Suzuki Quad Racer LT250R

LT250R (1985-1992)

Quick Reference Data

ix

General Information

1

(13)

Manual organization

Notes, cautions and warnings

Service hints

Torque specifications

Safety first

Special tips

Expendable supplies

Parts replacement

Serial numbers

Basic hand tools

Tune-up and troubleshooting tools

Mechanic's tips

``Off the road'' rules

Safety

Troubleshooting

14

(5)

Operating requirements

Emergency troubleshooting

Engine starting

Engine performance

Engine noises

Excessive vibration

Front suspension and steering

Brake problems

Lubrication, Maintenance and Tune-Up

19

(32)

Pre-checks

Engine lubrication

Service intervals

Tires and wheels

Periodic lubrication

Periodic maintenance

Engine tune-up

Engine (1985-1986)

51

(36)

Engine operating principles

Engine lubrication

Servicing engine in frame

Engine removal/installation

Cylinder head

Cylinder

Reed valve assembly

Piston, piston pin and piston rings

Primary drive gear, balancer drive gear, balancer driven gear and water

Pump drive gear

Magneto

Drive socket

Kickstarter

Crankcase and crankshaft

Break-in procedure

Engine (1987 and Later)

87

(49)

Engine operating principles

Engine lubrication

Servicing engine in frame

Engine removal/installation

Cylinder head

Cylinder

Reed valve assembly

Exhaust valve

Piston, piston pin and piston rings

Exhaust valve governor, primary drive gear balancer drive gear and balancer driven gear

Magneto

Drive sprocket

Kickstarter

Crankcase and crankshaft

Break-in procedure

Clutch and Transmission

136

(26)

Clutch operation

Clutch

Clutch release mechanism

Clutch cable

External shift mechanism

Transmission and internal shift mechanism

Clutch and Transmission (1987 and Later)

162

(27)

Clutch operation

Clutch

Clutch release mechanism

Clutch cable

External shift mechanism

Transmission and internal shift mechanism

Transmission

Fuel and Exhaust Systems

189

(19)

Carburetor operation

Carburetor service

Carburetor adjustments

Air filter air box

Throttle cable

Fuel shutoff valve

Fuel tank

Exhaust system

Exhaust system repair

Electrical System

208

(13)

Capacitor discharge ignition

Ignition coil

Lighting system

Magneto testing

Switches

Wiring diagrams

Cooling System

221

(16)

Cooling system check

Pressure check

Radiator

Water pump (1985-1986 models)

Water pump (1987 and later models)

Hoses

Front Suspension and Steering

237

(20)

Front wheel

Front hub

Steering system

Tires

Rear Axle and Suspension

257

(28)

Rear wheel

Rear axle and driven sprocket (1985-1986 models)

Rear axle (1987 and later models)

Driven sprocket (1987 and later models)

Rear axle inspection

Drive sprocket and drive chain (1985-1986 models)

Drive sprocket and drive chain (1987 and later models)

Drive chain

Rear axle bearing housing (1985-1986 models)

Rear axle bearing housing (1987 and later models)

Shock absorber adjustment

Shock absorber and linkage

Swing arm

Brakes

285

(29)

Disc brakes

Front brake pad replacement

Rear brake pad replacement

Front master cylinder

Rear master cylinder

Front caliper

Rear caliper

Front brake disc

Rear brake disc

Front brake hose replacement

Rear brake hose replacement

Bleeding the system

Rear brake pedal

Body

314

(5)

Seat

Front fender

Rear fender

Front hand grip

Rear hand grip

Index

319

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Suzuki Quad Racer LT250R

Summary

Table of Contents

Supplemental Materials