Suzuki LT230S & QuadSport 230 1986–1990 Factory Service Manual (P/N 99500-42034-01E)

This official 249-page OEM workshop manual (P/N 99500-42034-01E) is the master reference for the QuadSport 230 series. It documents the complete transition of model-year specifications from 1986 through 1988, providing comprehensive data across engine, chassis, electrical, and fuel systems.

• Instant PDF Download: Secure immediate access to the documentation directly on your device the moment your order is placed.
• Comprehensive Trim Coverage: Includes targeted factory service data for the LT230SG, LT230SH, and LT230SJ variants.
• Visual Diagnostics: Features 29 high-resolution exploded-view diagrams optimized for workshop printing, alongside 16 critical torque specification tables.
• Workshop Optimized: A fully indexed and searchable PDF architecture allows mechanics to rapidly locate schematics, chapters, and wiring diagrams.

Engine and Chassis Documentation

This factory reference provides the precise data required for standard maintenance and complete overhaul procedures on the 229cc four-stroke engine and chassis. It effectively breaks down periodic maintenance schedules, engine removal steps, and transmission disassembly.

Professionals in the shop gain immediate access to technical parameters for the Mikuni VM26SS carburetor, including specific float height adjustments and main jet specifications. Detailed exploded views support accurate cylinder head and crankcase reassembly, ensuring the exact alignment of gaskets, O-rings, and circlips. The documentation also covers servicing tolerances for the double A-arm front suspension and the swingarm rear configuration. For additional context on navigating these layouts, explore how factory workshop documentation is structured.

Specification Highlights

Clearances and wear limits are strictly documented for high-stress engine components, including the piston, rings, camshaft, and rocker arms. Cylinder head bolt torque values are specified in a multi-stage sequence, dictating a final-stage torque of 21–25 N-m (15.0–18.0 lb-ft) for 8 mm bolts.

Other critical tolerances include:

• Camshaft journal oil clearance limit: 0.150 mm
• Intake valve clearance: 0.03–0.08 mm

This technical documentation contains advanced service data designed strictly for reference purposes. Safe and effective maintenance requires qualified mechanics utilizing proper workshop tooling and standard industry safety protocols.