Product Category:
High-performance sport ATV
Target Audience:
Enthusiasts, racers, and DIY mechanics seeking to maintain and repair their Suzuki LT250R.
Key Competitors Era:
Yamaha YFZ250 'Banshee' (later models), Honda TRX250R.
Manual Advantage 1:
Instant digital download, eliminating shipping delays.
Manual Advantage 2:
Printable format allows for custom binding and field-use convenience (less risk of damaging an original manual).
Manual Advantage 3:
Provides dealership-level repair information for DIY use.
Primary Coverage:
Complete Service, Repair, and Workshop Manual
Additional Coverage:
General Information, Engine, Transmission, Chassis, Steering, Suspension, Brakes, Electrical System, Fuel System, Lubrication, Frame, Clutch, Seats System, Locks, Lightning
Estimated Page Count:
Likely 300+ pages (typical for full workshop manuals of this era, specific count not provided)
Type:
Workshop Service Repair Manual
Format:
PDF (Adobe Acrobat)
Engine:
Complete disassembly, assembly, inspection, overhaul, tuning, and troubleshooting of the 250cc 2-stroke engine.
Transmission:
Gearbox disassembly, inspection, repair, lubrication, and adjustment procedures.
Chassis And Frame:
Frame inspection, repair, and component mounting; including suspension and steering linkages.
Suspension:
Front and rear suspension component inspection, maintenance, adjustment (preload, damping), and overhaul. Includes shock absorbers, swingarm, and linkages.
Brakes:
Front and rear brake system maintenance, bleeding, caliper overhaul, pad replacement, and rotor inspection. Likely covers hydraulic systems.
Steering:
Steering system inspection, adjustments, tie-rod ends, and bearing maintenance.
Electrical System:
Wiring diagrams, ignition system troubleshooting, lighting, battery service, charging system inspection.
Fuel System:
Carburetor disassembly, cleaning, tuning, fuel tank maintenance, and fuel line inspection.
Clutch:
Clutch mechanism inspection, adjustment, and replacement of components (plates, springs).
Lubrication:
Lubrication points, fluid types, and recommended service intervals for various components.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, air filter cleaning, spark plug replacement, brake adjustments.
Troubleshooting:
Diagnostic procedures for common issues related to engine performance, starting, electrical faults, and braking.
Engine Rebuild:
Detailed steps for complete engine teardown, component inspection (piston, rings, cylinder, crankshaft, bearings), and reassembly.
Component Overhaul:
Step-by-step instructions for overhauling the carburetor, brakes, and other key components.
Adjustment Procedures:
Carburetor jetting and idle adjustment, clutch cable adjustment, chain slack adjustment, suspension settings.
Wiring Diagrams:
Comprehensive electrical schematics for easy troubleshooting and repair.
Depth Level:
Comprehensive, covering all aspects from basic maintenance to full engine and transmission rebuilds.
Diagnostic Capabilities:
Includes troubleshooting flowcharts and symptom-based diagnostics.
Rebuild Instructions:
Detailed disassembly and assembly procedures with torque specifications and clearances.
Engine Type:
2-Stroke, Single Cylinder
Displacement:
246 cc (for 1985-1986 models)
Bore X Stroke:
66.0 mm x 72.0 mm (typical for this engine family, confirm in manual)
Cooling System:
Liquid-Cooled
Ignition:
CDI (Capacitor Discharge Ignition)
Horsepower Estimate:
Approx. 25-30 HP (stock, varies by tuning and year)
Torque Estimate:
Approx. 20-25 lb-ft (stock, varies by tuning and year)
Carburetor:
Mikuni VM34SS (or similar, common for the era)
Fuel Type:
Unleaded gasoline (87-91 octane recommended), 2-stroke oil pre-mix (ratio specified in manual)
Oil System:
Premix fuel/oil, separate oil injection system (confirm specific model variant)
Length:
Approx. 70.1 inches (1780 mm) (typical, confirm in manual)
Width:
Approx. 46.1 inches (1170 mm) (typical, confirm in manual)
Height:
Approx. 42.3 inches (1075 mm) (typical, confirm in manual)
Dry Weight:
Approx. 357 lbs (162 kg) (typical, confirm in manual)
Fuel Capacity:
Approx. 2.6 gallons (9.8 L) (typical, confirm in manual)
Engine Oil Change:
Refer to manual for specific hours or mileage, typically every 20-30 hours of operation for sport ATVs.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions. Details in manual.
Chain Lubrication Adjustment:
Regularly, as per manual recommendations (e.g., every 500 miles or 50 hours).
Spark Plug Replacement:
Refer to manual, typically every 100-150 hours or as needed based on condition.
Engine Oil Type:
Suzuki recommends specific 2-stroke engine oil for premix or oil injection (details in manual). Typical viscosity: SAE 10W-30 or 10W-40 for transmission/gearbox if separate.
Coolant Type:
Ethylene glycol-based antifreeze/coolant (50/50 mix with distilled water), specific type in manual.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (confirm in manual).
Common Wear Items:
Piston rings, clutch plates, carburetor jets, suspension bushings, brake pads/rotors.
Engine Carburation:
Carburetor can be sensitive to altitude and temperature changes, requiring re-jetting. Common issue addressed in manual's tuning section.
Clutch Slippage:
Can occur with hard use; manual provides inspection and replacement procedures.
Suspension Wear:
Bushings and seals in suspension can wear, leading to looseness; manual covers replacement.
Manufacturer:
Suzuki Motor Corporation
Lt250R Introduction:
Introduced in the mid-1980s as Suzuki's flagship sport ATV, built for performance and racing.
Key Upgrades 1985 Vs 1986:
While specific year-to-year changes are often subtle in early models, 1986 saw some refinements over the inaugural 1985 model. Manual will detail these.
Production Period Covered:
1985-1992 (with this manual covering the initial phase)
