🏷️ Basic Information Identification Make: Suzuki Model: LT-Z250 QuadSport Product Type: Online Service Repair Manual Codes Common Chassis Codes: K4, K5, K6, K7, K8, K9 👋 Introduction Market Position Target Audience: Owners, DIY mechanics, and professional technicians working on the Suzuki LT-Z250 QuadSport. Purpose: To provide comprehensive instructions for the repair, maintenance, and servicing of the Suzuki LT-Z250 QuadSport. Key Features Completeness: Covers all aspects of the vehicle, from basic maintenance to complete overhaul procedures. Detail Level: Detailed step-by-step instructions with clear diagrams and illustrations. Diagnostic Focus: Emphasis on troubleshooting and identifying the root cause of problems. 📋 Manual Details Coverage Areas Years Covered: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 Region Applicability: Global (specifications may vary slightly by market) Page Count Estimated Page Count: Over 400 pages (typical for comprehensive service manuals) Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full disassembly, inspection, repair, and reassembly of all engine components (e.g., cylinder head, piston, crankshaft, camshaft). Engine Fuel System: Carburetor (Mikuni BSR36) service, cleaning, adjustment, and troubleshooting; fuel pump, fuel filter, and fuel tank maintenance. Engine Ignition System: Ignition timing, spark plug specifications, CDI unit, and troubleshooting of ignition-related issues. Engine Cooling System: Radiator, fan, thermostat, coolant, and related hoses; flushing and refilling procedures. Transmission System: Clutch inspection, adjustment, and replacement; gearbox disassembly, inspection, and lubrication; gear shift mechanism. Drivetrain System: Drive shaft, rear axle, differential, and hub maintenance; U-joint inspection and lubrication. Suspension System: Front and rear suspension components (A-arms, shocks, springs), ball joints, tie rods, steering knuckles, and alignment procedures. Braking System: Front and rear hydraulic disc brakes, caliper service, pad replacement, brake fluid bleeding, master cylinder, and hose inspection. Electrical System: Battery, starter, charging system (stator, regulator/rectifier), lighting (headlight, taillight, brake lights), fuses, wiring diagrams, and troubleshooting. Frame And Bodywork: Frame inspection, front and rear fenders, seat, handlebars, controls, and plastic body panel removal/installation. Procedures Included Routine Maintenance: Oil changes, filter replacement, air filter cleaning/replacement, spark plug service, chain adjustment, tire pressure checks, and lubrication points. Troubleshooting: Diagnostic procedures for common problems related to starting, running, electrical systems, and performance issues. Rebuild Procedures: Step-by-step instructions for complete engine, transmission, and carburetor rebuilds. Specifications Data: Torque specifications, clearances, fluid capacities, electrical values, and wear limits for all components. Wiring Diagrams: Detailed electrical system wiring schematics for easy troubleshooting. Technical Depth Diagnostic Capabilities: Advanced diagnostics for ignition, fuel, electrical, and mechanical systems, including specific fault codes and their meanings (where applicable). Repair Complexity: Covers everything from basic adjustments and fluid changes to complete engine and transmission overhauls. Special Tools: Lists any specific Suzuki specialty tools required for certain procedures. 📊 Manual Specifications File Format File Format: PDF Searchability: Searchable text for quick information retrieval. Print Quality Print Quality: High-resolution, clear diagrams and text suitable for printing. Binding Type Binding Type: N/A (Digital PDF download) Paper Type Paper Type: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, DOHC, single-cylinder, liquid-cooled Displacement: 249.2 cc (15.2 cu. in.) Bore X Stroke: 72.0 mm x 61.2 mm (2.83 in. x 2.41 in.) Compression Ratio: 11.3:1 Performance Estimated Horsepower: Approximately 20-25 HP (varies by specific year and tune) Estimated Torque: Approximately 15-18 lb-ft (varies by specific year and tune) Fuel System Fuel Delivery: Mikuni BSR36 CV carburetor Fuel Type: Unleaded gasoline, 87 octane or higher Lubrication System Oil Type: Suzuki 4-stroke motorcycle oil SAE 10W-40 API SE, SF or SG, or ACEA A1/A2/B1 Oil Capacity With Filter: 1.5 L (1.6 US qt) Cooling System Coolant Type: Suzuki Long Life Coolant (or equivalent ethylene glycol-based coolant with distilled water, 50:50 mixture) 🔧 Transmission Standard Transmission Type: Constant mesh, 5-speed manual Clutch Type: Wet, multi-plate Features Reverse Gear: Yes Fluid Specifications Transmission Oil Type: API GL-4, SAE 80W hypoid gear oil Fluid Capacities Transmission Oil Capacity: 0.6 L (0.6 US qt) 📐 Dimensions Exterior Overall Length: Approx. 1785 mm (70.3 in.) Overall Width: Approx. 1135 mm (44.7 in.) Overall Height: Approx. 1070 mm (42.1 in.) Wheelbase: Approx. 1245 mm (49.0 in.) Ground Clearance: Approx. 250 mm (9.8 in.) Weights Dry Weight: Approx. 176 kg (388 lbs) Curb Weight: Approx. 183 kg (403 lbs) 🛡️ Safety Features Ratings Safety Standards: Designed to meet relevant ATV safety standards for its intended use (off-road recreational). Active Features Brakes: Hydraulic disc brakes front and rear for reliable stopping power. Throttle Limiter: Some models may feature an adjustable throttle limiter for beginner riders. Passive Features Handlebars: Wide handlebars for improved control and stability. Footwells: Aggressively treaded footpegs and guards for secure footing. 💡 Technology Features Infotainment Infotainment System: N/A (Basic ATV, no integrated infotainment system) Driver Assistance Driver Assistance Features: N/A (Basic ATV, no electronic driver assistance systems) Connectivity Connectivity Features: N/A (Basic ATV, no connectivity features) Lighting Lighting Type: Halogen...