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Suzuki LT-Z250 Quad Sport 2004-2009 Repair Service Manual

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🏷️ Basic Information Identification Make: Suzuki Model: LT-Z250 Quad Sport Year: 2004-2009 Codes Vehicle Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Target Audience: Primarily mechanical technicians familiar with ATV service procedures, as well as knowledgeable owners Competitive Analysis Manual Advantage: Provides information and procedures equivalent to authorized dealer service departments, enabling professional-quality service Key Features Information Reliability: Strives for accuracy, providing the most reliable information for repairs User Benefit: Enables owners to get the best value from their vehicle and perform maintenance/repairs like a professional Safety Emphasis: Highlights safety equipment usage and precautions, including the importance of torque wrenches Special Tool Reference: Refers to and illustrates recommended or required special tools with Suzuki part numbers 📋 Manual Details Coverage Areas Covered Years: 2004, 2005, 2006, 2007, 2008, 2009 Page Count Page Count: 325 Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete repair and overhaul, including disassembly and assembly Transmission: Complete repair and overhaul, including disassembly and assembly Fuel System: Detailed procedures for diagnosis and repair Ignition System: Diagnosis and repair procedures Lubrication System: Maintenance and repair procedures Exhaust System: Repair and maintenance information Electrical System: Comprehensive coverage including wiring diagrams and troubleshooting Bodywork: Repair and maintenance procedures Procedures Included Routine Maintenance: Detailed instructions for tune-ups and regular servicing Troubleshooting: Diagnostic procedures for common and uncommon issues Repair Overhaul: In-depth repair and overhaul instructions for all major components Assembly Disassembly: Step-by-step guidance for component removal and installation Proprietary Components: Includes instructions for proprietary parts as sourced from component manufacturers Technical Depth Depth: Advanced diagnostics, complete rebuilds, and specialized adjustments 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Yes, printable pages Binding Type Delivery Method: Electronic delivery via Email Paper Type Physical Format: Not a hard copy ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke Displacement: 249 cc Cooling System: Liquid-cooled Ignition: CDI Performance Estimated Horsepower: Approx. 22.5 HP @ 7,500 rpm (for reference, not explicitly stated in product info, but typical for this engine) Estimated Torque: Approx. 16.4 lb-ft @ 6,000 rpm (for reference, not explicitly stated in product info, but typical for this engine) Fuel System Fuel Delivery: Carburetor (Mikuni BSR32) Fuel Type: Unleaded gasoline Lubrication System Oil Type: Refer to manual for specific Suzuki recommendations (e.g., SAE 10W-40 API SG or higher) Oil Capacity: Refer to manual for exact capacity with filter change (typically around 1.5-2.0 liters) 🔧 Transmission Standard Transmission Type: 5-speed manual with reverse Clutch Type: Wet multi-plate Features Final Drive: O-ring sealed chain Transmission Oil Type: Refer to manual for specific Suzuki recommendations (e.g., Suzuki Gear Oil, SAE 80) 📐 Dimensions Exterior Overall Length: Approx. 1835 mm (72.2 in) Overall Width: Approx. 1120 mm (44.1 in) Overall Height: Approx. 1070 mm (42.1 in) Weights Dry Weight: Approx. 183 kg (403.4 lbs) Fuel Tank Capacity: 10 L (2.6 US gal) Ground Clearance: Approx. 240 mm (9.4 in) 🛡️ Safety Features Ratings Atv Classification: Sport ATV Active Features Braking System Front: Dual hydraulic disc brakes Braking System Rear: Single hydraulic disc brake Suspension Front: Independent, double A-arm, oil-damped, coil spring Suspension Rear: Swingarm type, oil-damped, coil spring Passive Features Lighting: Dual halogen headlights, LED taillight/brake light 💡 Technology Features Infotainment Dashboard: Basic digital/analog display for speed, RPM, odometer, trip meter, neutral indicator, oil warning, etc. Driver Assistance Atv Features: None beyond standard mechanical systems Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/hours (typically every 1000 miles or 6 months) Air Filter Cleaning: Refer to manual for specific intervals (dependent on operating conditions) Spark Plug Replacement: Refer to manual for specific intervals (e.g., every 4000 miles or annually) Valve Adjustment Interval: Refer to manual for specific intervals (e.g., every 4000 miles or annually) Fluid Specifications Engine Oil Viscosity: SAE 10W-40 recommended (verify in manual) Coolant Type: Ethylene glycol based antifreeze (50/50 mix with distilled water recommended) Brake Fluid Type: DOT 3 or DOT 4 (verify in manual) Known Issues Common Wear Items: Brake pads, tires, chain and sprockets, wheel bearings (typical for sport ATVs) Potential Carburetor Issues: Carburetor may require periodic cleaning and adjustment due to fuel quality or usage Electrical Connector Corrosion: As with many powersports vehicles, electrical connectors can be susceptible to corrosion if exposed to moisture; manual covers inspection and cleaning 📚 Vehicle History Brand Heritage Manufacturer: Suzuki Motor Corporation Sport Atv Legacy: Suzuki has a strong heritage in sport ATVs with iconic models like the LT250R and LT500R Model Evolution Lt Z Series Introduction: The LT-Z series represents Suzuki's modern generation of sport ATVs, building on previous successful platforms Production Production Period: 2004-2009 Manufacturing Location: Typically manufactured in Japan by Suzuki 🏆 Awards & Recognition Recognitions Industry Reputation: Suzuki's sport ATVs are generally well-regarded for...
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Suzuki LT-Z250 Quad Sport 2004-2009 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
LT-Z250 Quad Sport
Year:
2004-2009
Codes
Vehicle Type:
All-Terrain Vehicle (ATV)
👋 Introduction
Market Position
Target Audience:
Primarily mechanical technicians familiar with ATV service procedures, as well as knowledgeable owners
Competitive Analysis
Manual Advantage:
Provides information and procedures equivalent to authorized dealer service departments, enabling professional-quality service
Key Features
Information Reliability:
Strives for accuracy, providing the most reliable information for repairs
User Benefit:
Enables owners to get the best value from their vehicle and perform maintenance/repairs like a professional
Safety Emphasis:
Highlights safety equipment usage and precautions, including the importance of torque wrenches
Special Tool Reference:
Refers to and illustrates recommended or required special tools with Suzuki part numbers
📋 Manual Details
Coverage Areas
Covered Years:
2004, 2005, 2006, 2007, 2008, 2009
Page Count
Page Count:
325
Manual Type
Manual Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete repair and overhaul, including disassembly and assembly
Transmission:
Complete repair and overhaul, including disassembly and assembly
Fuel System:
Detailed procedures for diagnosis and repair
Ignition System:
Diagnosis and repair procedures
Lubrication System:
Maintenance and repair procedures
Exhaust System:
Repair and maintenance information
Electrical System:
Comprehensive coverage including wiring diagrams and troubleshooting
Bodywork:
Repair and maintenance procedures
Procedures Included
Routine Maintenance:
Detailed instructions for tune-ups and regular servicing
Troubleshooting:
Diagnostic procedures for common and uncommon issues
Repair Overhaul:
In-depth repair and overhaul instructions for all major components
Assembly Disassembly:
Step-by-step guidance for component removal and installation
Proprietary Components:
Includes instructions for proprietary parts as sourced from component manufacturers
Technical Depth
Depth:
Advanced diagnostics, complete rebuilds, and specialized adjustments
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Yes, printable pages
Binding Type
Delivery Method:
Electronic delivery via Email
Paper Type
Physical Format:
Not a hard copy
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, 4-stroke
Displacement:
249 cc
Cooling System:
Liquid-cooled
Ignition:
CDI
Performance
Estimated Horsepower:
Approx. 22.5 HP @ 7,500 rpm (for reference, not explicitly stated in product info, but typical for this engine)
Estimated Torque:
Approx. 16.4 lb-ft @ 6,000 rpm (for reference, not explicitly stated in product info, but typical for this engine)
Fuel System
Fuel Delivery:
Carburetor (Mikuni BSR32)
Fuel Type:
Unleaded gasoline
Lubrication System
Oil Type:
Refer to manual for specific Suzuki recommendations (e.g., SAE 10W-40 API SG or higher)
Oil Capacity:
Refer to manual for exact capacity with filter change (typically around 1.5-2.0 liters)
🔧 Transmission
Standard
Transmission Type:
5-speed manual with reverse
Clutch Type:
Wet multi-plate
Features
Final Drive:
O-ring sealed chain
Transmission Oil Type:
Refer to manual for specific Suzuki recommendations (e.g., Suzuki Gear Oil, SAE 80)
📐 Dimensions
Exterior
Overall Length:
Approx. 1835 mm (72.2 in)
Overall Width:
Approx. 1120 mm (44.1 in)
Overall Height:
Approx. 1070 mm (42.1 in)
Weights
Dry Weight:
Approx. 183 kg (403.4 lbs)
Fuel Tank Capacity:
10 L (2.6 US gal)
Ground Clearance:
Approx. 240 mm (9.4 in)
🛡️ Safety Features
Ratings
Atv Classification:
Sport ATV
Active Features
Braking System Front:
Dual hydraulic disc brakes
Braking System Rear:
Single hydraulic disc brake
Suspension Front:
Independent, double A-arm, oil-damped, coil spring
Suspension Rear:
Swingarm type, oil-damped, coil spring
Passive Features
Lighting:
Dual halogen headlights, LED taillight/brake light
💡 Technology Features
Infotainment
Dashboard:
Basic digital/analog display for speed, RPM, odometer, trip meter, neutral indicator, oil warning, etc.
Driver Assistance
Atv Features:
None beyond standard mechanical systems
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/hours (typically every 1000 miles or 6 months)
Air Filter Cleaning:
Refer to manual for specific intervals (dependent on operating conditions)
Spark Plug Replacement:
Refer to manual for specific intervals (e.g., every 4000 miles or annually)
Valve Adjustment Interval:
Refer to manual for specific intervals (e.g., every 4000 miles or annually)
Fluid Specifications
Engine Oil Viscosity:
SAE 10W-40 recommended (verify in manual)
Coolant Type:
Ethylene glycol based antifreeze (50/50 mix with distilled water recommended)
Brake Fluid Type:
DOT 3 or DOT 4 (verify in manual)
Known Issues
Common Wear Items:
Brake pads, tires, chain and sprockets, wheel bearings (typical for sport ATVs)
Potential Carburetor Issues:
Carburetor may require periodic cleaning and adjustment due to fuel quality or usage
Electrical Connector Corrosion:
As with many powersports vehicles, electrical connectors can be susceptible to corrosion if exposed to moisture; manual covers inspection and cleaning
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation
Sport Atv Legacy:
Suzuki has a strong heritage in sport ATVs with iconic models like the LT250R and LT500R
Model Evolution
Lt Z Series Introduction:
The LT-Z series represents Suzuki's modern generation of sport ATVs, building on previous successful platforms
Production
Production Period:
2004-2009
Manufacturing Location:
Typically manufactured in Japan by Suzuki
🏆 Awards & Recognition
Recognitions
Industry Reputation:
Suzuki's sport ATVs are generally well-regarded for their performance and reliability within their class.
Ratings
Consumer Reviews:
Owner feedback often highlights its good balance of power and handling for recreational riding.
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