1986 Suzuki LT250R Manual

The 1986 Suzuki LT250R is a high-performance two-stroke sport ATV featuring a 246cc liquid-cooled engine, 5-speed transmission with reverse, full suspension system, front and rear hydraulic disc brakes, and rugged off-road capabilities. This manual covers safety precautions, technical specifications, maintenance procedures, troubleshooting, and operational guidelines for optimal performance and longevity.

Features at a Glance

Key components: 246cc two-stroke liquid-cooled engine, Mikuni VM26SS carburetor, CDI ignition, 5-speed transmission with reverse, full suspension system, hydraulic disc brakes front and rear.

Feature	Description
Engine Type	246cc, 2-stroke, liquid-cooled single cylinder
Carburetor	Mikuni VM26SS slide type
Ignition System	CDI (Capacitor Discharge Ignition)
Transmission	5-speed constant mesh with reverse
Final Drive	Chain drive
Suspension Front	Telescopic fork, oil damped
Suspension Rear	Swingarm, oil damped
Brakes Front/Rear	Hydraulic disc
Tire Size Front	21x7-10
Tire Size Rear	20x10-9

Safety Precautions

Always wear proper safety equipment and follow safe riding practices.

1. Always wear DOT-approved helmet, eye protection, gloves, and protective clothing.
2. Never operate under the influence of alcohol or drugs.
3. Inspect ATV before each ride for proper operation.
4. Ride only in designated areas and avoid public roads.
5. Do not carry passengers - designed for single rider only.

WARNING! This is a high-performance sport ATV. Inexperienced riders should receive proper training before operation.

Technical Specifications

• Engine: 246cc, 2-stroke, liquid-cooled single cylinder
• Bore x Stroke: 67.0 x 70.0 mm
• Compression Ratio: 7.4:1
• Carburetion: Mikuni VM26SS
• Lubrication: Suzuki CCI (Crankcase Cylinder Injection)
• Ignition: CDI
• Starting System: Kick starter
• Transmission: 5-speed constant mesh with reverse
• Final Drive: Chain, 520 pitch
• Suspension Travel Front: 6.7 inches
• Suspension Travel Rear: 6.3 inches
• Brakes: Hydraulic disc front and rear
• Dry Weight: 324 lbs (147 kg)
• Fuel Capacity: 2.6 US gallons (10 liters)
• Oil Capacity: 1.3 US quarts (1.2 liters)

Controls and Instruments

Familiarize yourself with all controls before operation.

Handlebar Controls: Throttle, front brake lever, clutch lever, engine stop switch, choke lever, headlight switch.

Foot Controls: Gear shift lever, rear brake pedal.

Instrument Panel: Speedometer, odometer, neutral indicator, reverse indicator, high beam indicator.

Key Switches: Main key switch, steering lock.

Pre-Ride Inspection

Perform these checks before every ride:

1. Check fuel level and add proper fuel/oil mixture
2. Inspect tires for proper pressure and damage
3. Check brake operation and fluid levels
4. Verify throttle moves freely and returns automatically
5. Check chain tension and lubrication
6. Test all lights and electrical components
7. Check for loose bolts or fasteners
8. Verify oil injection system operation

CAUTION! Never operate with damaged or malfunctioning components.

Maintenance Schedule

Item	Every Ride	Every 3 Months	Every 6 Months	Every Year
Engine Oil	Check	Change	-	-
Air Filter	Visual Check	Clean/Replace	-	-
Spark Plug	-	Check/Clean	Replace	-
Brake Fluid	Check Level	-	Change	-
Chain	Lubricate	Adjust	-	-
Wheel Bearings	-	-	Inspect	Repack
Suspension	Visual Check	-	Inspect	Service

Engine Maintenance

Proper engine maintenance is critical for performance and longevity.

1. Fuel System: Use premium unleaded gasoline mixed with Suzuki CCI oil at 20:1 ratio
2. Spark Plug: NGK BR8ES, gap 0.024-0.028 inches
3. Air Filter: Clean with solvent and re-oil with foam filter oil
4. Cylinder Compression: Should be 120-150 psi
5. Carburetor Adjustment: Pilot screw 1-1/2 turns out, main jet #220
6. Crankcase Oil: SAE 10W-40, change every 3 months or 20 hours

WARNING! Always use proper fuel/oil mixture to prevent engine damage.

Transmission & Drive System

Maintain proper chain tension and lubrication.

1. Chain Adjustment: 1.0-1.4 inches free play at midpoint
2. Chain Lubrication: Apply chain lube after cleaning
3. Transmission Oil: SAE 10W-40, capacity 1300ml
4. Gear Shift Pattern: 1-down, 4-up, neutral between 1st and 2nd
5. Reverse Operation: Stop completely, pull reverse lever, shift to reverse

Tip: Check chain tension frequently as loose chains can derail and cause damage.

Suspension & Brakes

Regular inspection ensures safe handling and braking.

1. Front Suspension: Check fork oil level, replace every 2 years
2. Rear Suspension: Inspect shock absorber for leaks
3. Brake Pads: Replace when worn to 1mm thickness
4. Brake Fluid: DOT 4, change every 2 years
5. Tire Pressure: Front 3.6 psi, Rear 3.6 psi (check when cold)

WARNING! Worn brakes or suspension components can cause loss of control.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, fuel issues, compression	Check spark plug, fuel flow, compression test
Poor performance	Clogged air filter, carb issues	Clean air filter, check carburetor settings
Transmission problems	Low oil, worn gears	Check oil level, inspect transmission
Brakes not working	Air in lines, worn pads	Bleed brakes, replace pads
Electrical issues	Battery, stator, wiring	Check battery voltage, stator output
Overheating	Low coolant, radiator blockage	Check coolant level, clean radiator

Service: Contact authorized Suzuki dealer for major repairs.

Storage & Winterization

Proper storage prevents damage during extended non-use.

1. Drain fuel from carburetor and fuel tank
2. Change engine oil and transmission oil
3. Remove spark plug and add oil to cylinder
4. Clean entire ATV thoroughly
5. Inflate tires to maximum pressure
6. Store in dry, covered area
7. Disconnect battery if equipped

CAUTION! Old fuel can gum up carburetor and fuel system components.