1987-1998 Suzuki LT ATVs (LT-4WD/LT-F4WDX/LT-F250) Service & Repair Manual

SUZUKI LT-4WD, LT-F4WDX & LT-F2S0 • 1987-1998

Chapter one . General Information ChaPlerTWQ . Troubleshooting Chapter Three Lubrication, Maintenance and Tune-up Chapter Four • Engine Top End Chapter Five Engine Lower End Chapter Six •. Clutch Chapter Seven • Transmission and Shift Mechanism Chapter Eight • Fuel and Exhaust Systems • Chapter Nine . Electrical System Chapter Ten ..,. Front Suspension and Steering .... Chapter Eleven Front Drive Mechanism Four-Wheel Drive ChaplerTwelve _ Rear Suspension, Rear Axle and Final Drive ~ Chapter Thirteen _ Brakes .... Chapter Fourteen _ Body " Index II Wiring Diagrams II

, CONTENTS QUICK REFERENCE DATA •.•..• • •• •• •. •• ••••••• •• •• •••••••••• ••. .• .• .•• ..... • IX CHAPTER ONE GENERAL INFORMATION ... .. . .. •••. ......... .... ... .... ... ..... .... .•• .... . . . 1 Manual organization NOles. cautions and warnings Safety first Service hints Washing the vehicle Torque specifications Fasteners Lubricants RTV gasket sealan t Thrcadl ock Gasket remover CHAPTER TWO Expendable suppli es Pans replacemcllI Basic hand l00ls Test equipment Precision measuring tools Speciallools Cleaning solvent Mechanic's tips Ball bearing replacement Oil seals Riding safcty TROUBLESHOOTING . .. .. . .. .. •• .•... .. .... .. .... .. .. . .. ... .. .. ..... • . .. . .. . 37 Operating requirements EleclricallrOubleshoOling Troubleshooting inslrumenls Test equipment Starting the engine Basic test procedures Emergency troubleshooting Electrical problems Engine sianing troubleshooting Charging system troubleshooting Engine performance Ignition system troubleshooting Engine noises Electric starter system troubleshooting Engine lubrication Carburetor troubleshoot ing Clutch Excessive vibration Gearshift linkage Fron! suspension and steering Transmission Brake problems

CHAPTER THREE LUBRICATION, MAINTENANCE ANO TUNE-UP _ .• ..... . .. _..... • ....... _. ..•.•... 58 Pre-checks Service intervals Tires and wheels Battery New battery installation CHAPTER FOUR Battery electrical cable connectors Periodic lubrication Periodic mainlenance Engine tune-up ENGINE TOP END •..•. __. __• . • ...... __ .... •... •.•.•.•.• .• ........ • ........ .. 92 Engine principles Engine cooling Cleanliness Servicing engine in frame Cylinder head cover CHAPTER FIVE Cylinder head and camshaft Valves and valve components Cylinder Piston, piston pin and pislon rings Camshaft cha in tensioner adjust er ENGINE LOWER END .. .. _.... __ . ... . . _. . .•...•.•.•.•.•.• .... •.•.•.•.•.• .... 147 Servicing engine in frame Engine Right-hand crankcase cover Left-hand crankcase cover Recoil staner Staner clutch and gears Oil pump Oil strainer CHAPTER SIX Oil cooler (LT-F4WDX 1280 eel models) Sub-transmission output shaft and rear final driven gear Secondary driven output shaft (4-wheel drive models) Crankcase and crankshaft Break-in procedure CLUTCH .. .. .. ..... . . . _. . . ...• _ ... . .. _. _ .•.•.•.• . ..•.• ...... •. _. _. _. _ ...•. 195 Clutch operation Centrifugal clutch CHAPTER SEVEN Manual clutch Clutch li fting mechanism TRANSMISSION AND SHIFT MECHANISM .. . _. _. _. . . _. _ .. .. ... . .. _. _. .. _. .. _. .. 21 6 Main transmission external shift mechani sm Main transmission internal shift mechanism Main transmission internal shift mechanism inspection CHAPTER EIGHT Sub-transmission and shift mechanism Gearshift lever cOnlroi mechanism FUEL AND EXHAUST SYSTEMS •.•.•.•.•.• .......... •.•.•.•.•.•..•...•.• ..... 266 Carburetor operation Carburetor service Carburetor (1987-1989 models) Carburetor (l990-0n models) Cleaning and inspection (all models) Carburetor adjustmenls Fuel system cleanliness inspection Thronle cable Choke cable (1990-on models) Fuel shut off valve Fuel tank Fuel pump Air filter hous ing Exhaust system 1 • • • • • • , •

CHAPTER NINE ELECTRICAL SYSTEM El eclrical connectors Battery negative tcnninal Charging syst em ...•...•.••.. . ... . .... •.. •.•... ..... .••• . •• ••• • ••. .. .. 300 Vollage regulillor/reclifier AC generator Capacitor discharge ignition Pickup coil I gn iti on coil Starting system Electric starter CHAPTER TEN Starter relay Neutral relay Li ghting system Switches Odometer housing (2·w hccl drive models) Speedometer housing (4~whcel drive models) OUlpullcrminal Fuses Wiring diagrams FRONT SUSPENSION AND STEERING .... •.• ...... . .. ... ... . ...• ....... . .. .... 343 Front wheel Tires and wheels Shock absorber CHAPTER ELEVEN Front hub and brake drum Steering system Front suspension FRONT DRIVE MECHANISM FOUR·WHEEL DRIVE ......... • .. •... •• .... ... • ..... 370 Front drive axles Propell er shafl CHAPTER TWELVE Front differential REAR SUSPENSION, REAR AXLE AND FINAL DRIVE ..... .. ... .... ..... •.. , .••... 384 Rear wheel Shock absorber Rear hub a nd brake drum CHAPTER THIRTEEN Rear suspension ann Rear drive axles BRAKES .. . .. .. .. . .. .. . ...... •.• .......... •• ... .. . .. . .. ... .. . ..• .......... 402 Front drum brakes Rear drum brake Drum brake in spection (front and rear) Rear drum brake cable and foo t pedal CHAPTER FOURTEEN Front master cylinder Front brake hose replacement Bleeding the system BODy .. ....... . ................ ... .... .. . .. ... .. .... .. ....... .... .. .. .... 434 Seat Rear fender and rear rack From fender, from rack and front grip Footre st assembly Trailer hitch plate INDEX .. ..... ... . ... . ................. . ..... ... .. ... ..... . .. . ............. 444 WIRING DIAGRAMS ...... .. .. . .... ... . .. .. ...... ....... .. ... .. . ........ ..... 448

QUICK REFERENCE DATA ATV INFORMATION MODEL: YEAR: VIN NUMBER: ENGINE SERIAL NUMBER: CARBURETOR SERIAL NUMBER OR 1.0. MARK: TIRE INFLATION PRESSURE (COLD)· Tire pre •• ure Front tires A •• , tI .... Load capacity 0 •• .., 0., .. , LT·F250 models All loads 25 3.' 25 3.' LT-4WD model . Up 10 80 kg (175 lb.) 3. ••• 20 2.' 80-172 kg (175-380 lb.) 35 5.1 20 2.' LT · F4WDX model. ~1I1~)dS up to In kg 3. ••• 27.5 • •• 90 lb. maximum 'TIre Inllation pressure for factory equipped tires. Aftermarket tirea may require different Inllation pre •• ure. Fuel lank Including reserve Reserve only Engine 011 change 011 and fitter change Engine overhaul Front differenti al (4-wheel drive) REFILL CAPACITIES AND SPECIFICATIONS Capacity 12 liters (3.2 U.S. gal.) 2.0 liters (2. t U.S. qt.) 3500 ml (3.7 U.S . qt •. ) 3600 ml (3.8 U.S . qt• .) 3860 ml (4.1 U.S. qt• .) ISO ml (5.1 U.S . OL) IX "' .. 85-95 octane or higher SAE 10W/40 Hypold gear 011 SAE 90 (GL-S)

TUNE-UP AND MAINTENANCE T IGHTENING TORQUE S It em Cylinder head 8 mm nuts 250cc 280cc Cylinder head-to-cyllnder 6 mm nuts Cyllnder-to-crankcase 6 mm nuts Timing hole cap (17 mm) Engine 011 drain plug Front differential Fill cap Drain bolt Exhaust syatem Exhaust plpe-to-cyllnder head nuts MuHler-tG-ilixhaust pipe bott Muffler mounting bolts Valve clearance Intake Exhaust Compression pressure (at lea level) Standard Service limit (min.) Spark ~ug .tandard type U.S. models Canadian models Spark plug gap Idle speed 250 cc models 280 cc models Pilot Krew Initial opening 250 cc models 280 cc models Item a nd Model Headlight LT-25O LT-4WD, LT -F4WDX Taillight Speedometer and odometer Indicator tight LT -250 LT-4WD, LT -FWDX Nom ft .-lb. 18-23 13-16.5 21-25 15-18 7-11 5-8 7-11 5-8 20-25 14.5-18.0 18-23 13-16.5 20-30 14.5-21 .5 20-30 14. 5-21 .5 9-12 6.5-8.5 18-23 13-16.5 18-28 13-20 TUNE -UP SPECIFICATIONS 0.03-0.08 mm (0.001-0.003 In.) 0.08-0.13 mm (0.003-0.005 In.) 1000-1400 kPa (142-199 psi) 800 kPa (114 psI) NGK 07EA, NO X22E5-U NGK OR7EA, NO X22ESR-U 0.6-0.7 mm (0.024-0.028 In.) 1350-1450 rpm 1400-1600 rpm 2 turns out 25/89 turns out REPLACEMENT BULBS Voltage/Wattage 12V 45145W 12V 30130W 12VSW 12V 3.4W 12V2W 12V 3.4W x

INTRODUCTION This detailed. comprehensive manual covers Ihe Suzuki LT-F2S0. LT-4WD and LT- F4W DX from 1987- 1998. The expert text gives complete infonnation on maintenance. tune-up. repair and overhaul. Hundreds of photos and drawings guide you through every step. The book includes all you will need to know 10 keep your Suzuki run- ning right. A shop manual is a reference. You want to be able to find infonnation fast. As in all Clymer books, this one is designed with you in mind. All chapters arc thumb-tabbed. Imponant items are extensively indexed at the rear of the book. A ll procedures. tables. photos. eel. in this manual are for the reader who may be working on the vehicle for the first lime or using this manual for the first lime. AlIlhe mosl frequently used specifications and capacities arc summa- rized in the Quick Rejerence Dara pages at the front of the book. Keep the book handy in your tool box. [t wi ll help you better understand how your ATV operates, lower repair costs and generally im prove your satisfaction with the ATV.

CHAPTER ONE GENERAL INFORMATION This detailed comprehensive manual covers the Suzuki LT·F250 Quad Runner (246 ee), LT-4WD Quad Runner (246 ee) and LT-F4WOX King Quad (280 ee) from 1987-1998. Troubleshooting. tunc-up. maintenance and repair are nOI difficult. if you know what tools and equipment to use and what 10 do. Step-by-step in- siruclions guide you through jobs nmging from simple maintenance 10 complete engine and suspension overhaul. This manual can be used by anyone from a first time do-it-yourselfer 10 a professional mechanic. Detailed drawings and clear photographs give you all thc infomtation you need 10 do Ihc work right. Some of the procedures in Ih is manual require the usc ofspcciaitoo\ s. The resourceful mechan ic can, in many cases. think of acceptable substitutes for special tools- there is always another way. This can be as si mple as using a few pieces of threaded rod. washers and nuts to remove or install a bearing or fabricating a tool from scrap malerial. However. using a substitute for a special tool is not recommended as it can be dangerous to you and may damage the part. If you find that a tool can be designed and safely made, but will require some type of machine work. you may want to search out a local community college or high school that has a machine shop curriculum. Shop teachers sometimes welcome outside work that can be used as practical shop app li cations for advanced slU dents. Metric and U.S. Standards arc used throughout this manual. U.S. to metric conversion is given in Table 2. Tab les 1-5 are found at the end of the chapter. MANUA L ORGAN IZ AT ION This chapter provides general infonnation and discusses equipment and tools useful both for pre- ventive maintenance and troubleshooting. Chapter Two provides methods and suggestions for quick and accurate diagnosis and re pai r of problems. Troubleshooting procedures discuss typical symptoms and logical methods to pinpoint the trou- ble. Chapter Three cxplains all periodic lubrication and routine maintenan ce necessary to keep your Suzuki operating well. Chapter Three also includes recommended tune-up procedures. eliminating the need to consult other chapters on the various assemblies. Subsequent chapters describe specific systems such as the engine top end, engine bollom end. clutch assemblies. transmission. sub-transmission, fuel. exhaust. electrical. suspension, 2-wheel and 4-wheel drive trains. steering and brakes. Each I

2 chapler provides disassembly, repair. and assembly procedures in simple step-by-s tep form. If a repair is impractical for II home mechanic. it is so indicated. It is usually faster and less expensive 10 take such repairs to a Suzuki dealer or competent repair s hop_ Specifications concerning II particular system are included at the end of the appropriate chapter. NOTES, CA UTIO NS AN D WA RNINGS The terms NOTE. CAUTION and WARN I NG have specific meanings in this manual. A NOTE provides additional information to make II step or procedure easier or clearer. Di sregarding II NOTE could cause inco nv eni ence. but would nOl cause damage or personal i njury. A CAUTION emphasizes areas where equipment damage could occ ur. Di sregarding II CAlITlON could cause permanent mechanical damage: however, personal injury is unlikel y. A WARNING emphasizes areas where persona1 injury or even death could result from neg ligence. Mechanical damage may also occur. WARNINGS are /0 be wken seriously. In some cases, serious injury and death has resulted from disregarding similar warnings. SAFETY FIRST Professional mechanics can work for years and never sustain a serious injury. If you observe a few rules of common sense and safety. you can enjoy many safe hours servicing your own machine. If you CH APTE R ONE 4. Use the proper sized wrenches to avoid damage to fasteners and injury to yourself. 5. When loosening a ti ght or s tu ck nut. be guided by what would happen if the wrench should slip. Be careful; protect yourse lf accordingly. 6. When replacing a fastener. make sure to use one with the same meas urements and strength as the old one. Incorrect or mismatched fasteners can result in damage to the vehicle and possible personal injury. Beware of fastener kits th at are filled with cheap and poorly made nuts. bolts, washers and cOlier pins. Refer to Fasteners in this chapt er for additional information. 7. Keep al l hand and power t ools in good condition. Wipe greasy and oily tools after using them. They are difficu lt to hold and can cause injury. Replace or repair worn or damaged tools. 8. Keep your work area clean and unclull ered. 9. WeaI safety goggles during all operations involv- ing drilling. grinding, the use of a cold chisel or anytime you feel unsure about the safety of your ignore these rules you can h un yourself or damage the equipment. CD I. Neller use gasoline as a cleaning solvent. WARNING Gasoline should only be stored in an approl'ed safety gasoline storage con- winer, properly labeled. Spilled gasoline should be wiped up immediately. 2. Never smoke or use a lorch in the vicinity of flammable liquids. such as cleaning solvent . in open containers. 3. If welding or brazing is required on the machine. remove the fuel lank and rear shock 10 a safe dis- lance, at leasl 50 feet away.

1987-1998 Suzuki LT ATVs (LT-4WD/LT-F4WDX/LT-F250) Service & Repair Manual

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