This manual covers the QuadRunner series, specifically the LT230S Chain Drive, LT-F230G Shaft Drive, LT230G Shaft Drive, and LT250S Chain Drive models produced between 1985 and 1990. These versatile all-terrain vehicles (ATVs) were renowned for their reliability and performance, featuring air-cooled, four-stroke engines with displacements around 229cc for the LT230 models and 246cc for the LT250. The legacy in ATV development is evident in these models, which offered a balance of capability and user-friendliness, with some featuring a dual-range subtransmission for enhanced off-road performance.
This comprehensive service and repair manual provides essential information for maintaining and troubleshooting your QuadRunner. It details procedures for all major systems, including the engine, transmission, fuel, electrical, suspension, steering, and brakes. The manual covers routine maintenance, tune-ups, component rebuilds, and troubleshooting common issues, making it an invaluable resource for owners and technicians alike. With clear language, detailed illustrations, and wiring diagrams, this guide ensures you can keep your ATV in optimal condition.
Models Covered:
LT230S Chain Drive (1985-1988)
LT-F230G Shaft Drive (1985-1987)
LT230G Shaft Drive (1985-1986)
LT250S Chain Drive (1989-1990)
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.
Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Service hints / Torque specifications / Safety first / Service hints / Special tips / Expendable supplies / Parts replacement / Serial numbers / Basic hand tools / Tune-up and troubleshooting tools / Mechanic's tips / Off road rules / Riding safely
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Emergency troubleshooting / Engine starting / Engine performance / Engine noises / Excessive vibration / Front suspension and steering / Brake problems
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist / Service intervals schedule / Periodic lubrication / Engine oil and filter change / Control cable lubrication / Non-scheduled lubrication / Periodic maintenance / Non-scheduled maintenance / Reverse cable adjustment / Tune-up / Valve clearance / Compression test check / Spark plug / Air filter / Specifications
CHAPTER FOUR / ENGINE
Engine principles / Engine cooling / Serving engine in frame / Engine removal and installation / Cylinder head cover and rocker arm assembly / Cylinder head and camshaft / Valves and valve seats / Cylinder / Piston, piston pin and piston rings / Oil pump / Cam chain tensioner / Kickstarter (chain-driven models) / Recoil starter (shaft-driven models) / Starter gears (shaft-driven models) / Secondary bevel gear and drive gear set (shaft-driven models) / Crankcase and crankshaft / Break-in procedure / Specifications
CHAPTER FIVE / CLUTCH AND TRANSMISSION
Clutch operation / Centrifugal clutch / Manual clutch / Manual clutch inspection / Clutch lifting mechanism (shaft-driven models) / Clutch release mechanism (chain-driven models) / Clutch cable (chain-driven models) / External shift mechanism / Drive sprocket (chain-driven) / Transmission and internal shift mechanism / Dual-range subtransmission (shaft-driven LT-F230) / Specifications
CHAPTER SIX / FUEL AND EXHAUST SYSTEMS
Carburetor operation / Carburetor service / Throttle cable / Choke cable (shaft-driven models) / Fuel shutoff valve / Fuel tank / Fuel pump (shaft-driven models) / Exhaust system / Specifications
CHAPTER SEVEN / ELECTRICAL SYSTEM
Charging system (models so equipped) / Voltage regulator (shaft-driven models) / Alternator (shaft-driven models) / Magneto (chain-driven models) / Capacitor discharge ignition / Ignition coil / Starting system (models so equipped) / Starter / Starter solenoid / Lighting system / Switches / Odometer housing (shaft-driven models) / Fuse / Specifications
CHAPTER EIGHT / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Steering system / Tires / Specifications
CHAPTER NINE / REAR AXLE, SUSPENSION AND FINAL DRIVE
Rear wheel / Rear axle (shaft-driven models) / Rear axle and driven sprocket (chain-driven models) / Driven sprocket (chain-driven models) / Rear axle inspection (all models) / Final drive unit (shaft-driven models) / Drive sprocket and chain (chain-driven models) / Rear axle bearing and oil seal replacement (shaft-driven models) / Rear axle bearing housing (chain-driven models) / Shock absorber (chain-driven models) / Swing arm (chain-driven model) / Specifications
CHAPTER TEN / BRAKES
Drum brakes / Front drum brakes / Rear drum brake / Drum brake inspection (front hub and rear) / Disc brakes / Front brake pad replacement / Rear brake pad replacement / Front master cylinder (drum and disc brake models) / Rear master cylinder (disc brake models) / Front caliper / Rear caliper / Front brake disc / Rear brake disc / Front brake hose replacement (drum and disc brake models) / Rear brake hose replacement / Bleeding the system / Rear disc brake pedal / Specifications
CHAPTER ELEVEN / BODY
Front fender / Rear fender / Front hand grip / Rear hand grip / Front and rear carriers (shaft-driven models) / Specifications
SUPPLEMENT / 1987 AND LATER SERVICE INFORMATION
INDEX
WIRING DIAGRAMS
Models Covered:
LT230S Chain Drive (1985-1988)
LT-F230G Shaft Drive (1985-1987)
LT230G Shaft Drive (1985-1986)
LT250S Chain Drive (1989-1990)
This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.
Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
Manual Contents:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Service hints / Torque specifications / Safety first / Service hints / Special tips / Expendable supplies / Parts replacement / Serial numbers / Basic hand tools / Tune-up and troubleshooting tools / Mechanic's tips / Off road rules / Riding safely
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Emergency troubleshooting / Engine starting / Engine performance / Engine noises / Excessive vibration / Front suspension and steering / Brake problems
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist / Service intervals schedule / Periodic lubrication / Engine oil and filter change / Control cable lubrication / Non-scheduled lubrication / Periodic maintenance / Non-scheduled maintenance / Reverse cable adjustment / Tune-up / Valve clearance / Compression test check / Spark plug / Air filter / Specifications
CHAPTER FOUR / ENGINE
Engine principles / Engine cooling / Serving engine in frame / Engine removal and installation / Cylinder head cover and rocker arm assembly / Cylinder head and camshaft / Valves and valve seats / Cylinder / Piston, piston pin and piston rings / Oil pump / Cam chain tensioner / Kickstarter (chain-driven models) / Recoil starter (shaft-driven models) / Starter gears (shaft-driven models) / Secondary bevel gear and drive gear set (shaft-driven models) / Crankcase and crankshaft / Break-in procedure / Specifications
CHAPTER FIVE / CLUTCH AND TRANSMISSION
Clutch operation / Centrifugal clutch / Manual clutch / Manual clutch inspection / Clutch lifting mechanism (shaft-driven models) / Clutch release mechanism (chain-driven models) / Clutch cable (chain-driven models) / External shift mechanism / Drive sprocket (chain-driven) / Transmission and internal shift mechanism / Dual-range subtransmission (shaft-driven LT-F230) / Specifications
CHAPTER SIX / FUEL AND EXHAUST SYSTEMS
Carburetor operation / Carburetor service / Throttle cable / Choke cable (shaft-driven models) / Fuel shutoff valve / Fuel tank / Fuel pump (shaft-driven models) / Exhaust system / Specifications
CHAPTER SEVEN / ELECTRICAL SYSTEM
Charging system (models so equipped) / Voltage regulator (shaft-driven models) / Alternator (shaft-driven models) / Magneto (chain-driven models) / Capacitor discharge ignition / Ignition coil / Starting system (models so equipped) / Starter / Starter solenoid / Lighting system / Switches / Odometer housing (shaft-driven models) / Fuse / Specifications
CHAPTER EIGHT / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Steering system / Tires / Specifications
CHAPTER NINE / REAR AXLE, SUSPENSION AND FINAL DRIVE
Rear wheel / Rear axle (shaft-driven models) / Rear axle and driven sprocket (chain-driven models) / Driven sprocket (chain-driven models) / Rear axle inspection (all models) / Final drive unit (shaft-driven models) / Drive sprocket and chain (chain-driven models) / Rear axle bearing and oil seal replacement (shaft-driven models) / Rear axle bearing housing (chain-driven models) / Shock absorber (chain-driven models) / Swing arm (chain-driven model) / Specifications
CHAPTER TEN / BRAKES
Drum brakes / Front drum brakes / Rear drum brake / Drum brake inspection (front hub and rear) / Disc brakes / Front brake pad replacement / Rear brake pad replacement / Front master cylinder (drum and disc brake models) / Rear master cylinder (disc brake models) / Front caliper / Rear caliper / Front brake disc / Rear brake disc / Front brake hose replacement (drum and disc brake models) / Rear brake hose replacement / Bleeding the system / Rear disc brake pedal / Specifications
CHAPTER ELEVEN / BODY
Front fender / Rear fender / Front hand grip / Rear hand grip / Front and rear carriers (shaft-driven models) / Specifications
SUPPLEMENT / 1987 AND LATER SERVICE INFORMATION
INDEX
WIRING DIAGRAMS
