Market Position:
The Suzuki LT250R QUAD was a prominent sport ATV in its era, competing directly with models from Yamaha (Blaster/Banshee), Honda (TRX250R/300EX), and Kawasaki (Bayou/Mojave). It was known for its performance and handling, appealing to recreational riders and competitive racers.
Competitive Analysis:
The LT250R stood out with its liquid-cooled, 2-stroke engine, often featuring a robust powerband. Its chassis, derived from Suzuki's RM motocross bikes, provided excellent agility and suspension performance for its time. This manual caters to enthusiasts who value maintaining or restoring these capable machines.
Key Features:
Liquid-cooled 2-stroke engine, powerful performance, long-travel suspension, disc brakes front and rear, reliable Suzuki engineering.
Coverage Years:
1987, 1988, 1989, 1990, 1991, 1992
Region Of Origin:
Global (primarily North American and European markets)
Estimated Page Count:
Extensive (typical for comprehensive workshop manuals, often 300-500+ pages)
Manual Type:
Workshop Repair Manual / Service Manual
Engine:
Engine overhaul, disassembly, assembly, tuning, lubrication, cooling system, carburetor tuning, ignition system, exhaust system
Transmission:
Gearbox disassembly, inspection, assembly, clutch operation, shift mechanism
Chassis And Suspension:
Front suspension (A-arm, shock absorbers, steering), rear suspension (swingarm, shock absorber, linkage), wheel bearing maintenance, steering system
Brakes:
Hydraulic brake system, front and rear brake caliper service, master cylinder service, brake fluid bleeding, pad replacement, rotor inspection
Electrical System:
Wiring diagrams, lighting system, ignition coil, CDI unit, starter motor, battery maintenance, troubleshooting electrical faults
Fuel System:
Fuel tank maintenance, fuel lines, fuel filter, carburetor (Mikuni VM series) disassembly, cleaning, and adjustment
Bodywork And Controls:
Handlebar assembly, throttle control, brake levers, seat removal, fender maintenance, plastic panel replacement
Maintenance:
Regular maintenance checks, lubrication points, filter replacement, spark plug replacement, valve clearance adjustment (if applicable to the 2-stroke design, typically not), chain adjustment
Troubleshooting:
Diagnostic flowcharts for common problems, ignition system testing, carburetor issues, starting problems, suspension noise diagnosis
Repair:
Complete engine rebuild, gearbox repair, suspension component replacement, brake system overhaul, electrical component repair
Rebuilding And Restoration:
Detailed steps for component disassembly, cleaning, inspection, part replacement, and reassembly for a complete vehicle restoration
Technical Depth:
Comprehensive. Covers everything from basic fluid changes and adjustments to complete engine and transmission rebuilds, including detailed torque specifications and diagnostic procedures.
Engine Type:
2-stroke, liquid-cooled, reed valve inducted
Displacement:
246 cc (approx.)
Bore X Stroke:
66.0 mm x 72.0 mm (typical for this era)
Compression Ratio:
Approx. 7.2:1 (varies by year/model variant)
Horsepower Estimate:
30-35 HP (approx. at crank, varies by tuning and year)
Torque Estimate:
Approx. 20-25 lb-ft (varies)
Carburetor Model:
Mikuni VM Series (e.g., VM28SS or similar)
Fuel Type:
Unleaded gasoline (minimum 91 octane recommended), mixed with 2-stroke oil (e.g., SAE 10W-30 or specific 2T oil, typically 20:1 or 32:1 ratio)
Oil Type:
Suzuki CCI System (oil injection) or Pre-mix (depending on specific sub-model or modifications)
Safety Ratings:
N/A (ATVs are not subject to the same crash testing and safety rating systems as passenger vehicles. Emphasis is on rider skill and safe operation.)
Active Features:
Disc brakes front and rear, responsive steering, stable chassis geometry (for its class).
Passive Features:
Handlebar padding, integrated footwells with heel guards, throttle limiter (may vary by market/year).
Oil Change Interval:
Every 10-15 hours of operation or annually, depending on usage severity. Check manual for specific recommendations.
Air Filter Cleaning:
Every 5-10 hours of operation, or more frequently in dusty conditions.
Spark Plug Replacement:
Check and clean at 10-15 hours; replace at 20-30 hours or as needed based on condition.
Chain Adjustment Lubrication:
Check tension and lubricate every 5-10 hours of operation.
Transmission Oil Type:
API GL-4, SAE 80W-90 hypoid gear oil
Cooling System Coolant:
Mixture of permanent antifreeze and water (50:50 ratio), typically ethylene glycol-based.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
2 Stroke Oil Type:
Suzuki CCI system oil or high-quality 2-stroke oil meeting JASO FD or TC specifications.
Known Issues:
Carburetor jetting sensitivity to altitude and temperature, wear on clutch plates due to aggressive riding, potential for rear shock seal leaks, CDI unit failures (less common but possible), carburetor slide wear.
Preventative Maintenance:
Regular cleaning of the air filter and carburetor are crucial for maintaining optimal performance. Proper pre-mix ratios and quality oil are vital for engine longevity.
Brand Heritage:
Suzuki has a long and successful history in motorsports, including motocross and ATV racing. This heritage directly influenced the design and performance of the LT250R.
Model Evolution:
The LT250R was introduced as a significant upgrade over earlier Suzuki sport quads, benefiting from advancements in engine technology, suspension design, and chassis engineering shared with their RM motocross bikes. It paved the way for later models like the LT250S and the powerful LT500R 'Quadzilla'.
Production Period:
1987-1992 (This manual covers the second generation of the LT250R, which saw significant updates from the first generation.)
