Restoring an old 1990 LT250s

[Dirtweed]

Call me crazy, but I found this LT250s and all it really needed was a swing arm bearing and a good oil change and there
I go tearing this down. I've got it most of the way down just need to remove the engine and take the springs off
the shocks and ball joints off the A-arms and then it is off to the powder coater....just waiting for a warm day to get
back into the garage.

These were only made in 1989 and 1990 so some parts are as rare as hen's teeth. The plastics I bought were pricy!

all the pics...
http://www.pbase.com/dirtweed/1990_suzuki_lt250s&page=all

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[bkm]

I can honestly say I have never seen one of those and its kinda cool looking. I take it the fenders are NOS? What does plastic for something like this run?

[swampthang]

When I first got into quads I seen one of these things for sale in someones yard localy. I called them and talked to a woman and she said they wanted $500 for it. I asked what kind of 4wheeler it was she said it was an Oakleys, must have seen the Oakleys sticker on the fender.:lol: I was prolly about 11 years old at the time and had no clue what it was either. All my buddies taught it was a Quadzilla. Glad I didn't buy it now thinking it was a Oakleys Quadzilla special edition.

[90guy]

Nice find I always had wanted one the little brother to quadzilla wasnt it?

[Gearheadtom]

A buddy has one of those that he's been fixing up (with my help). His in an '89, and ya, parts are rare.
We're currently in the process of getting the motor fixed. Rod was seized when he got it, and nobody sells a rod kit. A few places sell the rod, bearing, and pin separate, not cheap tho. A few other parts he needs to find to, rear caliper, and maybe a bearing carrier.

[fabiodriven]

Wow man, that's a machine I never even knew existed. You just blew my mind. It's like a Suzuki 250X.

[MonroeMike]

I have a LT250s repair manual, if you need it.

[fabiodriven]

I have a LT250s repair manual, if you need it.

You would.

[Dirtweed]

Thanks guys, yeah it's a hard one to find and a harder one to find parts for. I did find a service manual on eBay thanks for the offer though!

The wife wouldn't allow a purchase of a new quad and I had to agree with the current prices, but we were OK with dumping some cash into
this one to have a rare vintage ride that looks good. The plastics I picked up NOS from a couple of different warehouses and the blue hood
from a dealership in Arkansas that was clearing out old parts. Also picked up a new headlight assembly...even though the one I have is fine.
The plastics altogether ran me over $800. (Ouch!) Bob Tracey's world of Cycles in PA actually had the NOS stickers in stock, something they
were quite surprised about. I could not find the decals for the front fender anywhere so I have to have those reproduced.

The carb needed rebuilding and of course there was no kit so I had to order the LT230S carb kit and order the parts for the LT250S that were
available. Kinda like a giant Easter Egg hunt for me. I have been tossing up what color to powder the frame with, but I might just do original colors.....
then I'll not want to ride it. Dunno, but I have some time to figure that out.

This quad was bought new at Hollink in Spencerport NY and was ridden, but not too hard. It has sat the last 10+ years in a garage untouched and
hasn't been started either. I brought it home and figured what the heck and tossed some gas in it. After a few kicks it started right up and ran
great. It has a small oil leak at the base of the Jug so we're going to open it up, check it all out and button it back up.

It should look pretty good when I'm done with it. I've done quite a few tractors over the last few years and the quads are a lot easier to work on
so it should be pretty easy.

Darrin

Here is one of the tractors I brought back to life....
http://www.pbase.com/dirtweed/1986_john_deere_216&page=all

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[90guy]

Nice I like that you know the history of the quad. I like that your wife agree with this project that'd be awesome! Nice tractor we had a 210 that after breaking the rod twice it was time to go down the road.

[Dirtweed]

Nice I like that you know the history of the quad. I like that your wife agree with this project that'd be awesome!

My wife likes the classic cars and machines....she can't ride due to having neck surgery a while back, but she doesn't mind us working
on them and keeping them in the garage. As long as she gets to park inside that is.




I have a 88 lt 230 Quadsport.I picked up a parts machine for it last summer .The 88 was origonaly blue and white like yours.The parts machine I got has orange mieres fenders on it that have been painted.Im going to redo the 88 over in the orange and black colors.

A guy by me had an 88 in orange and black for sale that was in really nice shape. We were thinking about it then that 250R popped up and we went with that.

[ezmoney1979]

Years ago my dads best friend had one in mint, almost new condition, probably only 50 hours on it. My dad was borrowing it and it was being kept up at his house. My uncle was in town and decided to go for a ride when no one was home and for whatever reason he went out to the paved road. He pulled out of the driveway without looking and got hit by a truck. His face took the impact of the side mirror, tearing it off of the truck and sending him down an embankment. The 250S was never the same, frame got tweaked, shocks and A-arms bent, front plastic destroyed, etc. I don't think my uncle was ever the same either, he was hurt very badly, lots of stitches. A helmet looked like it would have been a good idea...........

I owned a 1992 250X during that time. It was a better quad in every way than the LT250S. Not that the LT250S was bad, it was an easy to ride, fun little quad, just slower with worse suspension. And the build quality of the Honda was so much better. I really want to know who designed the kick start for the LT250S, that guy needs punched in the face, dare I say worse than a Tecate.

Good luck with the build, looks like you got the hard part done with finding the plastic. I really dig the lawn tractor too, very nice job!! :beer

[Dirtweed]

Wow your poor Uncle...that's rough.

Yeah it's not the best designed Quad, but I'm one for being different usually. That side kicker really didn't make any sense at all.
Take a look at the link I posted and see my John Deere 316, 420, 314 and the 112 I am working on now.

I just found a guy on another forum about 1.5 hours from my house is restoring his LT250s.
Got me excited some more....gotta get more information from him about the shocks he bought for the front and how to stuff that Banshee shock in the rear.

[atc007]

Great machines,head and shoulder above the 230's. The kickers are a dream if you give them a chance??! They start effortlessly. Had a LOT of them apart and had to retime them. I have one now,,needs restored for sure. I would LOVE to find nos plastic and seat for mine. VERY nice work dirt weed!

[bkm]

I was Service Honda's website and they say the plastic is still available for them. They are usually on top of whats available and whats been discontinued. Might want to check on that Bill.

[Kfx-xc-racer88]

i've seen a vid with one of those racing at the blackwater back in the day!

[Gearheadtom]

Crazy thing is me and a buddy of mine just found another lt250s at the local Sukuki dealer. We all though it was a 230 at first, until we looked closer. It's was abandoned for 3 years when it was brought in for service work. He's going to try and get a hold of the owner and see if he can buy it. So that's the second lt250s we know of in the province.

[tri-shee]

Great find on your suzuki . I have always like the look of that bike . Also i like is that you are bringing back to life are the old John Deere riding mowers . Great job on restoration . My dad gave me his old John Deere RX-73 rear engine with a 9 HP Kawasaki 10 years ago . All it needed at the time was a new carb . I still have it and it has a rear two bag grass catcher with it . Still runs great for around 27 years old . He bought it new . I bought a John Deere F-525 riding mower new in 1997 and it still runs great , still looks new . It has a 17 HP kawasaki motor . I like old vintage riding mowers . Keep up the good work . Later Blair

[Larry T Moore]

Buddy of mine bought a Quadzilla new and tore the trailprotrailprotrailprotrailpro out of it..but it still runs and its in the garage...Ive tried for years to buy it

[Dirtweed]

Just got the LT250s back from the powder coater. Of course I forgot a few small pieces that have to get done, but nothing that
I can't start without. The holding bay for parts in the front room so not good light for the pics, but you get the idea.


Darrin

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[SWIGIN]

That's gonna look SHARP!

[Dirtweed]

I've got the Axle and misc hardware headed in next week to get zinc coated and the foot pegs are going in to get
powder coated a nice blue. Got all the bearings I ordered in this week and need to get to my brothers
house to have them all pressed in so I can start slapping it back together.

[atc007]

I cannot WAIT to see this beauty on it's feet !!!!!!!!!! Great work my friend.

[Dirtweed]

Made some progress on the LT250s. I finally got the parts and started building it today. Missing a few bolts here and there, but at trip
to the Hardware store took care of that.

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[SWIGIN]

What tires are those on the back?

They look like turftamers but the knobs look bigger.

[Dirtweed]

18" Quad Cross Pro MX tires. Got them for a steal with the ITP rims.

[6speedthumper]

Really great to see someone saving one of these. I had an '87 LT230s about ten years ago. Was bored out, had cam & springs, and modded air box. Sucker was fast! I know these engines had a no so good oiling system. Idk, what the fix is, if any. I hated the kicker, too. But, use the decomp lever on the bars, and BANG! Fired right up! Tough quad all things considering... Keep up the good work!

[Dirtweed]

More updates on the quad. I don't have my 250R yet so I have to play with this one.
Got it rolling tonight....missing a few bolts and spacers as usual, but I'll get those in next
week. At least I can move it around the garage.

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[honda200xguy]

this thread makes me really want to go get that quadsport...like NOW!!!
im going to restore it also..so i'll need some tips in tricks from you dirtweed.
NICE JOB BUDDY!

[Dirtweed]

For the money you are going to put into a restore you might be better off just getting
one of the newer LTZ250 bikes from Suzuki like I said in the PM.

[honda200xguy]

For the money you are going to put into a restore you might be better off just getting
one of the newer LTZ250 bikes from Suzuki like I said in the PM.
Money isn't a factor..i've thought these bikes looked badass for years.

[Dirtweed]

Money isn't a factor..i've thought these bikes looked badass for years.


I like that attitude. The Baby Zilla did look nice when it was new. Can't wait to finish mine.

Post some pics if you buy the machine. You also might want to check with Bob Tracey's at that link I posted
to see if there are any rear fenders left. I know they had the decals for the rear on their shelves, but not sure
if they had anymore.

[Dirtweed]

Got tired of looking at it without plastics on it. Did the test fit of the plastics tonight. I'll have to find a better way to
attach the fronts since I don't really want to use the Mud flaps on the quad. Though I might have to in order to keep the
fronts from ripping off of just one attachment point.

We pick up the custom seat tomorrow so that should make it look better. Engine.....waiting................

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[Dirtweed]

The seat turned out OK. The 110ATC seat is going to Mrs Mosh for recovering once I can get it out from under my kid.

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[6speedthumper]

Looking very, very, nice! I wish I had my 230 still...

[Dirtweed]

Latest additions to the LT250s. New rear brake caliper and some Tusk G-Force extended hubs in 4/115. They share the same spline count
as my 1982 250R so I'll be able to swap tires between the two of them.

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[atc007]

Yeah,,but it's no TRX,,,lol,,, Keep rubbin it in !! Seriously,looking great man. What a beauty.

[trizilla]

lookin good darrin! keep it up

[tri-shee]

sweet bike !

[Dirtweed]

Thanks guys. Should be getting into the engine in the next three weeks. My brother should have his kids truck done by then
and my YZ125 rebuild should also be done this week. From everyone that I have talked to that has had one of these the timing
chain is probably going to need replacing so I think I'm just going to go order one this week.

My brothers friend can't make a proper Sprocket guard for it so the hunt is on again for a guard. I have one for the disc, but the one
for the sprocket is NLA from Suzuki.

[Kfx-xc-racer88]

That LT is soooooo cool!! better than new! :)

[Dirtweed]

Still haven't finished the LT250s as I keep finding new parts, plus now that I bought the '14 TRX450R I need to ride a bit on weekends.

I did pick up and install a new headlight, new control switch and a new toolbox which is about the size of a new mailbox.
Engine will be done next time I am at my brothers house and then I can really get it back together.

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[aldochina]

looks awsome. just saw one of these for sale recently. it was very nice original condition. dont see them often at all. i remember wanting one as a kid.

[Dirtweed]

I see it on CL now in Sparrowbush NY. Very nice condition indeed and the plastics are intact which you do not see ever.

[aldochina]

probably a hell of alot less than what you have invested in yours! But thats not the point i know! seems like a good price for it, especially with the papers!

[aldochina]

what are the rear tires your running on that? I like them alot

[Dirtweed]

They are ITP 18x8-8 Quad Cross Pro MX tires with 4/115 ITP rims. The tires are brand new on slightly used rims....a guy listed them for
$150 on CL, but after a couple of weeks he was down to $75 so I got them. Using G-Force 4/115 hubs.

[Dirtweed]

Finally got the engine back in today! Exhaust hooked up. This week running the cables and taking a few things to get re-powdered that I nicked up.

http://www.pbase.com/dirtweed/image/160099540/large.jpg

[clmeue37]

I wondered what was going on with this thing. I followed your build over at atvconnection when I was hanging out in the "big" 230 thread a lot. I don't miss that sideways kicker on the 230 though...Looking good!

[Dirtweed]

Thanks, yes it is a three year project....nothing new for me. I don't really have a dedicated workspace and in the winter all work stops. I figure my
ATC250R will take a couple more years to get done as well.

When it is all put together I have to get those fins clean.

[Dirtweed]

Just when I thought I was about done with this....(De-Compression cable arrives tomorrow and I can get this started finally)

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I find a part off a 1988 LT230s that I am going to fit to the LT250s. This is the Headlight I found for the LT230s. It looks like the mount is the same
for the headlight so it should bolt right on. Once I see it fits I am going to send it to Bruce for custom graphics and then I have to try to polish
the plastic.....I'd rather not paint it.

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Here is the LT230s that I saw posted that drove me to look for the headlight I thought it was pretty neat looking.
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[Dirtweed]

Well I finished it and put it up in it's place on the shelf.

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[lndy650]

thats awesome man! my uncle had one when i was a kid i loved the sideways kicker even as a kid i could start it. it blew a crank and when i got older he gave it to me and i put a 200s engine in it. not a lot of power but it was really fun.