This manual covers the QuadSport, a sport ATV designed for recreational riders and trail riding enthusiasts. Produced from 2002 through 2009, this model is known for its user-friendly handling, reliable four-stroke engine, and overall good value within its segment. Building on a legacy of capable off-road vehicles, the LT-Z250 offers a balanced performance that appeals to those seeking an enjoyable and dependable riding experience. This comprehensive service and repair manual provides detailed guidance for maintaining and repairing the QuadSport. It covers essential areas including engine overhaul, fuel system servicing, transmission and drivetrain maintenance, suspension and brake system repairs, and electrical system diagnostics. The manual includes step-by-step instructions, troubleshooting flowcharts, and detailed wiring diagrams, offering factory-level detail to assist both owners and professional technicians in keeping the vehicle in optimal condition. 🏷️ Basic Information Identification Make: Suzuki Model: LT-Z250 QuadSport Product Type: Service and Repair Manual Format: PDF Download 👋 Introduction Market Position Category: Sport ATV / Utility ATV Crossover Target Audience: Recreational riders, trail riding, light sport use. Competitive Analysis Competitors: Honda TRX250EX, Yamaha Warrior 350 (earlier models), Kawasaki Mojave 250. Key Features Vehicle Attributes: User-friendly handling, reliable engine, good value for its class. 📋 Manual Details Coverage Areas Years Covered: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 Page Count Estimated Pages: 350+ Manual Type Type: Comprehensive Service and Repair Manual Language Language: English 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, top-end and bottom-end rebuilds, valve adjustment, piston and cylinder inspection, camshaft timing. Fuel System: Carburetor tuning and rebuilding, fuel pump, fuel lines, fuel filter replacement. Transmission: Clutch operation and adjustment, gear inspection, lubrication, shifting mechanism. Drivetrain: Chain maintenance, sprocket inspection, rear axle and hub assembly. Suspension: Front and rear shock absorber service, spring replacement, A-arm bushings, steering linkage. Brakes: Hydraulic brake system, caliper overhaul, brake pad replacement, rotor inspection, brake fluid bleeding, parking brake adjustment. Electrical System: Battery testing and replacement, ignition system diagnosis, lighting circuits, starter motor, charging system (stator and regulator/rectifier). Cooling System: Radiator service, fan operation, coolant replacement, thermostat testing. Lubrication System: Oil pump operation, oil filter replacement, oil specifications and capacities. Frame And Body: Chassis inspection, body panel removal and installation, seat, handlebars, and footpeg maintenance. Procedures Included Maintenance: Routine maintenance checks, lubrication points, filter replacement intervals, valve lash adjustments, chain tensioning. Troubleshooting: Diagnostic flowcharts for common starting issues, running problems, electrical faults, and performance issues. Repair: Step-by-step instructions for component disassembly, repair, and reassembly. Diagnostics: Methods for diagnosing electrical circuits, fuel delivery problems, and mechanical failures. Wiring Diagrams: Detailed electrical wiring schematics for all circuits. Technical Depth Level Of Detail: Factory-level detail suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF Searchability: Fully searchable text for quick information retrieval. Print Quality Printability: Printable pages for on-hand reference. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, air-cooled Displacement: 246.5 cc Bore X Stroke: 72.0 mm x 61.1 mm Compression Ratio: 9.2:1 Valve Clearance Intake: 0.08 - 0.12 mm (0.003 - 0.005 in) Valve Clearance Exhaust: 0.10 - 0.14 mm (0.004 - 0.006 in) Performance Horsepower: Approximately 18-20 HP (estimated, varies by region/tuning) Torque: Approximately 14-15 lb-ft (estimated) Fuel System Carburetor Model: Mikuni BNS32 (likely) Fuel Type: Unleaded gasoline Fuel Tank Capacity: 2.6 US gal (9.8 L) 🔧 Transmission Standard Transmission Type: 5-speed manual with Reverse Features Clutch Type: Wet, multi-plate Final Drive: O-ring sealed chain, 520 size 📐 Dimensions Exterior Length: 70.1 in (1780 mm) Width: 45.1 in (1145 mm) Height: 43.1 in (1095 mm) Wheelbase: 48.6 in (1235 mm) Ground Clearance: 4.1 in (104 mm) Weights Dry Weight: 375 lbs (170 kg) Curb Weight: N/A (typically higher than dry weight) Cargo Front Rack Capacity: N/A (Sport ATV design) Rear Rack Capacity: N/A (Sport ATV design) 🛡️ Safety Features Ratings Safety Features General: Designed for off-road use; operator must wear appropriate safety gear. Active Features Brakes: Front disc brakes, Rear disc brake. Mechanical parking brake. Lighting: Halogen headlights, taillight/stoplight. Passive Features Handlebars: Handlebar padding for rider safety. 💡 Technology Features Infotainment Infotainment Features: N/A (Basic sport ATV, no digital displays or infotainment) Driver Assistance Driver Assistance Features: N/A Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 1000 km (600 miles) or 6 months, whichever comes first. Air Filter Cleaning: Clean every 500 km (300 miles) or more frequently in dusty conditions. Spark Plug Replacement: Replace every 5000 km (3000 miles) or as needed. Valve Adjustment Interval: Check/adjust every 4000 km (2500 miles). Chain Maintenance: Clean and lubricate every 500 km (300 miles); check tension regularly. Fluid Specifications Engine Oil Type: SAE 10W-40 API SE, SF, or SG. Engine Oil Capacity: 1.8 L (1.9 US qt) with oil filter change. Brake Fluid Type: DOT 3 or DOT 4. Coolant...