The LT-Z250 QuadSport, produced from 2004 to 2009, is a capable all-terrain vehicle known for its reliable performance and agile handling. Featuring a 246 cm³ liquid-cooled, single-cylinder engine with a 5-speed transmission and reverse, this model offers a balanced blend of power and control suitable for recreational riding. Its design emphasizes rider comfort and operational efficiency, with tapered handlebars and a robust suspension system. The QuadSport lineage is recognized for providing dependable powersports experiences, making the LT-Z250 a popular choice for those seeking a well-rounded ATV. This factory service manual provides comprehensive guidance for the maintenance, repair, and overhaul of the 2004-2009 LT-Z250 QuadSport. It covers all major systems, including the engine, transmission, fuel, electrical, suspension, brakes, and drivetrain, offering detailed step-by-step instructions, diagnostic procedures, and technical specifications. With factory-level detail and clear illustrations, this manual is an essential resource for technicians and owners alike, ensuring the longevity and optimal performance of the vehicle through proper care and repair. 🏷️ Basic Information Identification Make: Suzuki Model: LT-Z250 QuadSport Product Name: 2004-2009 Suzuki LT-Z250 Quad Sport Repair Manual PDF Codes Model Codes: LTZ250, Z250 👋 Introduction Market Position Target Audience: Designed for factory service technicians, apprentice mechanics, and experienced DIY owners. Competitive Analysis Manual Advantage: Provides instant download access, offering the same quality and detail as a printed factory manual. Key Features Visual Aids: Includes detailed illustrations, diagrams, exploded views, and photographs to guide repairs. Accuracy Reliance: Considered the sole authoritative source for repair advice for the specified model years. Tool Recommendation: Emphasizes the use of exact special tools as specified within the manual for optimal results and safety. 📋 Manual Details Coverage Areas Covered Years: 2004, 2005, 2006, 2007, 2008, 2009 Page Count Estimated Page Count: N/A (Digital Download) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Digital Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine: Complete overhaul, disassembly, reassembly, inspection, maintenance, troubleshooting, specifications. Transmission: Complete overhaul, disassembly, reassembly, inspection, maintenance, troubleshooting, specifications. Fuel System: Carburetor tuning, fuel pump, fuel lines, fuel tank inspection and maintenance. Electrical System: Ignition system, lighting, charging system, battery, wiring diagrams, troubleshooting. Suspension: Front and rear suspension inspection, adjustment, repair, fork seals, shock absorbers. Brakes: Brake system inspection, pad replacement, caliper service, fluid bleeding, master cylinder. Drivetrain: Chain maintenance, sprocket inspection, final drive unit service. Cooling System: Radiator inspection, fan operation, coolant specifications and replacement. Frame And Bodywork: Chassis inspection, body panel removal and installation, seat, handlebars. Wheels And Tires: Tire inspection, pressure specifications, wheel bearing service. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug replacement, lubrication. Troubleshooting: Diagnostic procedures for common and uncommon issues across all systems. Repair: Detailed step-by-step instructions for component removal, repair, and reassembly. Overhaul: Comprehensive procedures for complete engine and transmission rebuilds. Inspection: Visual and functional inspection guidelines for all major components. Technical Depth Depth: Factory level detail, suitable for professional technicians and experienced DIY enthusiasts. 📊 Manual Specifications File Format Digital Quality: High-resolution PDF with searchable text and clear, legible illustrations. Print Quality Printability: Designed for easy printing of individual sections or the entire manual. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Single-cylinder, SOHC, 4-valve Displacement: 246 cm³ (15.0 cu. in.) Bore X Stroke: 72.0 mm x 60.0 mm (2.83 in x 2.36 in) Compression Ratio: 9.7:1 Performance Estimated Horsepower: Approximately 18-20 HP (subject to tuning and specific model year variations) Estimated Torque: Approximately 14-16 lb-ft (subject to tuning and specific model year variations) Fuel System Fuel Delivery: Mikuni BSR32 flat-slide carburetor Fuel Tank Capacity: 2.9 US gal (11.0 L) Ignition Ignition System: Digital CDI (Capacitor Discharge Ignition) Cooling System Cooling Method: Liquid-cooled Lubrication Lubrication System: Wet sump 🔧 Transmission Standard Transmission Type: 5-speed constant mesh with reverse Features Clutch Type: Multi-plate wet clutch Drive System: 2WD (Rear wheel drive) Final Drive: O-ring sealed chain 📐 Dimensions Exterior Overall Length: 1790 mm (70.5 in) Overall Width: 1140 mm (44.9 in) Overall Height: 1150 mm (45.3 in) Weights Dry Weight: 183 kg (403 lbs) Curb Weight: N/A (Typically includes fluids, but not always quoted for ATVs) Wheelbase Wheelbase: 1240 mm (48.8 in) Ground Clearance Ground Clearance: 250 mm (9.8 in) 🛡️ Safety Features Ratings Safety Features Note: ATVs are not typically rated by organizations like NHTSA or IIHS in the same way as cars; safety relies on proper operation and maintenance. Active Features Braking System: Hydraulic disc brakes front and rear Passive Features Lighting: Dual 35W headlights, 15W taillight Handlebars: Tapered handlebars for improved rider control and comfort. 💡 Technology Features Infotainment Infotainment System: N/A (Basic powersports instrumentation: speedometer, odometer, neutral indicator, high-beam indicator). Driver Assistance Driver Assistance: N/A Connectivity Connectivity: N/A 🔧 Maintenance Service Intervals Engine Oil Change: Every 1000 km or 6 months, whichever comes...