1986 Suzuki LT250E Service Manual

Suzuki LT250E 1986 Service Manual Documentation

• Covers the 1986 Suzuki LT250E QuadRunner 250, including technical specs for the 4-stroke TSCC engine, 5-speed transmission, and independent double-wishbone front suspension.
• Official Suzuki publication 99500-42011-01E, first edition published 1986.
• Contains 276 pages of technical detail, including exploded-view chassis diagrams, engine assembly sequences, wiring schematics, and service threshold tables.
• Downloads to your account within seconds of checkout.
• Permanent availability in your purchase account — no re-buy required.
• OCR text layer lets you jump to a torque spec by keyword.
• Suitable for printing individual sections for shop-floor use.
• Includes detailed maintenance schedule for initial 200 km and recurring 1000 km service intervals.
• This 1986 edition remains the primary reference for the LT250E TSCC engine rebuild and chassis alignment settings.

Manual Coverage Scope

The 1986 Suzuki LT250E service manual contains comprehensive data for the maintenance and overhaul of this specific factory workshop documentation. Chapters are segmented into general information, engine service, fuel and lubrication systems, electrical diagnostics, and chassis maintenance. Readers will find distinct sections dedicated to the TSCC engine architecture, cylinder head servicing, clutch lock-up inspection, and crankcase disassembly. Each section transitions from component inspection to rebuild procedures, supported by specific torque values for engine mounting bolts, cylinder head nuts, and axle housing assembly.

Engine and Chassis Specifications

The specifications section lists vital clearances and fluid capacities necessary for maintaining the 249 cc engine and 5-speed constant mesh transmission. Engine oil capacity is documented at 1600 ml for standard changes and 2100 ml for full overhauls. Spark plug gap is specified at 0.6–0.7 mm. Intake valve clearance for the 1986 Suzuki LT250E is listed at 0.03–0.08 mm in the cylinder head specification table. Rear axle nut and lock nut tightening is documented at 160–200 N·m. The 1986 Suzuki LT250E fuel tank capacity is specified at 10.0 liters in the chassis specifications table. All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. This official 276-page Suzuki OEM workshop manual covers the 1986 Suzuki LT250E QuadRunner 250, documenting engine, chassis, electrical, and maintenance specifications for the TSCC-series build.