1988-1992 Suzuki LT230E/EJ/EK/EL/EM/EN QuadRunner 230 Service Manual
Detailed repair and maintenance procedures for your Suzuki LT230E QuadRunner, covering engine, chassis, and electrical systems. Includes diagrams and part numbers. Ref: 99500-42075-01E
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Sample pages from the 1988-1992 Suzuki LT230E/EJ/EK/EL/EM/EN QuadRunner 230 Service Manual manual
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Models Covered & Key Technical Specifications
SUZUKI LT230E / LT230EJ / LT230EK / LT230EL / LT230EM / LT230EN (99500-42075-01E) - 1988-1992 Consolidated Resource | ATV QuadRunner. Certified Fastening Values: 20 – 25 N·m controls the drain plug tightening torque. General Threaded Fastener Data: 11 - 9 mm governs the front wheel toe-in specification. Defined System Fill: 9.5 L (2.4 US/Imp gal) is specified as the fuel tank capacity. Key Power Framework: 1855 mm (73.0 in) is the overall length. Verified Throughput Data: 229 cm³ mapping defines the engine displacement. Factory Output Density: 172 kg (379 lbs) benchmarks establishes the dry mass.
Professional Workshop Service Manual & Technical Specifications
In-Depth Operations Installation Manual: ATV Suzuki LT230E LT230EK LT230EL LT230EM LT230EN QuadRunner 230 Manual - Maintenance, Troubleshooting & Diagnostics Repair-Index
Reference-Category: Suzuki LT230E / LT230EJ / LT230EK / LT230EL / LT230EM / LT230EN (99500-42075-01E) // Reference-Category: ATV / QuadRunner Logic // Reference-Category: Maintenance, Troubleshooting & Diagnostics.
| Performance-Element | Baseline | Calibration-Spec | |
|---|---|---|---|
| Overall Length | 1855 mm (73.0 in) | 1855 mm (73.0 in) | |
| Overall width | 1060 mm (41.7 in) | 1060 mm (41.7 in) | |
| Overall height | 1125 mm (44.3 in) | 1125 mm (44.3 in) | |
| Wheelbase | 1130 mm (44.5 in) | 1130 mm (44.5 in) | |
| Front track | 810 mm (31.9 in) | 810 mm (31.9 in) | |
| Rear track | 800 mm (31.5 in) | 800 mm (31.5 in) | |
| Ground clearance | 125 mm (4.9 in) | 125 mm (4.9 in) | |
| Seat height | 800 mm (31.5 in) | 800 mm (31.5 in) | |
| Dry mass | 172 kg (379 lbs) | 172 kg (379 lbs) | |
| Engine Type | Four-stroke, air-cooled, OHC, TDCC | Four-stroke, air-cooled, OHC, TDCC | |
| Number of cylinders | 1 | 1 | |
| Bore | 66.0 mm (2.598 in) | 66.0 mm (2.598 in) | |
| Stroke | 67.0 mm (2.638 in) | 67.0 mm (2.638 in) | |
| Piston displacement | 229 cm³ (14.0 cu, in) | 229 cm³ (14.0 cu, in) | |
| Compression ratio | 9.0 : 1 | 9.0 : 1 | |
| Carburetor | MIKUNI VM24SS, single | MIKUNI VM24SS, single | |
| Air cleaner | Polyurethane foam element | Polyurethane foam element | |
| Starter system | Electric and recoil | Electric and recoil | |
| Transmission | Wet multi-plate type, automatic, centrifugal type | Wet multi-plate type, automatic, centrifugal type | |
| Gearshift pattern, Forward | 5-forward constant mesh, 1-reverse | 5-forward constant mesh, 1-reverse | |
| Primary reduction | 3.56 (69/22) | 3.56 (69/22) | |
| Final reduction | 3.727 (41/11) | 3.727 (41/11) | |
| Gear ratios, Low | 3.083 (37/12) | 3.083 (37/12) | |
| 2nd | 1.933 (29/15) | 1.933 (29/15) | |
| 3rd | 1.444 (26/18) | 1.444 (26/18) | |
| 4th | 1.095 (23/21) | 1.095 (23/21) | |
| Top | 0.913 (21/23) | 0.913 (21/23) | |
| Reverse | 2.833 (29/12 x 34/29) | 2.833 (29/12 x 34/29) | |
| Drive chain | DAIDO D.I.D. 520VS or TAKASAGO RK520SM, 84 links | DAIDO D.I.D. 520VS or TAKASAGO RK520SM, 84 links | |
| Ignition type | SUZUKI "PEI" | SUZUKI "PEI" | |
| Ignition timing | 5° B.T.D.C. below 1 800 r/min | 5° B.T.D.C. below 1 800 r/min | |
| 30.5° B.T.D.C. above 3 800 r/min | 30.5° B.T.D.C. above 3 800 r/min | ||
| Spark plug | NGK D7EA, NIPPON DENSO X22ES-U, or CHAMPION RA8YC | NGK D7EA, NIPPON DENSO X22ES-U, or CHAMPION RA8YC | |
| NGK CR7ES, NIPPON DENSO X22ESR-U, or CHAMPION RA8YC – for Canada | NGK CR7ES, NIPPON DENSO X22ESR-U, or CHAMPION RA8YC – for Canada | ||
| Battery | 12V 43.2 kC (12 Ah)/10 HR | 12V 43.2 kC (12 Ah)/10 HR | |
| Headlight | 12V 45/45W | 12V 45/45W | |
| Taillight | 12V 5W | 12V 5W | |
| Reverse indicator light | 12V 2W | 12V 2W | |
| Neutral indicator light | 12V 2W | 12V 2W | |
| Fuse | 18A | 18A | |
| Front suspension | Independent, double wishbone, oil damped, spring pre-load 5-way adjustable | Independent, double wishbone, oil damped, spring pre-load 5-way adjustable | |
| Rear suspension | Swingarm, oil damped, spring preload fully adjustable | Swingarm, oil damped, spring preload fully adjustable | |
| Steering angle | Inside 35° | Inside 35° | |
| Outside 25° | Outside 25° | ||
| Caster | 6° ±1° | 6° ±1° | |
| Trail | 37 mm (1.4 in) | 37 mm (1.4 in) | |
| Turning radius | 2.5 m (8.2 ft) | 2.5 m (8.2 ft) | |
| Front brake | Disc brake, twin, hydraulically operated | Disc brake, twin, hydraulically operated | |
| Rear brake | Disc brake, hydraulically operated | Disc brake, hydraulically operated | |
| Front tire size | AT 21 x 7 – 10 | AT 21 x 7 – 10 | |
| Rear tire size | AT 22 x 11 – 9 | AT 22 x 11 – 9 | |
| Fuel tank including reserve | 9.5 L (2.4 US/Imp gal) | 9.5 L (2.4 US/Imp gal) | |
| Reserve | 1.0 L (1.1 US/Imp qt) | 1.0 L (1.1 US/Imp qt) | |
| Engine oil | Oil change | 1 500 ml (1.6/1.3 US/Imp qt) | 1 500 ml (1.6/1.3 US/Imp qt) |
| Filter change | 1 700 ml (1.8/1.5 US/Imp qt) | 1 700 ml (1.8/1.5 US/Imp qt) |
Service sections detail diagnostic procedures and maintenance schedules for the Suzuki QuadRunner 230. Key systems covered include the engine, fuel and lubrication, electrical, and chassis. Technical notes and part diagrams are provided for each component. Analytically requiring updated information, this manual documents torque specifications for engine mounting bolts to ensure proper clamp load consistency.
Engine Components Removal and Reassembly
Procedures for removing and reinstalling engine components are thoroughly outlined, including the cylinder head, camshaft, crankshaft, and transmission. Detailed diagrams illustrate the location and function of each part.
Fuel and Lubrication System
This section covers the fuel and oil systems, including carburetor adjustments, fuel line inspection, and oil change procedures. It details proper fluid recommendations and filter replacement steps.
Electrical System
Comprehensive coverage of the charging system, ignition system, starter system, lamps, switches, and battery. Includes wiring diagrams, inspection procedures, and troubleshooting tips for electrical issues.
Chassis and Suspension
Documents maintenance and repair for the front and rear wheels, brakes, steering, and suspension systems. Includes tire pressure specifications, brake pad replacement, and alignment procedures.
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