1985-1990 Suzuki LT230 and LT250 Service & Repair Manual

SUZUKI LT230 & LT250 • 1985-1990

Chapter One General Information Chapter Two • Troubleshooting Chapter Three II Lubrication, Maintenance and Tune-up Chapter Four . Engine Chapter Five Clutch and Transmission Chapter Six Fuel and Exhaust Systems Chapter Seven Electrical System Chapter Eight Front Suspension and Steering Chapter Nine Rear Axle, Suspension and Final Drive Chapter Ten Brakes Chapter Eleven Body Supplement 1987 and Later Service Information Index Wiring Diagrams -

CONTENTS OUICK REFERENCE DATA .. .... .. ........ .. ................... .. ... ..... ... .............................. .. .... .. ..... .. .... IX CHAPTER ONE GENERAL INFORMATION ........................... .. ................... .. ... ... .. .. . .. .. ....... ..................... ........ 1 Manual organizalion Service hints Torque specifications Safety firsl Spcrlal lipS Expendable sup pl ies Parts replacement CHAPTER TWO Serial numbers Basic hand tools Tunc-up and troubleshooling l00ls MechaniC'S lips -Off the road" rules Safel) TROUBLESHOOTING .. ... .. .... .. .... ... ... ... ... ........ .. ...... .............. .. ... ...................... .. ................... 15 Operating requirements Emergency troubleshooting Engme starting Engine pcrfonnance CHAPTER THREE Engine noises Excessive vibration Front suspension and steering Brake problems LUBRICATION, MAINTENANCE AND TUNE- UP ................................................................. 19 Pre-checks Service int ervals Tires and wheels Ballery (models so equippc<i) CHAPTER FOUR Periodic lubrication PeriodiC maintenance Engine tunc· up ENGINE ... ..... .. ........................................................ ,....................................... ...... ................. 51 Engme pnnciples Engine cooling Scrvicing engine in frame Engine Cylinder head cover and rocker arm assembly C) linder head and camshaft Valves and vah'e seats Cylinder Piston. piston pin and pIston rmgs 011 pump Cam chain tenSloner Kickstarter (chain.driven models) Recoil starter (shaft·driven models) Starter gea rs (s haft·drivcn models) Secondary bevel gea r and drive gear set (shaft·driven models) Crankcase and crankshaft Brcak·m procedure

CHAPTER FIVE CLUTCH AND TRANSMISSION ........ .. ........ ... ....... .. ............................................................. 94 Clutch operation Centri ruga l dutch Manual clutch (shaft-driven models) Manual clutch (c hain-driven models) Ma nual dutch inspection (a ll model s) Clutch lifting mechanism (shaft-driven models) CHAPTER SIX FUEL AND EXHAUST SYSTEMS Carburetor operntion Carburet or service Throllie cable Choke cable (shaft·dri ve n models) CHAPTER SEVEN ELECTRICAL SYSTEM Charging syste m (models so equipped) Voltage regula tor (s haft-driven models) Alternator (shaft-driven models) Magneto (c hain-driven models) Capacitor discharge ign ition Igni tion coi l Staning system (models so equipped) CHAPTER EIGHT FRONT SUSPENSION AND STEERING Front wheel Front hub CHAPTER NINE Clutch release mechanism (chain-driven models) Clutch cable (chain-driven models) Ex te rnal shi ft mechanism (a ll models) Dri ve sp rocket (c hai n-dri ve n) Transmission and internal shin mechanism Dual-range subtransmission (s haft-driven L T-F230) Fuel shutoff valve Fuel tank Fuel pump (shaft·driven models) Exhaust system Starter Starter solenoi d Light ing system Switches Odometer housing (sha ft -driven models) F" " Siccring system Tires 131 146 167 REAR AXLE , SUSPENSION AND FINAL DRIVE ............................................................... 185 Rear wheel Rear axle (shaft-driven models) Rear a xl e and drive n sprocket (Cha in-dri ven models) Dri ven sprocket (chain.driven model s) Rear axle inspection (all models) Final dr ive un it (s haft -<lr iven models) CHAPTER TEN Dri ve sprocket and chain (chain-driven model s) Rear axle bearing and oil seal replacemen t (s haft-dri ve n model s) Rear axle bearing housing (chain-driven model s) Shock absorber (c hain-dri ven model s) Swing arm (chain-driven models) BRAKES ..•........•.........•.......... •.. ..........•. .. ..•.. .. ...... .. .. ....... ... ... ... ... ........................ .• .. ....•. .....•• 202 Drum brakes From drum brakes Rear drum brake Drum brake inspection (rront hub and rear) Disc brakes Front brake pad replacement Rear brake pad replacemen t Front master cylinder (drum and disc brake model s) Rear master cy linder (disc brake models) From caliper Rear caliper Front brake disc Rear brake disc Front brake hose replacement (drum and di sc brake models) Rear brake hose replacemem I1I ceding the system Rear disc brake pedal

CHAPTER ELEVEN BODy ........... ......... ...... • ........... .... .. .... ... ..................... .......... ............ ........... ......... 232 Front fender Rear fender Front hand grip SUPPLEMENT Rear hand grip From and rear carriers (shaft-driven models) 1987 AND LATER SERVICE INFORMATION ...... •..• ............ •... .... • .................. ..•......... 239 Periodic maintenance Tunc-up Piston, piston pin and piston rings Transmission and internal shift mechanism Carburetor service Capacitor discharge ignition (LT250S models) SWItCheS Rear axle and driven sprocket (chain-driven models) Swing aml and shock absorbers (cham-driven models) Rear caJtper Front fender Rear fender INDEX ........ ...... .. .. ......... ........ ........... ................ .... ..... .......... .. ........ ...................... 256 WIRING DIAGRAMS ...•• ...... •• .... •.. ........ .......... •• ........ ••... ......... • .............................. • 260

QUICK REFERENCE DATA ATV INFORMATION MOOEL:, ___________________ YEAR : _______ _ VIN NUMBER:_ _ ____ __________ _____ _____ __ _ ENGINE SERIAL NUMBER :, __________________________ _ CARBURETOR SERIAL NUMBER OR 1.0. MARK: Valve clearance Intake Exhaust Compre •• lon pressure (at sea level) Standard Service limit (min.) Spark plug standard type* Hotter Standard heat range Coi,,", Spark plug resiltor type' Honer Standard heat range Colder Spark plug gap Idle speed Pilot aerew Initial opening Shaft drl .... Chain drive TUNE.UP SPECIFICATIONS 0. 03-0.08 mm (O.OOHl.OO3 In.) 0.08-0.13 mm (0.003..(1 .005 In.) 1,2()().1 ,600 kPa (171-228 pal) 1,000 kPa (1 " 2 pal) Champion A8Ve NGK 07EA, NO X22E5-U, Champion A8ye NGK D8EA, NO X24ES·U Champion RABye NGK DR7ES, NO X22ESR-U, Champion RA6YC NGK DR8EA, NO X24ESR-U 0.6-0.7 mm (0.024-0.028 In.) 1,350-1 ,450 rpm 2318 lurna out 2 turn a out 'Higher spark plug number. Indicate colder heat range for bolh NGK and NO. Haadllght Tallllghl Load capacity Shaftodrlv.n models Up to 70 kg (155 lb.) 70-120 kg (155-265 lb.) Chalnodrlven models Up to 105 kg (230 lb.) 105-170 kg (230-375 lb.) REPLACEMENT BULBI Volta,e/Watta,e 12\1 45/45W 12\1 5W TIAE INFLATION PREIIUAE (COLD)- TI ... p ..... u ... Front tire. .P. p.i 20 2.8 35 5.0 18 2.6 25 3.6 Aea, tire. .P. p.i 20 2.8 20 2.8 18 2.6 25 3.6 "TIre Inflation pressure fOf' faclory equipped Ilres. Aftermarket tlrea may require dlffetent Infletlon pressure. iX

Olado 010 52DV TakllSago RK520SM Item Fuel tank Shaft-driven Chaln·drlven Engine oil (shaft·driven) Oil and filler Overhaul Engine 011 (chaln·driven) Oil and fllter Overhaul Subtransmission Final drive unit Fuel Engine oil Subtranlmllslon 011 Final clrive unit 011 Brake fluid Drive chain lube Eltimsted Wind Speed 50 in MPH calm 50 5 48 10 40 15 3. 20 32 25 30 30 28 35 27 40 2. • 40 40 37 28 22 18 I. 13 11 10 Little Danler DRIVE CHAIN REPLACEMENT NUMBERS 84 links 84 links LUBRICANT CAPACITIES 10 Ute,.. (HI U.S. gal./2.11mp. gal.) 9.5 liters (2.4 U.S. gal. /2.0 Imp. gal.) 1,700 cc (1.8 U.S. qt./1.5 Imp. qt.) 1,900 cc (2.0 U.S. qt./ 1.7 Imp. qt.) 1,600 cc (1.7 U.S. qt./1.4 Imp. qt.) 1.700 cc 1'.8 U.S. ql./ l.5 Imp. qt.) 240·270 cc (8.1·9.1 U.S. oz./6.7-7.6 Imp. oz.) 165·175 cc (5.6·5.9 U.S. 0%. /4.6·4.9 Imp. oz.) RECOMMENDED FUEL AND LUBRICATION 30 30 27 " 9 4 0 -2 -4 --6 Unleeded or low-Ieacl; 85·95 octane SAE10Wf40; API SE or SF Hypoid gear oil SAE 90; API GL·5 Hypold gear oil SAE 90; API GL·s DOT 3. DOT 4 or SAE J1703 SAE 90 gear oil or chain lubricant recommended for O·rlng chains WIND CHILL FACTORS Actual Thermometer Read!n&: (0 F) 20 10 0 -10 -20 -30 Equivalent Temperature (O f) 2. 10 0 -10 -20 I -30 " • -5 -15 1-26 -3' 4 -9 -21 33 -4. -58 -5 - 18 I -.36 -45 -58 -72 -10 25 -39 -53 --67 -82 -15 -29 -44 -59 -74 -88 -18 -33 -48 --63 -79 -94 -20 -35 -49 --67 -82 -98 -21 -37 -53 --69 -85 - 100 Increasing Oanler Great Oanler (for properly clothed --40 -50 --40 -50 --47 -57 -70 -aJ -85 -99 -9. -110 -104 -118 -109 -125 -113 -129 -116 -132 person) • Danser from Ireezmg of u;poud flesh, ·Wind speeds greater than 40 mph have little addlhonel effect x ~ - --'" 95 -ll2 -124 - 133 -140 -145 -148

'tom CyMncMf Mad cover bolt Cyllndetn.ad 8 mm bolts 8 mm boltl Cylinder bale nut Ten,loner adjult bolt Alternator rotor nut Shaft·drlven Chaln·drlven Drive aprocket nut Front wheel hub nut Handlebar upper holder boItl Slearlnil ahaft Holder bolta Lower nut Shaft,drlven Chaln·driven St .. rlng knuckle Ann bolt Knuckle-te-wilhbone nut Knuckl .. to-Iowar wllhbone clamping bolt Wlahbone-Ie-frlme boltl and nuta TIe .... , End locknut. Locknuta Shaft·drlven Chaln·drlven Shock abaorber bolta Rear hub nut Wheel nut. Axlll locknut Axle Inner nut Drive aprocket boltJi lind nuta 1985·1988 1987·t990 Rear axlll bearing houllng bolts 1985·1986 1987·1990 Reat brake dllc bolt. Shock absorber bolta end nut. Swing arm pivot boll and nut Subtranamlulon-to-final drive nuta 1.110·1.130 1.140-1.180 1.170-1.190 1.200·1.220 1.230·1.250 1.280·1.2110 GENERAL TORQUI: 1"_C'PlCATIONI "'"' 9·11 7-11 21·25 7·f1 a·a 150·170 50-60 ao·loo 50-80 18·28 18·28 22·35 38·80 35·35 40-80 ..... 50·70 22-35 23·35 40-80 40·60 85-115 45-66 160·200 180.200 25·39 45·85 18·28 85·120 15·25 40-80 50-60 24·31 fl.·lb. 6.5·' 5·8 15·18 5·a U-8 108·123 38-43.5 51·72 38·58 13·20 13·20 111·25 27·43 211·33 29·43 32 ... 311·51 18·211 28·33 29-'" 2'''' 82,83 33-47 115·144 115-144 18-211 32-47 13·20 61.5·117 ,,.,8 29·44 36-58 17·23 DllCh~ Almaal dlactwlrv-d One-qua"M charged One·half charca-d Th, .... quart.,. ctwlrged Fully ctwlrged

Prior to .ach rid. of operation Ev.ry I month. of Operation or 1,000 km or 100 mil •• Evary 12 month. of op.ration or 2,000 km or 1,200 mllas Ev.ry 5,000 Itm or 3,000 mil •• Evary 2 y •• ,.. MAINTENANCE SCHEDULE- • In.pect tire. and rim. and check Inflallon pre •• ure • Check driva chain ten.lon, edJu.1 If nec .... ry (model. to equipped) • Lubricate drive chain • Lubricale conlrol cable. • Ch.nge engln. oil and oil filter • Clean and oil air filter elem.nt (perlonn sooner if used In wet or dU.ty terr. In) • Check end adjust the carburetor • Cheek Ignition timing (COl Ignition) • Check cylinder head nut., cylinder nut. and exheu.t pip. nutl, tighten If nece.sary • Check e'eclrolyte 'evel in battery, add dl.tIIled waler if neces.ary (mode'. 10 .qulpped) • In.pect brake hOI.1 for cracked or .woll.n end. , replace if nec •••• ry • Check brake fluid leva' In masle, cylinder(s), add fluid II necessary • In.pect fuel IInel for chafed, cr.ckad or .wollen end., replace If n.c .... ry • Check throttle operation, adJu.t If nec •••• ry • Clean and lubricate drlva chain (model. to .qulpped) • In'p.ct driva chain .lider (model •• 0 equlpp.d) • AdJu.t drive chaIn t.n.lon • Check oil level in final drive unit, add 011 If nece.sary (model •• 0 aqulpped) • Check oil level In dual-ranga .ubtran.ml •• lon, add oil if necesaary (model •• 0 equipped) • Check and adJult clutch free play • Check and adju.t brake(l) • Check drum braka lining waar Indlcator(.) • Check and adjust rea, braka pedal If" play • Lubricate r •• r brak. pedal and .hlft lever • Check Ure .nd wheel condition • In.pect front .ta.ring lor loo •• ne •• • Check wheel bearing. for smooth operation • Check engine mounting bolt. for Ughlna .. • Check chassl. bolt. for tlghtna •• • Check and adJu.t to.-In • Inspect and clean .paril plug. regap II nece.aary • In.pect valve cle.tance , adJu.t if nece .. ery • Run a compresaion teat • In.pect decompr.saion lavar Irea play, adJu.t If nece.sary (modals so equIpped) • inspecl cam chain len lion, adjust It n.ce .. ary • Change final driva 011 (moda'. 10 .qulpp.d) • Change dual-ranga lublranlmlilion oil (modal• • 0 equipped) • Replace . paril plug • R.place hydraulic brake lIuld • Replace fuel ho.e. • Replace flexible brake ho.el • Thi. Suzuki factory maintenance achedule ....ould be conllderad ea a guide to g.nera' maintenance end lubrication interv.i •. H.rder than nonnalule (tacing) and expolure to mud, weter, .. nd, high humidity, etc. will naturally dictate mora frequent att.nlion to mo.t malnlenance Items. xu

1985-1990 Suzuki LT230 and LT250 Service & Repair Manual

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