Suzuki LT230 and LT250 Service Repair Manual 1985-1990

Models Covered:

• LT230S Chain Drive (1985-1988)
• LT-F230G Shaft Drive (1985-1987)
• LT230G Shaft Drive (1985-1986)
• LT250S Chain Drive (1989-1990)

This manual is a valuable resource for both professional technicians and first-time owners or amateurs. It provides easy-to-read instructions and all the necessary information to perform procedures correctly.

Keep this shop manual handy and use it regularly to perform routine and preventive maintenance. This will save you time and money by preventing premature failure and unnecessary repairs.

Manual Contents:

• QUICK REFERENCE DATA
• CHAPTER ONE / GENERAL INFORMATION
  • Manual organization
  • Service hints
  • Torque specifications
  • Safety first
  • Service hints
  • Special tips
  • Expendable supplies
  • Parts replacement
  • Serial numbers
  • Basic hand tools
  • Tune-up and troubleshooting tools
  • Mechanic's tips
  • Off road rules
  • Riding safely
• CHAPTER TWO / TROUBLESHOOTING
  • Operating requirements
  • Emergency troubleshooting
  • Engine starting
  • Engine performance
  • Engine noises
  • Excessive vibration
  • Front suspension and steering
  • Brake problems
• CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
  • Pre-ride checklist
  • Service intervals schedule
  • Periodic lubrication
  • Engine oil and filter change
  • Control cable lubrication
  • Non-scheduled lubrication
  • Periodic maintenance
  • Non-scheduled maintenance
  • Reverse cable adjustment
  • Tune-up
  • Valve clearance
  • Compression test check
  • Spark plug
  • Air filter
  • Specifications
• CHAPTER FOUR / ENGINE
  • Engine principles
  • Engine cooling
  • Serving engine in frame
  • Engine removal and installation
  • Cylinder head cover and rocker arm assembly
  • Cylinder head and camshaft
  • Valves and valve seats
  • Cylinder
  • Piston, piston pin and piston rings
  • Oil pump
  • Cam chain tensioner
  • Kickstarter (chain-driven models)
  • Recoil starter (shaft-driven models)
  • Starter gears (shaft-driven models)
  • Secondary bevel gear and drive gear set (shaft-driven models)
  • Crankcase and crankshaft
  • Break-in procedure
  • Specifications
• CHAPTER FIVE / CLUTCH AND TRANSMISSION
  • Clutch operation
  • Centrifugal clutch
  • Manual clutch
  • Manual clutch inspection
  • Clutch lifting mechanism (shaft-driven models)
  • Clutch release mechanism (chain-driven models)
  • Clutch cable (chain-driven models)
  • External shift mechanism
  • Drive sprocket (chain-driven)
  • Transmission and internal shift mechanism
  • Dual-range subtransmission (shaft-driven LT-F230)
  • Specifications
• CHAPTER SIX / FUEL AND EXHAUST SYSTEMS
  • Carburetor operation
  • Carburetor service
  • Throttle cable
  • Choke cable (shaft-driven models)
  • Fuel shutoff valve
  • Fuel tank
  • Fuel pump (shaft-driven models)
  • Exhaust system
  • Specifications
• CHAPTER SEVEN / ELECTRICAL SYSTEM
  • Charging system (models so equipped)
  • Voltage regulator (shaft-driven models)
  • Alternator (shaft-driven models)
  • Magneto (chain-driven models)
  • Capacitor discharge ignition
  • Ignition coil
  • Starting system (models so equipped)
  • Starter
  • Starter solenoid
  • Lighting system
  • Switches
  • Odometer housing (shaft-driven models)
  • Fuse
  • Specifications
• CHAPTER EIGHT / FRONT SUSPENSION AND STEERING
  • Front wheel
  • Front hub
  • Steering system
  • Tires
  • Specifications
• CHAPTER NINE / REAR AXLE, SUSPENSION AND FINAL DRIVE
  • Rear wheel
  • Rear axle (shaft-driven models)
  • Rear axle and driven sprocket (chain-driven models)
  • Driven sprocket (chain-driven models)
  • Rear axle inspection (all models)
  • Final drive unit (shaft-driven models)
  • Drive sprocket and chain (chain-driven models)
  • Rear axle bearing and oil seal replacement (shaft-driven models)
  • Rear axle bearing housing (chain-driven models)
  • Shock absorber (chain-driven models)
  • Swing arm (chain-driven model)
  • Specifications
• CHAPTER TEN / BRAKES
  • Drum brakes
  • Front drum brakes
  • Rear drum brake
  • Drum brake inspection (front hub and rear)
  • Disc brakes
  • Front brake pad replacement
  • Rear brake pad replacement
  • Front master cylinder (drum and disc brake models)
  • Rear master cylinder (disc brake models)
  • Front caliper
  • Rear caliper
  • Front brake disc
  • Rear brake disc
  • Front brake hose replacement (drum and disc brake models)
  • Rear brake hose replacement
  • Bleeding the system
  • Rear disc brake pedal
  • Specifications
• CHAPTER ELEVEN / BODY
  • Front fender
  • Rear fender
  • Front hand grip
  • Rear hand grip
  • Front and rear carriers (shaft-driven models)
  • Specifications
• SUPPLEMENT / 1987 AND LATER SERVICE INFORMATION
• INDEX
• WIRING DIAGRAMS