The 2004 Suzuki LT250 QuadSport is a capable all-terrain vehicle designed for recreational trail riding, offering a blend of performance and reliability. As part of Suzuki's esteemed ATV lineup, the LT250 QuadSport is recognized for its sport-oriented suspension, a potent 249 cc air-cooled, single-cylinder engine, and a user-friendly 5-speed manual transmission with reverse. Its robust construction and proven engineering make it a solid choice for riders seeking an enjoyable and dependable off-road experience, competing effectively within the sport ATV market of its era. This digital service and repair manual provides comprehensive guidance for the complete service and repair of your 2004 Suzuki LT250 QuadSport. It covers essential maintenance procedures, detailed troubleshooting steps, diagnostic information, and parts replacement instructions for all major systems, including the engine, transmission, drivetrain, suspension, brakes, and electrical components. With over 300 pages of detailed information, including high-resolution diagrams and specifications, this manual is an indispensable resource for owners and technicians aiming to maintain, repair, and optimize the performance and longevity of their ATV. 🏷️ Basic Information Identification Make: Suzuki Model: LT250 QuadSport Year: 2004 Vehicle Type: All-Terrain Vehicle (ATV) Sub Model: QuadSport Codes Engine Code: Refer to manual for specific engine variant codes Chassis Code: LT250 👋 Introduction Market Position Positioning: The Suzuki LT250 QuadSport was positioned as a capable and versatile sport ATV, appealing to recreational riders seeking a balance of performance and reliability. Competitive Analysis Competitors: Competed with models from Yamaha (Warrior, Blaster), Honda (FourTrax series), and Kawasaki (Bayou, Mojave). Key Features Features: Sport-oriented suspension, powerful engine for its class, reliable drivetrain, user-friendly operation. Manual Value Value Proposition: Provides comprehensive technical data and procedures essential for maintaining and repairing the 2004 Suzuki LT250 QuadSport, enabling owners to perform their own maintenance and repairs, saving on service costs and extending vehicle lifespan. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Parts Replacement, Electrical Systems, Engine Rebuilds Page Count Estimated Pages: 300+ Manual Type Type: Digital Service and Repair Manual Language Language: English Format Format: Digital (likely PDF) File Type: PDF (Searchable Text) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, including disassembly, inspection, assembly, timing, valve adjustment, carburetor tuning. Transmission: Gearbox inspection, repair, clutch service, shift linkage adjustment. Drivetrain: Rear axle, drive shaft, differential (if applicable), wheel bearings. Suspension: Front and rear suspension components, shock absorber service, A-arm bushings, steering linkage. Brakes: Hydraulic brake system, caliper service, master cylinder, brake fluid replacement, pad replacement, bleeding procedures. Electrical: Ignition system, charging system (stator, regulator/rectifier), starter motor, battery, lighting, wiring diagrams. Fuel System: Carburetor assembly and tuning, fuel lines, fuel pump (if applicable), fuel filter. Cooling System: Air-cooled engine specific maintenance, cooling fins. Exhaust System: Muffler and pipe inspection and replacement. Steering: Handlebar assembly, steering stem, tie rods, steering knuckle. Body And Frame: Frame inspection, plastic body panel removal and installation, seat service. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, lubrication, chain adjustment. Troubleshooting: Diagnostic charts, common problems and solutions, identifying malfunctions. Repair: Step-by-step repair instructions for all major components. Diagnostics: System checks, electrical testing, component testing procedures. Rebuilds: Complete engine and transmission rebuild procedures. Disassembly Assembly: Detailed instructions for component removal and reinstallation. Wiring Diagrams: Comprehensive, easy-to-read electrical wiring schematics. Technical Depth Depth: Comprehensive, covering basic maintenance to full engine and transmission overhauls. Detail Level: Includes specifications, torque values, tolerances, and procedural steps with illustrations. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval. Printability: Printable pages for physical reference. Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Single-cylinder, SOHC Displacement: 249 cc (Cubic Centimeters) Bore X Stroke: 72.0 mm x 61.2 mm (Refer to manual for exact factory specs) Cooling System: Air-cooled Compression Ratio: Refer to manual for exact factory specifications Performance Horsepower: Approximately 19-22 HP (Varies by region and specific tuning) Torque: Refer to manual for exact specifications Fuel System Carburetor: Mikuni VM Series (Likely 32mm or similar, refer to manual for exact model) Fuel Type: Unleaded Gasoline (Octane rating as per manual recommendations) Ignition Ignition System: CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Transmission Type: 5-speed manual with Reverse Clutch Type: Wet, multi-plate Features Drive System: 2WD (Two-Wheel Drive), Chain Drive Gear Ratios: Refer to manual for specific gear ratios Final Drive: O-ring sealed chain 📐 Dimensions Exterior Overall Length: Approx. 72.0 inches (1830 mm) Overall Width: Approx. 45.7 inches (1160 mm) Overall Height: Approx. 43.1 inches (1095 mm) Wheelbase: Approx. 49.2 inches (1250 mm) Ground Clearance: Approx. 7.3 inches (185 mm) Weights Dry Weight: Approx. 397 lbs (180 kg) Fuel Capacity: 3.0 US gal (11.5 L) Tires Front Tire Size: AT22x7-10 Rear Tire Size: AT22x10-9 Brakes Front Brake Type: Dual hydraulic...