1986-1990 Suzuki LT230S / QuadSport 230 Service Manual

Suzuki LT230S 1986–1990 Technical Reference

• Covers the 1986–1990 Suzuki LT230S and QuadSport 230, including specific service data for the LT230SG, LT230SH, and LT230SJ trim variants
• Original OEM publication P/N 99500-42034-01E, copyright 1990
• Contains 29 detailed exploded-view diagrams, 16 critical torque specification tables, and comprehensive wiring and fuel system schematics
• Accessible from your device as soon as the order is placed
• Stored against your account so you can retrieve it after a hard-drive loss
• Print resolution preserves exploded-view detail
• Indexed PDF search covers every chapter and appendix
• This 1990 edition is the master reference for the QuadSport 230, documenting the full transition from 1986 through 1988 model-year specifications

Engine and Chassis Documentation

The 1986–1990 Suzuki LT230S service manual details standard maintenance and overhauling procedures for the 229 cm³ four-stroke engine and chassis systems. Chapters provide data on periodic maintenance, engine removal and remounting, transmission disassembly, fuel system architecture, and electrical circuit identification. This documentation provides specific instructions for cleaning the air filter, inspecting the drive chain, and performing valve clearance checks on the overhead cam configuration.

Technicians find in-depth data regarding the Mikuni VM26SS carburetor, including float height adjustments and main jet specifications. Cylinder head and crankcase reassembly instructions are supported by detailed exploded-view illustrations, ensuring accurate placement of gaskets, O-rings, and circlips. The manual includes specific guidance for servicing the wishbone front suspension and the swingarm rear suspension.

Specification Highlights

Engine component clearances and wear limits are documented for critical parts including the piston, rings, camshaft, and rocker arms. Cylinder head bolt torque values are specified in a multi-stage sequence, with final-stage values of 21–25 N-m (15.0–18.0 lb-ft) for 8 mm bolts. Camshaft journal oil clearance limit is documented at 0.150 mm in the engine specification section. Valve clearance for the intake is listed at 0.03–0.08 mm in the valve specification table. For more details, explore how factory workshop documentation is structured to assist in your technical reviews.

Note: This document contains service data for reference purposes and should be used by qualified mechanics to guide maintenance activities.

An official 249-page Suzuki OEM workshop manual covering the 1986–1990 Suzuki LT230S, documenting engine, chassis, electrical, and fuel-system specifications for the QuadSport 230 series build.