Vehicle Types:
All-Terrain Vehicles (ATVs)
Models Covered:
LT230S, LT230G, LT230GE, LT-F230G, LT250S
Years Covered:
1985, 1986, 1987, 1988, 1989, 1990
Product Name:
Suzuki LT230S LT230GE LT250S Service Manual Repair 1985-1990 PDF Download
Target Audience:
DIY enthusiasts, ATV owners, independent repair shops seeking detailed repair and maintenance information for specific Suzuki ATV models.
Value Proposition:
Provides a consolidated and comprehensive resource for a range of Suzuki ATVs from a specific era, offering detailed procedures and specifications crucial for effective maintenance and repair.
Manual Highlights:
Comprehensive coverage, detailed diagrams, specific torque values, searchable PDF format, no printing restrictions, free replacement support.
Primary Coverage:
Complete tear down and rebuild, maintenance, troubleshooting
Specific Topics:
Pictures, part diagrams, torque specs, fluid specifications, valve clearance, engine overhaul, transmission repair, brake service, electrical system diagnostics, suspension adjustments
Manual Type:
Aftermarket Service/Repair Manual
Authenticity Note:
Not a factory manual
Digital Features:
Clickable chapters, searchable text
Usage Rights:
No restrictions on printing or saving/burning to disc
Replacement Policy:
Free replacement offered for lost manuals
Powertrain:
Engine (top-end, bottom-end, lubrication, cooling), Transmission (gearbox, clutch, drive shaft), Fuel System (carburetor, fuel pump), Exhaust System
Chassis:
Frame, Suspension (front forks, rear swingarm, shocks/struts), Steering System, Brakes (front and rear calipers, rotors, master cylinders, lines, pads), Wheels and Tires
Electrical:
Ignition System (stator, CDI, spark plug), Charging System (magneto, rectifier), Lighting System, Battery, Switches
Body Panels:
Fenders, plastics, seat, tank, handlebars
Maintenance:
Oil change schedule, fluid level checks, lubrication points, air filter cleaning/replacement, spark plug gap and replacement, chain adjustment, brake pad inspection/replacement, tire pressure checks
Repair Overhaul:
Complete engine rebuild, transmission overhaul, carburetor rebuild and tuning (jetting, mixture screw adjustment), brake system bleeding and caliper service, suspension component replacement, steering linkage service, electrical component testing and replacement
Troubleshooting:
Diagnostic guides for common problems such as starting issues, no spark, poor performance, hard shifting, brake problems, and electrical faults. Includes error code diagnosis if applicable.
Installation:
Procedures for installing common aftermarket parts or replacing major components.
Depth Level:
Comprehensive (covers detailed component disassembly, inspection, measurement, and reassembly)
Data Availability:
Detailed torque specifications for critical fasteners, valve clearance specifications, engine bore and stroke dimensions, compression ratio data, fluid capacities, and viscosity recommendations.
Engine Type:
Four-stroke, air-cooled, single-cylinder (typical for these models)
Displacement Lt230S:
229cc (approx.)
Displacement Lt250S:
246cc (approx.)
Bore X Stroke Lt230S:
Refer to manual for specific measurements (e.g., typical approx. 69mm x 62.2mm)
Bore X Stroke Lt250S:
Refer to manual for specific measurements (e.g., typical approx. 72mm x 61.2mm)
Compression Ratio:
Refer to manual for exact specifications (typically around 9.0:1 to 10.0:1)
Horsepower Lt230S:
Refer to manual for exact figures (estimated 16-18 HP)
Horsepower Lt250S:
Refer to manual for exact figures (estimated 18-20 HP)
Carburetor Type Lt230S:
Mikuni VM series (e.g., VM26SS common)
Carburetor Type Lt250S:
Mikuni VM series (e.g., VM28SS common)
Fuel Type:
Unleaded gasoline
Fuel Pump:
Mechanical diaphragm pump
Carburetor Adjustments:
Idle speed, air-fuel mixture screw, jetting (main jet, pilot jet, needle position)
Oil Type:
API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for exact Suzuki specification)
Oil Capacity:
Refer to manual for specific capacity (typically around 1.5 - 2.0 liters)
Cooling Method:
Air-cooled
Ignition System:
CDI (Capacitor Discharge Ignition)
Spark Plug Type:
Refer to manual for specific plug type and gap (e.g., NGK DPR8EA-9 common)
Transmission Type:
5-speed constant mesh manual transmission
Clutch Type:
Wet, multi-plate
Gear Ratios:
Refer to manual for detailed gear ratios
Drive Type:
Chain drive (LT230S, LT250S) or Shaft drive (LT230G, LT230GE, LT-F230G)
Reverse Gear:
Yes (standard on most models)
Transmission Oil Type:
Gear oil (refer to manual for specific viscosity and API rating, often GL-4 or GL-5)
Transmission Oil Capacity:
Refer to manual for specific capacity (typically around 0.5 - 0.8 liters for gearbox)
Length:
Refer to model-specific specifications in manual (e.g., LT230S around 73 inches)
Width:
Refer to model-specific specifications in manual (e.g., LT230S around 44 inches)
Height:
Refer to model-specific specifications in manual (e.g., LT230S around 43 inches)
Dry Weight:
Refer to model-specific specifications in manual (e.g., LT230S around 330 lbs)
Fuel Tank Capacity:
Refer to manual for specific capacity (typically around 2.5 - 3.0 gallons)
Ground Clearance:
Refer to manual for specific measurements (e.g., LT230S around 5.9 inches)
Safety Standards:
ATV safety standards of the era, manufacturer-recommended operating procedures.
Braking System:
Hydraulic disc brakes front and rear (LT230S/LT250S) or drum/disc combinations depending on model year and configuration. Shaft drive models may have different configurations.
Throttle Limiter:
Potential for aftermarket or factory modifications to limit throttle response for novice riders.
Rollover Protection:
N/A (ATVs typically do not have factory-installed rollover protection systems; operator awareness and safety gear are paramount)
Operator Training:
Emphasis on proper riding techniques, protective gear (helmet, goggles, boots, gloves, protective clothing), and understanding ATV limitations.
Infotainment System:
N/A (These are utility/recreational ATVs from the 1980s, lacking advanced infotainment systems.)
Driver Assistance Features:
N/A (No electronic driver assistance features available on these models.)
Connectivity Options:
N/A (No connectivity options.)
Lighting System:
Halogen headlights and taillight for illumination and visibility. Manual covers bulb replacement and wiring.
Engine Oil Change:
Refer to manual for specific interval, typically every 100-200 hours or annually. Clean the oil screen during oil changes.
Air Filter Service:
Inspect and clean every 10-20 hours of operation, depending on conditions. Replace as needed.
Spark Plug Replacement:
Refer to manual for interval, typically every 200-400 hours or annually. Check and adjust gap periodically.
Chain Adjustment Lubrication:
Inspect and adjust chain tension and lubricate every 10-20 hours. Replace chain and sprockets when worn.
Brake System Maintenance:
Inspect brake pads, rotors, and fluid levels regularly. Flush and replace brake fluid every 1-2 years.
Valve Clearance Adjustment:
Refer to manual for initial adjustment interval and subsequent checks, typically around 200-400 hours.
Engine Oil Viscosity:
SAE 10W-30 or 10W-40 recommended (confirm with manual)
Transmission Oil Viscosity:
Refer to manual for specific gear oil viscosity (e.g., SAE 80 or 85W-90)
Brake Fluid Type:
DOT 3 or DOT 4 recommended (confirm with manual)
Carburetor Problems:
Clogged jets, fuel leaks, idle instability, bogging issues due to gummed-up fuel or worn components.
Electrical System Issues:
Faulty stators, weak charging systems, worn wiring harnesses, switch failures leading to no-spark or lighting problems.
Suspension Wear:
Worn fork seals, shock absorbers losing damping, worn bushings in the swingarm and steering head.
Drive Train Wear:
Stretched drive chains, worn sprockets, worn U-joints (on shaft drive models), worn wheel bearings.
Suzuki Atv Legacy:
Suzuki has a strong history in ATV manufacturing, known for reliable and performance-oriented machines. The LT-series ATVs were popular in their time for recreational use and utility.
Lt230 Series:
The LT230 platform was a versatile offering, available in both chain-drive (LT230S Quadsport) for sporty performance and shaft-drive (LT230G/GE Quadrunner) for simplicity and durability. The LT-F230G was a variant of the shaft-drive model.
Lt250S:
The LT250S was a more performance-oriented sibling to the LT230S, offering increased displacement and generally higher specifications for a more aggressive riding experience.
Production Period:
1985-1990 for the specific models covered by this manual.
