole, in order to direct the oil into the diff.

While doing this I also replaced the front brake vent lines and discovered one of the drain plugs in the brake backing plate is missing, off to the dealer for me....

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EastCoastWest
2007 Ski-doo GTX 500SS 9225 km
1997 Suzuki KQ 300 showing 1320 km but I know it's higher than that.

Edited: 05/06/2008 at 05:46 AM by EastCoastWest

Well, you just described my rear end clicking to a tee. So how much are these u-joints? Looks like I definately need one on the right hand rear, it clicks quite often when turning or changing gears. As for the front diff, I am going to have to change that gear oil. I hope that is all it is. It clicks very loudly while in 4 wheel drive and diff lock. Are the u-joints something I could change out myself or is it something that should be done by someone with experience? Thanks guys, thanks alot. Learning more and more everyday.

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1995 KQ 300 - OLDSCHOOLQUAD

Bump
(edited my last post)

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EastCoastWest
2007 Ski-doo GTX 500SS 9225 km
1997 Suzuki KQ 300 showing 1320 km but I know it's higher than that.