Suzuki ATV LT 250 Quad Sport 2002-2009 Factory Service Repair Manual Download Pdf
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🏷️ Basic Information Identification Make: Suzuki Model: LT250 Quad Sport Vehicle Type: All-Terrain Vehicle (ATV) Category: Sport ATV Codes Chassis Code: Not explicitly provided in product data, but typically LT250PF for this generation. 👋 Introduction Market Position Positioning: The Suzuki LT250 Quad Sport was positioned as a capable and versatile sport ATV, offering a balance of performance and maneuverability for recreational riding and trail exploration. It competed in a segment with models from Yamaha, Honda, and Kawasaki. Competitive Analysis Competitors: Yamaha Warrior 350, Honda TRX300EX, Kawasaki Mojave 250. Key Features Features: Reliable engine, comfortable suspension, agile handling, durable construction, suitable for a wide range of riders. Manual Purpose Purpose: To provide comprehensive diagnostic, repair, maintenance, and service information equivalent to that used by authorized Suzuki dealerships. 📋 Manual Details Coverage Areas Model Years: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 Specific Variants: All LT250 Quad Sport models within the specified year range. Page Count Estimated Pages: Extensive (typical for a full factory service manual, often 500+ pages) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, driveline, cooling system, exhaust system, fuel system. Chassis: Frame, suspension (front and rear), steering, wheels, tires. Brakes: Front and rear brake systems (hydraulic disc brakes). Electrical: Ignition system, lighting, starting system, charging system, battery, wiring diagrams, sensors, ECU. Bodywork: Body panels, fenders, seat, handlebars, controls, decals. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning/replacement. Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides. Repair: Detailed step-by-step repair instructions for all major components and systems, including disassembly and reassembly. Overhaul: Complete engine and transmission overhaul procedures, including specifications and tolerances. Adjustments: Carburetor tuning, clutch adjustment, brake bleeding, suspension adjustments. Technical Depth Depth: Comprehensive, covering everything from basic user maintenance to complete engine rebuilds and advanced electrical diagnostics. 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable PDF with clear diagrams and text. Print Quality Printability: Printable on standard home or office printers. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: 4-stroke, SOHC, single-cylinder Displacement: 246cc (approximate, specific designation LT250 may vary slightly based on market tuning) Bore X Stroke: Refer to manual for exact specifications, typically around 72.0 mm x 61.2 mm. Cooling System: Liquid-cooled Performance Horsepower: Estimated 20-25 HP (varies by tuning and market). Torque: Refer to manual for exact specifications. Fuel System Carburetor: Mikuni VM32SS (typical, refer to manual for exact model and jetting). Fuel Type: Unleaded gasoline Engine Internals Compression Ratio: Refer to manual for exact specifications, typically around 9.5:1. Ignition Ignition Type: CDI (Capacitor Discharge Ignition) Lubrication Oil Type: Refer to manual for specific Suzuki brand or SAE viscosity recommendations (e.g., SAE 10W-40 or 20W-50). Oil Capacity Capacity: Refer to manual for exact capacity (typically 1.0-1.2 Liters). 🔧 Transmission Standard Type: 5-speed manual with reverse Optional Options: N/A for this model; 5-speed manual was standard. Features Clutch: Wet, multi-plate Drive System: 2WD (Rear Wheel Drive) Final Drive: Chain drive Fluid Type Transmission Oil Type: Refer to manual for specific Suzuki gear oil or SAE viscosity recommendations (e.g., SAE 80W-90). Fluid Capacity Transmission Oil Capacity: Refer to manual for exact capacity. 📐 Dimensions Exterior Length: Refer to manual for exact specifications (typically around 1800-1850 mm). Width: Refer to manual for exact specifications (typically around 1100-1150 mm). Height: Refer to manual for exact specifications (typically around 1050-1100 mm). Weights Dry Weight: Refer to manual for exact specifications (typically around 200-215 kg). Curb Weight: Refer to manual for exact specifications. Payload Capacity: Refer to manual for exact specifications. Wheels Tires Front Tire Size: AT22x7-10 (typical, refer to manual for exact). Rear Tire Size: AT22x10-9 (typical, refer to manual for exact). Front Wheel Size: 10x5.5 (typical, refer to manual for exact). Rear Wheel Size: 9x8 (typical, refer to manual for exact). Bolt Pattern: Refer to manual for exact specifications. 🛡️ Safety Features Ratings Atv Safety Standards: Manufactured to meet relevant industry safety standards for ATVs. Specific ratings like NHTSA or IIHS are not applicable to ATVs in the same way as passenger vehicles. Active Features Braking System: Hydraulic disc brakes front and rear, providing strong stopping power. Throttle Limiter: Some models may have adjustable throttle limiters for younger or less experienced riders (check manual for details). Passive Features Handlebar Protectors: Standard on most sport ATVs for rider protection. Footwells: Provide protection for rider's feet. Recommended Gear Safety Equipment: Helmet, eye protection, gloves, long sleeves and pants, sturdy boots (as recommended in the manual). 💡 Technology Features Infotainment Infotainment System: Not applicable; this is a utility/sport ATV with no complex infotainment features. Driver Assistance Driver Assistance Features: Not applicable; designed for direct rider control. Connectivity Connectivity Features: Not applicable. Engine...
Not explicitly provided in product data, but typically LT250PF for this generation.
👋 Introduction
Market Position
Positioning:
The Suzuki LT250 Quad Sport was positioned as a capable and versatile sport ATV, offering a balance of performance and maneuverability for recreational riding and trail exploration. It competed in a segment with models from Yamaha, Honda, and Kawasaki.
Comprehensive, covering everything from basic user maintenance to complete engine rebuilds and advanced electrical diagnostics.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable PDF with clear diagrams and text.
Print Quality
Printability:
Printable on standard home or office printers.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Type:
4-stroke, SOHC, single-cylinder
Displacement:
246cc (approximate, specific designation LT250 may vary slightly based on market tuning)
Bore X Stroke:
Refer to manual for exact specifications, typically around 72.0 mm x 61.2 mm.
Cooling System:
Liquid-cooled
Performance
Horsepower:
Estimated 20-25 HP (varies by tuning and market).
Torque:
Refer to manual for exact specifications.
Fuel System
Carburetor:
Mikuni VM32SS (typical, refer to manual for exact model and jetting).
Fuel Type:
Unleaded gasoline
Engine Internals
Compression Ratio:
Refer to manual for exact specifications, typically around 9.5:1.
Ignition
Ignition Type:
CDI (Capacitor Discharge Ignition)
Lubrication
Oil Type:
Refer to manual for specific Suzuki brand or SAE viscosity recommendations (e.g., SAE 10W-40 or 20W-50).
Oil Capacity
Capacity:
Refer to manual for exact capacity (typically 1.0-1.2 Liters).
🔧 Transmission
Standard
Type:
5-speed manual with reverse
Optional
Options:
N/A for this model; 5-speed manual was standard.
Features
Clutch:
Wet, multi-plate
Drive System:
2WD (Rear Wheel Drive)
Final Drive:
Chain drive
Fluid Type
Transmission Oil Type:
Refer to manual for specific Suzuki gear oil or SAE viscosity recommendations (e.g., SAE 80W-90).
Fluid Capacity
Transmission Oil Capacity:
Refer to manual for exact capacity.
📐 Dimensions
Exterior
Length:
Refer to manual for exact specifications (typically around 1800-1850 mm).
Width:
Refer to manual for exact specifications (typically around 1100-1150 mm).
Height:
Refer to manual for exact specifications (typically around 1050-1100 mm).
Weights
Dry Weight:
Refer to manual for exact specifications (typically around 200-215 kg).
Curb Weight:
Refer to manual for exact specifications.
Payload Capacity:
Refer to manual for exact specifications.
Wheels Tires
Front Tire Size:
AT22x7-10 (typical, refer to manual for exact).
Rear Tire Size:
AT22x10-9 (typical, refer to manual for exact).
Front Wheel Size:
10x5.5 (typical, refer to manual for exact).
Rear Wheel Size:
9x8 (typical, refer to manual for exact).
Bolt Pattern:
Refer to manual for exact specifications.
🛡️ Safety Features
Ratings
Atv Safety Standards:
Manufactured to meet relevant industry safety standards for ATVs. Specific ratings like NHTSA or IIHS are not applicable to ATVs in the same way as passenger vehicles.
Active Features
Braking System:
Hydraulic disc brakes front and rear, providing strong stopping power.
Throttle Limiter:
Some models may have adjustable throttle limiters for younger or less experienced riders (check manual for details).
Passive Features
Handlebar Protectors:
Standard on most sport ATVs for rider protection.
Footwells:
Provide protection for rider's feet.
Recommended Gear
Safety Equipment:
Helmet, eye protection, gloves, long sleeves and pants, sturdy boots (as recommended in the manual).
💡 Technology Features
Infotainment
Infotainment System:
Not applicable; this is a utility/sport ATV with no complex infotainment features.
Driver Assistance
Driver Assistance Features:
Not applicable; designed for direct rider control.
Connectivity
Connectivity Features:
Not applicable.
Engine Management
ECU:
Engine Control Unit (ECU) manages ignition timing and fuel delivery parameters based on sensor inputs. Refer to manual for detailed diagnostics.
🔧 Maintenance
Service Intervals
Initial Service:
Break-in service recommended around 500 miles or 10 hours (refer to manual for exact break-in procedure and schedule).
Engine Oil Change:
Every 1000 miles or 100 hours, or every 6 months (whichever comes first, refer to manual for specific conditions).
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions. Refer to manual for specific intervals.
Spark Plug Service:
Inspect and clean/gap every 600 miles or 60 hours; replace as needed. Refer to manual for correct gap.
Chain Lubrication Adjustment:
Lubricate and check tension at frequent intervals, especially after riding in wet conditions. Refer to manual for correct tension.
Fluid Specifications
Engine Oil Viscosity:
SAE 10W-40 or SAE 20W-50 API SE, SF, SG or SH (refer to manual for exact Suzuki recommendation and API service classification).
Coolant Type:
Permanent antifreeze coolant (ethylene glycol based) with distilled water (50:50 mixture). Refer to manual for specific Suzuki coolant type.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for exact specification).
Known Issues
Common Wear Items:
Brake pads, tires, spark plug, air filter, chain and sprockets, wheel bearings.
Potential Performance Issues:
Carburetor gumming if not run regularly, clutch wear, suspension wear with high mileage use. Overheating if cooling system is not maintained.
Troubleshooting Tips
Starting Problems:
Check fuel, spark, compression, and battery. Refer to manual's diagnostic section.
Parts Replacement
Oil Filter Part Number:
Refer to manual or Suzuki parts fiche for exact part number (e.g., 16510-03G00 or equivalent).
Air Filter Part Number:
Refer to manual or Suzuki parts fiche for exact part number.
📚 Vehicle History
Brand Heritage
Heritage:
Suzuki has a long and successful history in the powersports industry, including a strong legacy in ATV manufacturing, known for its innovative and reliable machines.
Model Evolution
Predecessors:
The LT250 Quad Sport evolved from earlier Suzuki sport ATVs, inheriting design cues and technical advancements.
Generation Overview:
This generation of the LT250 Quad Sport (2002-2009) represents a refinement of Suzuki's sport ATV platform, focusing on performance, rider comfort, and reliability.
Production
Manufacturing Location:
Primarily manufactured in Japan or at Suzuki's overseas facilities.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific 'awards' for this model year are not readily documented, Suzuki ATVs have consistently been recognized for their performance, reliability, and value within the powersports community over the years.
Ratings
Consumer Ratings:
Generally well-regarded by owners for its balance of performance and affordability.
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