1987 Suzuki Quadsport 230 Manual

The 1987 Suzuki Quadsport 230 is a four-wheel ATV featuring a 229cc air-cooled four-stroke engine, 5-speed manual transmission with reverse, front and rear suspension, front and rear drum brakes, electric start, and manual choke. This manual covers safety precautions, operation, maintenance, troubleshooting, and specifications for proper use and care of your Quadsport 230.

Features at a Glance

Key components: 229cc four-stroke engine, 5-speed transmission with reverse, front and rear suspension, drum brakes, electric start system.

Safety Precautions

Always wear proper safety gear and follow operating guidelines.

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

WARNING! This ATV can be hazardous to operate. Always follow safety guidelines and never exceed your skill level.

Controls and Operation

Familiarize yourself with all controls before operation.

1. Starting: Turn key ON, set choke for cold starts, press electric start button.
2. Shifting: Use clutch lever and shift pedal - pattern: N-1-2-3-4-5 with reverse separate.
3. Braking: Use both front and rear brake levers simultaneously for balanced stopping.
4. Throttle: Twist grip throttle - release completely to return to idle.
5. Lighting: Headlight, taillight, and neutral indicator light controls.

CAUTION! Practice in open area before riding. Learn brake and throttle control.

Specifications

• Engine: 229cc 4-stroke, air-cooled, SOHC
• Bore x Stroke: 67.0mm x 65.0mm
• Compression Ratio: 9.5:1
• Carburetor: Mikuni VM24SS
• Ignition: CDI electronic ignition
• Transmission: 5-speed constant mesh with reverse
• Final Drive: Chain drive
• Suspension Travel Front: 5.9 inches (150mm)
• Suspension Travel Rear: 5.5 inches (140mm)
• Tire Size Front: 21x7-10
• Tire Size Rear: 20x10-9
• Fuel Type: Regular unleaded (87 octane or higher)

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Engine Maintenance

Proper engine care ensures reliable performance.

1. Oil Change: Drain when warm, replace with 10W-40 motorcycle oil (1.7 quarts).
2. Air Filter: Remove foam element, clean in solvent, re-oil with filter oil.
3. Spark Plug: NGK DR8ES, gap 0.024-0.028 inches. Replace if electrodes worn.
4. Valve Clearance: Check every 600 miles - intake 0.002-0.003 in, exhaust 0.003-0.004 in.
5. Carburetor: Clean jets and passages if performance issues occur.

Tip: Always use genuine Suzuki parts for optimal performance.

Transmission and Drive

Transmission and final drive maintenance procedures.

1. Clutch Adjustment: Proper free play at lever (10-15mm).
2. Shift Mechanism: Lubricate linkage points periodically.
3. Drive Chain: Clean and lubricate regularly, adjust tension (1.0-1.4 inches play).
4. Sprockets: Inspect for wear - replace if teeth are hooked.
5. Transmission Oil: Same as engine oil - changed with engine oil service.

WARNING! Never operate with loose or damaged drive chain.

Brake System

Front and rear drum brake maintenance.

1. Brake Adjustment: Adjust cable tension at lever for proper free play.
2. Brake Shoes: Inspect for wear - replace if lining thickness below 1.0mm.
3. Brake Drums: Clean and inspect for scoring or damage.
4. Cables: Lubricate periodically and replace if frayed or damaged.
5. Brake Lever: Proper free play essential for safe operation.

CAUTION! Test brakes at low speed after adjustment.

Suspension and Tires

Suspension adjustment and tire maintenance.

1. Front Suspension: Adjust spring preload for rider weight and terrain.
2. Rear Shocks: Preload adjustment available - set for load conditions.
3. Tire Pressure: Front 3.6 psi, Rear 3.6 psi (check when cold).
4. Tire Inspection: Check for cuts, embedded objects, or abnormal wear.
5. Wheel Bearings: Check for play and lubricate during tire service.

Tip: Proper tire pressure improves handling and reduces wear.

Storage and Care

Proper storage procedures for extended periods.

1. Fuel System: Add fuel stabilizer or drain carburetor and tank.
2. Battery: Remove and store with full charge in cool, dry place.
3. Cleaning: Wash thoroughly and apply protectant to plastic surfaces.
4. Storage Position: Place on stand to relieve tire and suspension pressure.
5. Cover: Use breathable cover to protect from dust and moisture.

CAUTION! Never store with fuel in carburetor - can cause damage.

Troubleshooting

Service: For complex issues, consult authorized Suzuki dealer.

Parts: Use genuine Suzuki parts for proper fit and performance.