The 1990 Suzuki LT250RL is a performance-oriented, lightweight All-Terrain Vehicle (ATV) designed for sport and recreational use. Building on Suzuki's reputation for reliable and capable off-road machines, this model offers a dynamic riding experience with its 246 cc two-stroke, liquid-cooled engine and 5-speed transmission. Known for its agility and responsiveness, the LT250RL was positioned against competitors like the Honda TRX250R and Yamaha Warrior 200, embodying the spirit of a competitive sport ATV from its era. This comprehensive service repair manual provides detailed information in English for owners and technicians. It covers all essential aspects of the 1990 Suzuki LT250RL, including complete engine disassembly and assembly, transmission and clutch service, fuel system tuning, ignition system diagnostics, and suspension adjustments. The manual also includes troubleshooting guides, electrical system schematics, technical specifications such as torque values, and procedures for routine maintenance and component rebuilds, empowering users to maintain and repair their ATV effectively. 🏷️ Basic Information Identification Make: Suzuki Model: LT250RL Year: 1990 Vehicle Type: All-Terrain Vehicle (ATV) Product Name: Suzuki LT250RL 1990 Service Repair Manual PDF Download 👋 Introduction Market Position Segment: Sport/Recreational ATV Target Audience: Enthusiasts and owners of the 1990 Suzuki LT250RL Competitive Analysis Competitors: Honda TRX250R, Yamaha Warrior 200, Kawasaki Mojave 250 Key Features Vehicle Focus: Performance-oriented, lightweight sport ATV Manual Benefit: Empowers owners to perform comprehensive maintenance and repairs, saving on professional service costs Manual Value Proposition Diy Capability: Enables owners to confidently perform a wide range of repairs and maintenance, increasing the lifespan and reliability of their ATV. 📋 Manual Details Coverage Areas Language: English Format: PDF Download Manual Type: Service Repair Manual Page Count: Estimated 200-300 pages (typical for this era of service manual) 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, and component diagnosis Transmission: Gearbox maintenance, clutch operation, and drive shaft service Fuel System: Carburetor tuning and rebuilding, fuel pump operation, and fuel line maintenance Ignition System: Spark plug specifications, timing adjustments, and ignition coil testing Cooling System: Radiator, fan, and coolant flow diagnostics Lubrication System: Oil pump, filter, and oil passage servicing Frame And Suspension: Front and rear suspension component inspection, adjustment, and repair; shock absorber specifications Brakes: Hydraulic brake system service, pad replacement, caliper overhaul, and bleeding procedures Electrical System: Wiring diagrams, battery maintenance, lighting system service, and starter motor diagnosis Bodywork And Trim: Panel removal and installation, seat maintenance, and handlebar component service Procedures Included Maintenance: Routine checks, lubrication, filter replacement, and general upkeep Troubleshooting: Diagnostic flowcharts for common problems and their resolutions Repair: Step-by-step instructions for component repair and replacement Rebuilds: Detailed instructions for engine, transmission, and carburetor rebuilds Adjustments: Carburetor, ignition timing, and suspension adjustments Suspension Adjustment: Details on adjusting preload and damping for optimal handling Wheel And Tire Service: Information on tire pressure, mounting, and wheel bearing maintenance Technical Depth Diagnostics: Advanced diagnostic procedures for electrical and mechanical issues Specifications: Torque values, clearances, tolerances, and fluid capacities Wiring Diagrams: Comprehensive electrical system schematics Part Identification: Identification of key components and their part numbers (often included in reference sections) Torque Specifications: Detailed torque values for all critical fasteners Special Tools: Lists and descriptions of specialized tools required for specific procedures 📊 Manual Specifications File Format File Type: PDF Searchable: Likely searchable text (depending on original scan quality) Printable: Yes Resolution: High-resolution for clarity of diagrams and text Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled Displacement: 246 cc Bore X Stroke: 66.0 mm x 72.0 mm (typical for this model) Compression Ratio: 7.0:1 (typical) Cylinder Arrangement: Single cylinder, forward-inclined Valvetrain: Reed valve intake Performance Horsepower: Approximately 24-26 HP (estimated at crankshaft) Torque: Estimated 20-22 lb-ft Fuel System Carburetor Model: Mikuni VM28SS (typical) Fuel Type: Unleaded gasoline (87 octane or higher recommended) Fuel Delivery: Carburetor with electric fuel pump Lubrication System Oil Type: 2-stroke premix oil or Suzuki's CCI (Crankcase Cylinder Injection) system (manual will specify) Oil Capacity: Manual will specify (e.g., 1.2L for CCI system) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh with manual clutch and reverse Drive Type: Chain drive Features Clutch Type: Wet, multi-plate Reverse Gear: Included Final Drive: O-ring sealed chain Fluid Type Transmission Oil: Manual will specify (typically SAE 80 or SAE 10W-40 gear oil) 📐 Dimensions Exterior Length: Approximately 1860 mm (73.2 in) Width: Approximately 1100 mm (43.3 in) Height: Approximately 1065 mm (41.9 in) Wheelbase: Approximately 1250 mm (49.2 in) Weights Dry Weight: Approximately 170 kg (375 lbs) Tires Front Tire Size: AT22 x 7-10 (typical) Rear Tire Size: AT22 x 10-8 (typical) Brakes Front Brake Type: Dual hydraulic disc Rear Brake Type: Single hydraulic disc 🛡️ Safety Features Ratings Atv Safety Standards: Adheres to ANSI/SVIA standards (relevant for the era) Active Features Throttle Limiter: Manual may detail adjustment or removal of throttle limiter Passive Features...