🏷️ Basic Information

Make:

Suzuki

Model:

LT250R / LTR250 Quad Racer

Model Nickname:

Quad Racer

Product Name:

Suzuki LT250R LTR250 Quad Racer Complete Workshop Service Repair Manual 1985 1986 PDF Download

Generation Identifier:

First Generation

Engine Code General:

246cc Liquid-Cooled Two-Stroke Single-Cylinder

👋 Introduction

Category:

High-performance sport ATV

Target Audience:

Enthusiast riders, racers, and DIY mechanics seeking to maintain and repair their Suzuki LT250R/LTR250.

Key Competitors Era:

Honda TRX250R, Yamaha YFZ250 (Banshee, though introduced slightly later), Kawasaki Tecate-4.

Vehicle Defining Traits:

Renowned for its powerful two-stroke engine, agile handling, and competitive performance in its class during the mid-to-late 1980s.

Manual Value Proposition:

Provides essential knowledge for maintaining optimal performance, diagnosing issues, and executing repairs, thus extending the lifespan and value of the vehicle.

📋 Manual Details

Manual Coverage Scope:

Comprehensive service, repair, and maintenance for the specified model years.

Estimated Page Count:

Likely exceeds 300 pages based on typical workshop manuals for this era.

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Systems:

Engine removal and installation, cylinder head, cylinder block, piston, crankshaft, connecting rod, carburetor (Mikuni VM Series), cooling system (radiator, fan, coolant), lubrication system, ignition system (CDI, spark plug), exhaust system.

Transmission Systems:

Gearbox internal inspection and repair, clutch operation and adjustment, shift lever mechanism, final drive (chain and sprockets).

Chassis Systems:

Frame inspection and repair, front suspension (A-arms, shocks, steering components), rear suspension (swingarm, linkage, monoshock), wheels and tires, braking system (front and rear discs, master cylinders, calipers, brake lines), steering system (handlebars, steering stem, bearings).

Electrical Systems:

Wiring diagrams, lighting system, battery, charging system (stator, regulator/rectifier), ignition coil, starter motor (if applicable, though unlikely for this model's era), kill switch, handlebar controls.

Bodywork And Trim:

Fenders, plastic body panels, seat, fuel tank, decals, graphics.

Maintenance Procedures:

Routine checks, oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid flush, coolant checks, general cleaning.

Repair Procedures:

Engine rebuilds (top-end and bottom-end), carburetor overhaul, suspension servicing, brake caliper rebuilds, clutch replacement, electrical component diagnosis and repair, steering bearing replacement.

Troubleshooting Guides:

Diagnostic charts for common starting issues, performance problems, electrical faults, and operational anomalies.

Special Tools And Techniques:

Identification and usage of specific Suzuki special tools required for certain procedures, torque specifications, alignment procedures.

Diagnostic Capabilities:

In-depth diagnostic procedures for mechanical and electrical systems, including step-by-step troubleshooting flowcharts and component testing methods.

Rebuild Instructions:

Detailed, step-by-step instructions for complete engine, transmission, suspension, and brake system rebuilds, including exploded diagrams and parts identification.

Specification Details:

Comprehensive technical data, including all crucial measurements, clearances, tolerances, torque specifications, fluid capacities, and electrical resistance values.

📊 Manual Specifications

File Type:

PDF

Searchable Text:

Likely, as most modern PDF manuals are generated with OCR or embedded text.

Print Readability:

Designed for clear printing with legible diagrams and text.

Binding For Digital:

N/A (Digital Download)

Paper Type For Printed:

N/A (Digital Download - intended for printing on standard paper)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 2-stroke, single-cylinder

Displacement:

246 cc (15.0 cu in)

Bore X Stroke:

66.0 mm x 72.0 mm (2.60 in x 2.83 in)

Compression Ratio:

6.5:1 (typical for this era, verify specific year)

Carburetor:

Mikuni VM28SS (single, slide type) or similar

Ignition:

CDI (Capacitor Discharge Ignition)

Starting System:

Kick starter

Cooling System:

Liquid-cooled with radiator and fan

Horsepower Estimated:

Approximately 30-35 HP (actual figures may vary and are often not officially published for ATVs of this era).

Torque Estimated:

Strong low-end and mid-range torque characteristic of performance 2-strokes.

Fuel Type:

Unleaded gasoline with 2-stroke oil pre-mix (ratio specified in manual, typically 20:1 or 32:1).

Fuel Tank Capacity:

Approximately 2.5 - 3.0 gallons (9.5 - 11.4 liters), depending on year.

🔧 Transmission

Transmission Type:

6-speed, constant mesh, sequential manual

Clutch Type:

Wet, multi-plate, manual operation

Final Drive:

O-ring sealed chain, 520 pitch (typical)

Gear Ratios:

Specific gear ratios are detailed within the manual for each of the 6 forward gears and reverse (if applicable).

Lubricant:

Manual will specify SAE 80W API GL-4 or GL-5 gear oil for the transmission/final drive housing.

📐 Dimensions

Overall Length:

Approximately 71.1 in (1805 mm) for 1985, may vary slightly for 1986.

Overall Width:

Approximately 47.6 in (1210 mm) for 1985, may vary slightly for 1986.

Overall Height:

Approximately 42.9 in (1090 mm) for 1985, may vary slightly for 1986.

Wheelbase:

Approximately 49.2 in (1250 mm) for 1985, may vary slightly for 1986.

Dry Weight:

Approximately 360-370 lbs (163-168 kg), depending on year and specific equipment.

Ground Clearance:

Typically around 5.5-6.0 inches (140-150 mm).

🛡️ Safety Features

Atv Safety Standards:

Manufactured to meet relevant safety standards for ATVs of the era; specific crash ratings are not applicable to this type of vehicle.

Braking System:

Dual front hydraulic disc brakes, single rear hydraulic disc brake for strong stopping power.

Tires:

High-profile knobby tires for optimal traction on varied terrain. Specific tire sizes are detailed in the manual.

Handlebar Protection:

Often equipped with handlebar pads for rider safety.

Footwells:

Integrated footwells with heel guards for rider foot protection.

💡 Technology Features

Infotainment Features:

N/A (This era of sport ATV did not feature infotainment systems.)

Driver Assistance Systems:

N/A (No electronic driver assistance features are present on this model.)

Connectivity Features:

N/A (No connectivity features are present on this model.)

🔧 Maintenance

Oil Change Recommendation:

Regular oil changes for the transmission/final drive are critical. Intervals will be specified (e.g., every 20-30 hours of operation or annually).

Spark Plug Service:

Regular inspection and cleaning/replacement of the spark plug based on usage and performance.

Chain Maintenance:

Frequent cleaning, lubrication, and adjustment of the drive chain are essential for longevity and performance.

Air Filter Maintenance:

Crucial for engine longevity; requires regular cleaning and re-oiling, especially in dusty conditions.

Transmission Fluid:

SAE 80W API GL-4 or GL-5 gear oil. Manual will specify precise type and capacity.

Coolant Type:

Permanent type antifreeze coolant (ethylene glycol based), typically a 50/50 mix with distilled water. Manual will provide specific details.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid, as specified in the manual.

2 Stroke Oil Recommendation:

High-quality 2-stroke engine oil suitable for air-cooled or liquid-cooled performance engines, used for pre-mixing with fuel at the specified ratio (e.g., 20:1, 32:1).

Common Wear Items:

Piston rings, clutch plates, wheel bearings, steering head bearings, shock seals, and carburetor jets are common wear items requiring periodic inspection and replacement.

Carburetor Issues:

Clogging due to fuel deposits, worn needle valve, or incorrect jetting can affect performance.

Cooling System Performance:

Overheating can occur if the radiator is blocked, the fan is not operating, or coolant levels are low. The manual details checks for these.

Suspension Wear:

Degraded shock absorbers and worn bushings can impact handling and ride quality.

📚 Vehicle History

Suzuki Atv Legacy:

Suzuki has a long and successful history in ATV manufacturing, with the LT series being instrumental in establishing their reputation.

Lt250R Introduction:

The LT250R was introduced as a performance-oriented sport ATV, building on Suzuki's experience with two-stroke engines and off-road racing.

1985 Model:

The inaugural model, setting the standard for the Quad Racer line with its potent engine and agile chassis.

1986 Model:

Refinements and minor updates likely applied to the 1986 model, building on the success of the initial release. Specific differences are detailed within the manual.

Manufacturing Era:

Mid-1980s sport ATV era, a highly competitive and innovative period for ATV development.

🏆 Awards & Recognition

Racing Success:

The LT250R was a dominant force in ATV racing during its production years, achieving numerous victories and championships in various off-road disciplines.

Performance Acclaim:

Widely praised by automotive journalists and riders for its potent engine, sharp handling, and overall performance capabilities, cementing its status as a legendary sport ATV.