1986 Suzuki 230 Quadrunner Manual

The 1986 Suzuki 230 Quadrunner is a four-wheel ATV featuring a 229cc four-stroke single-cylinder engine, automatic clutch with 5-speed transmission, shaft drive system, front and rear suspension, electric start with backup recoil, front disc brake, rear drum brake, and full instrumentation. Below are key sections for safety, features, operation, maintenance, specifications, and troubleshooting.

1. Features at a Glance 2. Safety Information 3. Controls and Instruments 4. Specifications 5. Operation Instructions 6. Maintenance Schedule 7. Basic Maintenance Procedures 8. Troubleshooting 9. Storage Guidelines 10. Warranty Information

Features at a Glance

Key components: 229cc four-stroke engine, automatic clutch, shaft drive, full instrumentation, electric start.

Feature	Description
Engine Type	229cc 4-stroke, air-cooled, single cylinder
Transmission	5-speed with automatic clutch
Drive System	Shaft drive
Starting System	Electric with backup recoil starter
Brakes	Front disc, rear drum
Suspension	Front and rear suspension system
Fuel Capacity	3.2 gallons
Instrumentation	Speedometer, odometer, fuel gauge, neutral indicator
Tires	Front: 22x11-8, Rear: 22x12-9
Weight	Approximately 385 lbs

Safety Information

Always wear proper protective equipment and follow safe operating procedures.

Always wear helmet, eye protection, gloves, and protective clothing.
Never operate under influence of alcohol or drugs.
Inspect ATV before each use for proper operation.
Use only in approved areas; avoid public roads.
Never carry passengers on single-rider ATV.

WARNING! ATV operation is hazardous and can result in serious injury or death. Always follow safety guidelines and receive proper training.

Controls and Instruments

Familiarize yourself with all controls before operation.

Control	Function
Ignition Switch	Main power and starting control
Throttle Lever	Right handlebar control for acceleration
Front Brake Lever	Right handlebar control for front disc brake
Rear Brake Pedal	Right foot control for rear drum brake
Gear Shift Lever	Left foot control for gear selection
Choke Lever	For cold starting enrichment
Light Switch	Headlight and taillight control
Speedometer	Shows speed, odometer, trip meter
Fuel Gauge	Indicates fuel level
Neutral Indicator	Lights when transmission is in neutral

Specifications

Engine: 229cc 4-stroke, air-cooled, SOHC
Bore x Stroke: 70.0 x 59.6 mm
Compression Ratio: 9.0:1
Fuel System: Mikuni VM24SS carburetor
Ignition System: CDI electronic ignition
Transmission: 5-speed with automatic clutch
Final Drive: Shaft drive
Suspension Front: Independent double wishbone
Suspension Rear: Swingarm with shocks
Brakes Front: Single disc
Brakes Rear: Drum
Dimensions (LxWxH): 74.8 x 42.5 x 43.3 inches
Ground Clearance: 6.3 inches
Fuel Capacity: 3.2 gallons

Operation Instructions

Proper starting and operating procedures for optimal performance.

Pre-ride inspection: Check tires, controls, lights, oil level, fuel.
Starting: Turn fuel valve ON, set choke for cold engine, turn ignition ON, pull brake lever, press start button.
Warm-up: Allow engine to warm for 2-3 minutes before riding.
Shifting: Use gear shift lever; transmission features automatic clutch.
Braking: Use both front and rear brakes together for controlled stops.
Stopping: Shift to neutral, turn off ignition, turn fuel valve OFF.

CAUTION! Always perform pre-ride inspection. Never operate with mechanical issues.

Maintenance Schedule

Regular maintenance ensures long service life and safe operation.

Service Item	Every 100 mi	Every 500 mi	Every 1000 mi
Engine oil change	✓	✓	✓
Oil filter replacement		✓	✓
Air filter cleaning	✓	✓	✓
Spark plug inspection		✓	✓
Brake inspection	✓	✓	✓
Tire pressure check	✓	✓	✓
Drive shaft lubrication			✓
Wheel bearing inspection			✓

Basic Maintenance Procedures

Essential maintenance tasks for proper ATV care.

Engine Oil Change: Warm engine, drain oil, replace filter, refill with SAE 10W-40.
Air Filter Service: Remove foam element, clean in solvent, oil lightly, reinstall.
Spark Plug: Remove, clean, check gap (0.024-0.028 in), replace if worn.
Tire Pressure: Maintain 3.5 psi front, 3.5 psi rear for normal riding.
Brake Adjustment: Check lever/pedal free play; adjust if necessary.
Chain Adjustment: Check drive shaft play; lubricate universal joints.

WARNING! Always support ATV securely when performing maintenance. Use proper tools.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression issues	Check fuel valve, choke, spark plug, battery charge
Poor performance	Dirty air filter, clogged carburetor	Clean air filter, inspect carburetor jets
Electrical problems	Battery, fuse, wiring issues	Check battery voltage, fuses, connections
Brakes not working	Worn pads, air in lines, adjustment	Inspect pads, bleed brakes, adjust cables
Transmission issues	Low oil, clutch adjustment	Check oil level, adjust clutch cable
Overheating	Low coolant, dirty fins, rich mixture	Check coolant, clean fins, adjust carburetor

Storage Guidelines

Proper storage procedures for extended periods of non-use.

Fuel System: Add fuel stabilizer, run engine for 5 minutes, drain carburetor float bowl.
Battery: Remove battery, clean terminals, store fully charged in cool, dry place.
Tires: Inflate to recommended pressure, support ATV to lift tires off ground.
Cleaning: Thoroughly clean entire ATV, apply protectant to plastic and rubber.
Cover: Store in dry location with breathable cover.

CAUTION! Never store with fuel in carburetor. Always stabilize fuel for storage.

Warranty Information

Limited warranty coverage for 1986 Suzuki 230 Quadrunner.

Warranty Period: 12 months from date of purchase
Coverage: Manufacturer defects in materials and workmanship
Exclusions: Normal wear, improper maintenance, accidents, modifications
Service Network: Authorized Suzuki dealerships nationwide
Contact: Suzuki Customer Service: 1-800-828-RIDE

Always retain proof of purchase and complete warranty registration.