1987 Suzuki 230 4 Wheeler Manual

The 1987 Suzuki 230 is a four-wheel ATV featuring a 229cc four-stroke engine, automatic clutch, shaft drive system, front and rear suspension, electric start, reverse gear, front and rear racks, 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 transmission, shaft drive, front and rear suspension, electric start with backup recoil, reverse gear, front and rear cargo racks.

Feature	Description
Engine	229cc four-stroke, air-cooled
Transmission	Automatic clutch, 5-speed with reverse
Drive System	Shaft drive
Starting System	Electric start with backup recoil
Suspension	Front telescopic forks, rear swingarm
Brakes	Front and rear drum brakes
Fuel Capacity	3.7 gallons
Cargo Capacity	Front and rear racks
Instrumentation	Speedometer, odometer, fuel gauge
Lighting	Headlight, taillight, brake light

Safety Information

Always wear proper safety equipment and follow safe operating procedures.

Always wear helmet, eye protection, gloves, and protective clothing.
Never operate under influence of alcohol or drugs.
Do not carry passengers - designed for one rider only.
Avoid paved surfaces - not designed for road use.
Keep hands and feet away from moving parts.

WARNING! ATVs can be hazardous to operate. Always follow safety guidelines and receive proper training before use.

Controls and Instruments

Familiarize yourself with all controls before operation.

Handlebar Controls: Throttle lever, front brake lever, ignition switch, light switch, choke lever, starter button.

Foot Controls: Rear brake pedal, gear shift lever.

Instrument Panel: Speedometer, odometer, trip meter, neutral indicator, reverse indicator, fuel gauge, high beam indicator.

Key Positions: OFF, ON, START. Always return to ON after starting.

Specifications

Engine Type: 229cc, 4-stroke, air-cooled, SOHC
Bore x Stroke: 67.0mm x 65.0mm
Compression Ratio: 9.5:1
Fuel System: Mikuni VM24SS carburetor
Ignition System: CDI electronic ignition
Transmission: 5-speed with automatic clutch and reverse
Final Drive: Shaft drive
Suspension Front: Telescopic forks, 5.9 inches travel
Suspension Rear: Swingarm, 5.9 inches travel
Brakes Front/Rear: Drum brakes
Tires Front/Rear: AT22 x 11-8 / AT22 x 11-8
Dimensions (LxWxH): 76.8 x 43.3 x 43.7 inches
Seat Height: 30.7 inches
Ground Clearance: 6.7 inches
Dry Weight: 386 lbs
Fuel Capacity: 3.7 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, turn key to ON, pull brake lever, press starter button.
Warm-up: Allow engine to warm for 2-3 minutes before riding.
Shifting: Use gear shift lever - down for lower gears, up for higher gears.
Reverse: Come to complete stop, shift to R position, use throttle gently.
Braking: Use both front and rear brakes together for controlled stopping.

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

Maintenance Schedule

Regular maintenance ensures long service life and reliable operation.

Item	Every 100 mi	Every 500 mi	Every 1000 mi	Every Year
Engine oil	Check	Change	-	-
Oil filter	-	-	Change	-
Air filter	Check	Clean	Replace	-
Spark plug	-	-	Check/Replace	-
Brake pads	Check	-	Check/Replace	-
Tire pressure	Check	-	-	-
Drive shaft	-	Lubricate	-	-
Wheel bearings	-	-	Check	Repack

Basic Maintenance Procedures

Essential maintenance tasks for proper ATV care.

Engine Oil Change: Warm engine, drain oil, replace filter, refill with 10W-40.
Air Filter Service: Remove cover, clean foam element with solvent, re-oil.
Spark Plug: Remove old plug, gap to 0.024-0.028 inches, install new plug.
Tire Pressure: Maintain 3.5 psi front, 3.5 psi rear for normal riding.
Brake Adjustment: Adjust brake lever/pedal free play to specification.
Chain Adjustment: Check tension, adjust to 1-1.5 inches free play.

Tip: Always use genuine Suzuki parts for optimal performance and reliability.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, battery	Check fuel valve, spark plug, battery charge, choke setting
Poor performance	Air filter, carburetor	Clean air filter, check carburetor settings, fuel quality
Hard shifting	Clutch, oil level	Check clutch adjustment, engine oil level and condition
Electrical issues	Battery, connections	Check battery voltage, clean connections, test fuses
Overheating	Cooling, oil	Check oil level, clean cooling fins, avoid slow speeds
Brake problems	Adjustment, wear	Adjust brake cables, check pad wear, bleed if necessary

Note: For complex issues, consult authorized Suzuki service center.

Storage Guidelines

Proper storage procedures for extended periods of non-use.

Fuel System: Add fuel stabilizer, run engine for 5 minutes, turn fuel valve OFF.
Battery: Remove battery, clean terminals, store fully charged in cool place.
Tires: Inflate to proper pressure, elevate off ground if possible.
Cleaning: Wash thoroughly, apply protectant to plastic and rubber parts.
Cover: Use breathable cover in dry, well-ventilated area.

CAUTION! Never store with fuel in carburetor without stabilizer.

Warranty Information

1987 Suzuki 230 4-wheeler limited warranty: 12 months from date of purchase with no mileage limitation. Warranty covers defects in material and workmanship. Normal maintenance items, tires, and normal wear items excluded. See dealer for complete warranty details and requirements.

For technical support or warranty claims, contact authorized Suzuki dealership or Suzuki Customer Service at 1-800-828-RIDE.