The LT-Z250 Quad Sport, produced from 2004 to 2009, is a sport All-Terrain Vehicle (ATV) engineered for recreational riding and performance. Building on a strong heritage in sport ATVs, the LT-Z250 offers a robust single-cylinder, 4-stroke, 249cc liquid-cooled engine, paired with a 5-speed manual transmission and reverse. Its design emphasizes agility and control, featuring independent front double A-arm suspension and a swingarm rear suspension, complemented by dual hydraulic disc brakes at the front and a single hydraulic disc brake at the rear. The vehicle's construction prioritizes durability and a balanced power-to-weight ratio, making it a capable machine for various off-road terrains. This comprehensive workshop service manual provides in-depth technical information and procedures for the LT-Z250 Quad Sport models from 2004 through 2009. It covers all essential aspects of maintenance, diagnosis, and repair, including detailed instructions for engine, transmission, fuel, ignition, lubrication, exhaust, electrical systems, and bodywork. The manual offers step-by-step guidance for routine maintenance, assembly, disassembly, and advanced troubleshooting, enabling both mechanical technicians and knowledgeable owners to perform professional-quality service. It also references special tools and emphasizes safety precautions, ensuring the vehicle is maintained to optimal standards for performance and longevity. 🏷️ 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...