Download Suzuki Quad Racer 250 LT250R LT 250R 1985-1986 Service Repair Workshop Manual PDF
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🏷️ Basic Information Identification Make: Suzuki Model: QuadRacer 250 Model Code: LT250R Model Years Covered: 1985, 1986 👋 Introduction Market Position Product Category: High-performance sport ATV Target Audience: Enthusiasts, racers, and DIY mechanics seeking to maintain and repair their Suzuki LT250R. Competitive Analysis Key Competitors Era: Yamaha YFZ250 'Banshee' (later models), Honda TRX250R. Key Features Manual Advantage 1: Instant digital download, eliminating shipping delays. Manual Advantage 2: Printable format allows for custom binding and field-use convenience (less risk of damaging an original manual). Manual Advantage 3: Provides dealership-level repair information for DIY use. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service, Repair, and Workshop Manual Additional Coverage: General Information, Engine, Transmission, Chassis, Steering, Suspension, Brakes, Electrical System, Fuel System, Lubrication, Frame, Clutch, Seats System, Locks, Lightning Page Count Estimated Page Count: Likely 300+ pages (typical for full workshop manuals of this era, specific count not provided) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF (Adobe Acrobat) 📖 Manual Coverage Systems Covered Engine: Complete disassembly, assembly, inspection, overhaul, tuning, and troubleshooting of the 250cc 2-stroke engine. Transmission: Gearbox disassembly, inspection, repair, lubrication, and adjustment procedures. Chassis And Frame: Frame inspection, repair, and component mounting; including suspension and steering linkages. Suspension: Front and rear suspension component inspection, maintenance, adjustment (preload, damping), and overhaul. Includes shock absorbers, swingarm, and linkages. Brakes: Front and rear brake system maintenance, bleeding, caliper overhaul, pad replacement, and rotor inspection. Likely covers hydraulic systems. Steering: Steering system inspection, adjustments, tie-rod ends, and bearing maintenance. Electrical System: Wiring diagrams, ignition system troubleshooting, lighting, battery service, charging system inspection. Fuel System: Carburetor disassembly, cleaning, tuning, fuel tank maintenance, and fuel line inspection. Clutch: Clutch mechanism inspection, adjustment, and replacement of components (plates, springs). Lubrication: Lubrication points, fluid types, and recommended service intervals for various components. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, air filter cleaning, spark plug replacement, brake adjustments. Troubleshooting: Diagnostic procedures for common issues related to engine performance, starting, electrical faults, and braking. Engine Rebuild: Detailed steps for complete engine teardown, component inspection (piston, rings, cylinder, crankshaft, bearings), and reassembly. Component Overhaul: Step-by-step instructions for overhauling the carburetor, brakes, and other key components. Adjustment Procedures: Carburetor jetting and idle adjustment, clutch cable adjustment, chain slack adjustment, suspension settings. Wiring Diagrams: Comprehensive electrical schematics for easy troubleshooting and repair. Technical Depth Depth Level: Comprehensive, covering all aspects from basic maintenance to full engine and transmission rebuilds. Diagnostic Capabilities: Includes troubleshooting flowcharts and symptom-based diagnostics. Rebuild Instructions: Detailed disassembly and assembly procedures with torque specifications and clearances. 📊 Manual Specifications File Format File Type: PDF Platform Compatibility: PC and Mac Searchability: Likely text-searchable, allowing for quick navigation. Print Quality Printability: High-quality, designed for printing specific sections or entire manuals. Binding Type Recommended Binding: 3-ring binder (as suggested in product description) Paper Type Suggested Paper: Standard printer paper, or heavier stock for frequently used sections. ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke, Single Cylinder Displacement: 246 cc (for 1985-1986 models) Bore X Stroke: 66.0 mm x 72.0 mm (typical for this engine family, confirm in manual) Cooling System: Liquid-Cooled Ignition: CDI (Capacitor Discharge Ignition) Performance Horsepower Estimate: Approx. 25-30 HP (stock, varies by tuning and year) Torque Estimate: Approx. 20-25 lb-ft (stock, varies by tuning and year) Fuel System Carburetor: Mikuni VM34SS (or similar, common for the era) Fuel Type: Unleaded gasoline (87-91 octane recommended), 2-stroke oil pre-mix (ratio specified in manual) Oil System: Premix fuel/oil, separate oil injection system (confirm specific model variant) 🔧 Transmission Standard Transmission Type: 6-Speed Manual Sequential Clutch Type: Wet Multi-Plate Clutch Features Drive System: Chain Drive Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 70.1 inches (1780 mm) (typical, confirm in manual) Width: Approx. 46.1 inches (1170 mm) (typical, confirm in manual) Height: Approx. 42.3 inches (1075 mm) (typical, confirm in manual) Weights Dry Weight: Approx. 357 lbs (162 kg) (typical, confirm in manual) Fuel Capacity: Approx. 2.6 gallons (9.8 L) (typical, confirm in manual) 🛡️ Safety Features Ratings Atv Classification: Sport ATV Active Features Braking System: Hydraulic disc brakes front and rear (dual front, single rear typical). Passive Features Lighting: Headlights and taillight/brake light. 💡 Technology Features Infotainment Infotainment System: Not applicable for this era of sport ATV. Focus is on mechanical and electrical systems. Driver Assistance Driver Assistance Features: None (basic mechanical and electrical systems). Connectivity Connectivity Features: None. 🔧 Maintenance Service Intervals Engine Oil Change: Refer to manual for specific hours or mileage, typically every 20-30 hours of operation for sport ATVs. Air Filter Cleaning: Frequent cleaning recommended, especially in dusty conditions. Details in manual. Chain Lubrication Adjustment: Regularly, as per manual recommendations (e.g., every 500 miles or 50 hours). Spark Plug Replacement: Refer to manual, typically every 100-150 hours or as needed based on condition. Fluid Specifications Engine Oil...
Likely 300+ pages (typical for full workshop manuals of this era, specific count not provided)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF (Adobe Acrobat)
📖 Manual Coverage
Systems Covered
Engine:
Complete disassembly, assembly, inspection, overhaul, tuning, and troubleshooting of the 250cc 2-stroke engine.
Transmission:
Gearbox disassembly, inspection, repair, lubrication, and adjustment procedures.
Chassis And Frame:
Frame inspection, repair, and component mounting; including suspension and steering linkages.
Suspension:
Front and rear suspension component inspection, maintenance, adjustment (preload, damping), and overhaul. Includes shock absorbers, swingarm, and linkages.
Brakes:
Front and rear brake system maintenance, bleeding, caliper overhaul, pad replacement, and rotor inspection. Likely covers hydraulic systems.
Steering:
Steering system inspection, adjustments, tie-rod ends, and bearing maintenance.
Electrical System:
Wiring diagrams, ignition system troubleshooting, lighting, battery service, charging system inspection.
Fuel System:
Carburetor disassembly, cleaning, tuning, fuel tank maintenance, and fuel line inspection.
Clutch:
Clutch mechanism inspection, adjustment, and replacement of components (plates, springs).
Lubrication:
Lubrication points, fluid types, and recommended service intervals for various components.
Premix fuel/oil, separate oil injection system (confirm specific model variant)
🔧 Transmission
Standard
Transmission Type:
6-Speed Manual Sequential
Clutch Type:
Wet Multi-Plate Clutch
Features
Drive System:
Chain Drive
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approx. 70.1 inches (1780 mm) (typical, confirm in manual)
Width:
Approx. 46.1 inches (1170 mm) (typical, confirm in manual)
Height:
Approx. 42.3 inches (1075 mm) (typical, confirm in manual)
Weights
Dry Weight:
Approx. 357 lbs (162 kg) (typical, confirm in manual)
Fuel Capacity:
Approx. 2.6 gallons (9.8 L) (typical, confirm in manual)
🛡️ Safety Features
Ratings
Atv Classification:
Sport ATV
Active Features
Braking System:
Hydraulic disc brakes front and rear (dual front, single rear typical).
Passive Features
Lighting:
Headlights and taillight/brake light.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable for this era of sport ATV. Focus is on mechanical and electrical systems.
Driver Assistance
Driver Assistance Features:
None (basic mechanical and electrical systems).
Connectivity
Connectivity Features:
None.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Refer to manual for specific hours or mileage, typically every 20-30 hours of operation for sport ATVs.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions. Details in manual.
Chain Lubrication Adjustment:
Regularly, as per manual recommendations (e.g., every 500 miles or 50 hours).
Spark Plug Replacement:
Refer to manual, typically every 100-150 hours or as needed based on condition.
Fluid Specifications
Engine Oil Type:
Suzuki recommends specific 2-stroke engine oil for premix or oil injection (details in manual). Typical viscosity: SAE 10W-30 or 10W-40 for transmission/gearbox if separate.
Coolant Type:
Ethylene glycol-based antifreeze/coolant (50/50 mix with distilled water), specific type in manual.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (confirm in manual).
Carburetor can be sensitive to altitude and temperature changes, requiring re-jetting. Common issue addressed in manual's tuning section.
Clutch Slippage:
Can occur with hard use; manual provides inspection and replacement procedures.
Suspension Wear:
Bushings and seals in suspension can wear, leading to looseness; manual covers replacement.
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation
Model Evolution
Lt250R Introduction:
Introduced in the mid-1980s as Suzuki's flagship sport ATV, built for performance and racing.
Key Upgrades 1985 Vs 1986:
While specific year-to-year changes are often subtle in early models, 1986 saw some refinements over the inaugural 1985 model. Manual will detail these.
Production
Production Period Covered:
1985-1992 (with this manual covering the initial phase)
🏆 Awards & Recognition
Recognitions
Atv Performance Recognition:
The LT250R was a highly regarded performance ATV in its time, favored by racers for its power and handling, though specific awards are not detailed here.
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