2002-2013 Suzuki OZARK 250 / LT-F250 ATV Service Repair Manual (Highly Detailed FSM PDF Preview) Download
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The Suzuki Ozark 250 (LT-F250) is a versatile and reliable utility ATV, produced from 2002 through 2013. Known for dependable engineering, this model is well-suited for recreational riders, light farm work, and general trail riding. Its design emphasizes ease of use, making it an accessible option for riders of varying experience levels. The Ozark 250 offers a robust 249 cc engine, a 5-speed manual transmission with automatic clutch and reverse, and a shaft drive system, all contributing to its durable performance across different conditions. This comprehensive workshop service and repair manual provides detailed guidance for maintaining and repairing your Suzuki Ozark 250. Covering essential systems such as the engine, drivetrain, fuel system, lubrication, chassis, and electrical components, this manual offers step-by-step instructions for everything from routine maintenance, including oil changes and filter replacements, to complete component rebuilds. It also includes troubleshooting guides and technical specifications, empowering owners and technicians to keep the vehicle in optimal condition and address any potential issues effectively. 🏷️ Basic Information Identification Make: Suzuki Model: Ozark 250 Model Code: LT-F250 Production Years Covered: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013 Codes Vin Prefix: JS1 👋 Introduction Market Position Segment: Entry-level to mid-range utility ATV Target Audience: Recreational riders, light-duty farm work, general trail riding. Competitive Analysis Competitors: Honda TRX250TE/EX, Kawasaki Bayou 250, Yamaha Bruin 250. Key Features Durability: Known for Suzuki's reliable engineering, suitable for various conditions. Ease Of Use: User-friendly design, accessible for less experienced riders. Value Proposition Manual Value: Provides dealership-level repair and maintenance information, saving significant costs on professional servicing. 📋 Manual Details Coverage Areas Manual Type: Official Full Workshop Service and Repair Manual Page Count: 477 pages Language: English Delivery Method: Instant Download Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete teardown, rebuild, troubleshooting, specifications, maintenance, diagrams. Drivetrain: Transmission, gears, clutches, drive shafts, maintenance, repair. Fuel System: Carburetor tuning (main jet, pilot jet, slow jet), fuel pump, fuel injection (if applicable), maintenance, troubleshooting. Lubrication System: Oil specifications, capacities, lubrication points, maintenance, troubleshooting. Chassis: Frame, suspension (front forks, rear struts, linkage), steering, wheels, brakes, body panels. Electrical System: Ignition system, starting system, lighting, charging system (stator, rectifier, battery), wiring diagrams, troubleshooting, error codes. Procedures Included Maintenance: Periodic maintenance schedules, fluid changes (coolant, engine oil), filter replacements, valve clearance adjustments, spark plug service. Repair: Complete component teardown and rebuild, assembly instructions, component replacement procedures. Troubleshooting: Diagnostic flowcharts, common problems, solutions for starting issues, engine performance, electrical faults. Technical Depth Depth: Comprehensive coverage from basic maintenance to complete engine and drivetrain rebuilds, including detailed diagnostics and specifications. 📊 Manual Specifications File Format File Format: PDF Print Quality: Printable without restriction Searchable: Likely searchable due to PDF format, though explicit mention is not made. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, air-cooled, SOHC Displacement: 249 cc (15.2 cu. in.) Bore X Stroke: 72.0 mm x 61.2 mm (2.83 in x 2.41 in) Compression Ratio: 9.2:1 Carburetor: Mikuni BNS32 (likely, specific designation may vary) Fuel Delivery: Carbureted (potential for EFI on later models, but manual likely focuses on carb) Performance Horsepower: Approximately 16-18 HP (varies by specific model year and tuning) Torque: Approximately 14-16 lb-ft (varies by specific model year and tuning) Fuel System Fuel Tank Capacity: Approx. 2.8 US gal (10.5 L) Fuel Type: Unleaded gasoline 🔧 Transmission Standard Transmission Type: 5-speed manual with automatic clutch and reverse Drive Type: 2WD (Shaft Drive) Features Clutch Type: Automatic centrifugal clutch Final Drive: Shaft drive with enclosed grease-lubricated final drive housing. 📐 Dimensions Exterior Overall Length: Approx. 72.8 in (1850 mm) Overall Width: Approx. 43.1 in (1095 mm) Overall Height: Approx. 41.5 in (1055 mm) Weights Dry Weight: Approx. 450 lbs (204 kg) Curb Weight: Approx. 470 lbs (213 kg) Weight Capacity: Not explicitly stated, but designed for rider and light cargo. Cargo Front Rack Capacity: Approx. 20 kg (44 lbs) Rear Rack Capacity: Approx. 40 kg (88 lbs) 🛡️ Safety Features Ratings Safety Certification: Complies with EPA standards. ATV safety training recommended. Active Features Brakes: Front: Dual hydraulic disc; Rear: Single hydraulic disc. Tires: Front: AT22 x 7-10; Rear: AT22 x 10-10 (common sizes, specific tread patterns may vary). Passive Features Lighting: Headlights, taillight/brake light. Hand Guards: Standard on most models for protection against debris. 💡 Technology Features Infotainment Infotainment System: N/A (Basic utility ATV, no complex infotainment system). Driver Assistance Traction Control: N/A (2WD, no electronic traction aids). Connectivity Connectivity Features: N/A (No Bluetooth, USB, or other connectivity features). 🔧 Maintenance Service Intervals Engine Oil Change: Every 1,000 km (600 miles) or 6 months, whichever comes first (refer to manual for exact recommendation). Spark Plug Check: Every 1,000 km (600 miles). Air Filter Cleaning: Every 1,000 km (600 miles) or more frequently in dusty conditions....
The Suzuki Ozark 250 (LT-F250) is a versatile and reliable utility ATV, produced from 2002 through 2013. Known for dependable engineering, this model is well-suited for recreational riders, light farm work, and general trail riding. Its design emphasizes ease of use, making it an accessible option for riders of varying experience levels. The Ozark 250 offers a robust 249 cc engine, a 5-speed manual transmission with automatic clutch and reverse, and a shaft drive system, all contributing to its durable performance across different conditions.
This comprehensive workshop service and repair manual provides detailed guidance for maintaining and repairing your Suzuki Ozark 250. Covering essential systems such as the engine, drivetrain, fuel system, lubrication, chassis, and electrical components, this manual offers step-by-step instructions for everything from routine maintenance, including oil changes and filter replacements, to complete component rebuilds. It also includes troubleshooting guides and technical specifications, empowering owners and technicians to keep the vehicle in optimal condition and address any potential issues effectively.
Complete component teardown and rebuild, assembly instructions, component replacement procedures.
Troubleshooting:
Diagnostic flowcharts, common problems, solutions for starting issues, engine performance, electrical faults.
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to complete engine and drivetrain rebuilds, including detailed diagnostics and specifications.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality:
Printable without restriction
Searchable:
Likely searchable due to PDF format, though explicit mention is not made.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, air-cooled, SOHC
Displacement:
249 cc (15.2 cu. in.)
Bore X Stroke:
72.0 mm x 61.2 mm (2.83 in x 2.41 in)
Compression Ratio:
9.2:1
Carburetor:
Mikuni BNS32 (likely, specific designation may vary)
Fuel Delivery:
Carbureted (potential for EFI on later models, but manual likely focuses on carb)
Performance
Horsepower:
Approximately 16-18 HP (varies by specific model year and tuning)
Torque:
Approximately 14-16 lb-ft (varies by specific model year and tuning)
Fuel System
Fuel Tank Capacity:
Approx. 2.8 US gal (10.5 L)
Fuel Type:
Unleaded gasoline
🔧 Transmission
Standard
Transmission Type:
5-speed manual with automatic clutch and reverse
Drive Type:
2WD (Shaft Drive)
Features
Clutch Type:
Automatic centrifugal clutch
Final Drive:
Shaft drive with enclosed grease-lubricated final drive housing.
📐 Dimensions
Exterior
Overall Length:
Approx. 72.8 in (1850 mm)
Overall Width:
Approx. 43.1 in (1095 mm)
Overall Height:
Approx. 41.5 in (1055 mm)
Weights
Dry Weight:
Approx. 450 lbs (204 kg)
Curb Weight:
Approx. 470 lbs (213 kg)
Weight Capacity:
Not explicitly stated, but designed for rider and light cargo.
Cargo
Front Rack Capacity:
Approx. 20 kg (44 lbs)
Rear Rack Capacity:
Approx. 40 kg (88 lbs)
🛡️ Safety Features
Ratings
Safety Certification:
Complies with EPA standards. ATV safety training recommended.
Active Features
Brakes:
Front: Dual hydraulic disc; Rear: Single hydraulic disc.
Tires:
Front: AT22 x 7-10; Rear: AT22 x 10-10 (common sizes, specific tread patterns may vary).
Passive Features
Lighting:
Headlights, taillight/brake light.
Hand Guards:
Standard on most models for protection against debris.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic utility ATV, no complex infotainment system).
Driver Assistance
Traction Control:
N/A (2WD, no electronic traction aids).
Connectivity
Connectivity Features:
N/A (No Bluetooth, USB, or other connectivity features).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 1,000 km (600 miles) or 6 months, whichever comes first (refer to manual for exact recommendation).
Spark Plug Check:
Every 1,000 km (600 miles).
Air Filter Cleaning:
Every 1,000 km (600 miles) or more frequently in dusty conditions.
Valve Clearance Check:
Every 2,000 km (1,200 miles) or 12 months.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SE, SF or SG, or SJ, JASO MA certified motorcycle oil.
Engine Oil Capacity:
Approx. 1.8 L (1.9 US qt) with filter change.
Coolant Type:
Ethylene glycol-based coolant with distilled water (50/50 mix).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Carburetor Clogging:
Common in older ATVs due to fuel varnish buildup; requires regular cleaning and proper fuel storage.
Electrical Connections:
Corrosion or loose connections can lead to intermittent electrical issues; regular inspection recommended.
Suspension Wear:
Bushings and seals can wear over time, affecting ride quality and handling; routine inspection and replacement are important.
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation, a long-standing Japanese manufacturer known for motorcycles, ATVs, and automobiles.
Model Evolution
Development:
The Ozark 250 (LT-F250) was developed as an accessible and versatile utility ATV, building on Suzuki's experience in the ATV market. It was designed to offer a good balance of performance, reliability, and value.
Production
Manufacturing Location:
Primarily manufactured in Japan, with some assembly potentially occurring in other global locations.
Model Run:
The LT-F250 model line saw a consistent production run from 2002 to 2013, indicating its sustained popularity and market relevance.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
While specific awards are not highlighted, the sustained production run suggests market acceptance and value for its segment.
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