1986 Suzuki LT250R Service Manual (P/N 99500-22041-01E)

• Factory document identity: Suzuki LT250R factory service publication, P/N 99500-22041-01E, copyright 1985, supplied as a 204-page PDF.
• Model-year coverage: Contains the complete LT250RF base-manual procedures plus factory Section 9 for LT250RG ('86 MODEL) service data, component changes, and procedures that differ from the F model.
• Engine repair depth: Covers engine removal and reinstallation; complete disassembly and reassembly of the counterbalanced two-stroke engine; crankshaft and shim selection; cylinder, piston, ring, and reed-valve inspection; plus clutch, kick-starter, five-speed transmission, and gearshift service.
• Cooling and fuel systems: Documents radiator leak and cap testing, radiator removal, water-pump disassembly and reassembly, fuel-cock service, and carburetor removal, cleaning, float-level adjustment, and condition-specific jetting selection.
• Chassis and brake work: Includes wheel and hub-bearing service, hydraulic front and rear caliper and master-cylinder repair, brake bleeding, steering and toe-in adjustment, rear axle-housing work, and Full-Floating suspension removal, inspection, and reassembly.
• Diagnosis and electrical references: Provides symptom/cause/remedy charts for the engine, clutch, transmission, carburetor, cooling system, electrical system, handling, suspension, and brakes, backed by CDI and magneto tests, lighting-system checks, a full wiring diagram, switch charts, and routing views.
• Maintenance and tune-up: Includes the factory interval chart, lubrication points, and procedures for drivetrain, fuel, cooling, brake, steering, and chassis checks, with more frequent service called for under severe conditions.

This publication combines Suzuki's full LT250RF service information with the dedicated LT250RG update for the 249 cc, water-cooled two-stroke Quad Racer. Suzuki says it was produced primarily for experienced mechanics, while apprentice and do-it-yourself mechanics can also use it; engine splitting, hydraulic-brake repair, and chassis-bearing work still assume proper shop tools and established service practices. The foreword notes that country-market machines may have minor statutory differences from the standard specification.

How the 1986 LT250RG Coverage Works

The 1986 material is a differential supplement. Section 9 directs the reader to the LT250RF chapters wherever no G-model difference is listed, then marks changed service data and specifications. Suzuki applies the listed changes from the first production of the LT250RG.

For the LT250RG, Suzuki documents revised cylinder port shape and timing, a different cylinder-head gasket, and altered fourth- and top-gear components. The section also distinguishes the G-model rear-shock adjuster and preload setup, muffler, rear brake pad, under-guard and reservoir changes, plus radiator and reservoir hose routing.

Parts and settings differ here: the 1986 G-model uses the MIKUNI VM34SS, not the RF model's VM32SS, and receives its own condition-based jetting table, magneto/CDI changes, and ignition specifications. That distinction matters when selecting carburetor parts or baseline settings.

Repair, Inspection, and Overhaul Detail

The engine chapter reaches well beyond routine tune-up work. It covers crankcase separation, crankshaft removal and installation, crankshaft runout and shim selection, transmission and shift-fork inspection, clutch plate and spring checks, cylinder and head distortion, bore and piston inspection, piston-ring limits, reed-valve checks, reassembly, and final adjustments.

Chassis chapters address front-wheel and tire service, twin front discs, the rear hydraulic disc, calipers and master cylinders, steering knuckles and tie rods, the independent double-wishbone front suspension, rear axle and housing, swingarm, cushion linkage, and Full-Floating rear suspension. These sections contain removal, disassembly, inspection, reassembly, and adjustment procedures rather than specifications alone.

Diagnostics, Diagrams, and Shop Data

Troubleshooting tables connect symptoms, possible causes, and remedies for hard starting, stalling, engine noise, clutch slip or drag, shifting faults, carburetor overflow, overheating, ignition and lighting faults, steering and handling complaints, suspension trouble, and hydraulic-brake problems.

Illustrated references include the counter-balancer operation diagram; carburetor slow-, main-, starter-, and float-system diagrams; the water-pump exploded assembly; CDI ignition and AC lighting schematics; the full wiring diagram; and wire, cable, brake-hose, and radiator-hose routing views.

The service-data section supplies component-specific torque tables, a general fastener chart, capacities and approved-fluid information, wear limits, clearances, electrical test values, and adjustment data. A 39-item special-tool list identifies factory numbers such as 09920-13120 for the crankcase separating tool, 09910-32812 for the crankshaft installer, 09920-53710 for the clutch-sleeve-hub holder, and 09930-40113 for the rotor holder.

Component-Specific Service Cautions

The engine reassembly notes warn against tapping the crankshaft into the crankcase because crankshaft alignment accuracy can be affected; the specified installer is required. The brake chapters flag high-pressure air as a caliper-piston damage risk and prohibit solvent or gasoline when cleaning hydraulic components.

Read the factory precautions before beginning repair work. They cover ventilation when running the engine, explosive fuel handling, brake-fluid leakage, tire inflation, one-time-use circlips, and post-service operational checks.