Suzuki LT 250 Quad Sport 2002-2009 Service Repair Manual
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🏷️ Basic Information Identification Make: Suzuki Model: LT250 Quad Sport Model Variant: QuadSport Model Nickname: QuadSport Vehicle Type: All-Terrain Vehicle (ATV) Generation Generation Identifier: 2002-2009 models Codes Chassis Code Prefix: RM 👋 Introduction Market Position Segment: Sport/Recreational ATV Target Audience: Enthusiasts seeking performance and off-road capability Competitive Analysis Key Competitors: Yamaha Warrior/Banshee, Honda TRX series, Kawasaki Mojave/Bayou Key Features Performance Orientation: Designed for agile handling and sporty performance Visual Content: Includes photos and illustrations for visual guidance Value Proposition Utility: Enables owners to perform repairs and maintenance, saving on service costs 📋 Manual Details Coverage Areas Covered Years: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 Geographical Coverage: Global (assuming North American and European specifications where applicable) Page Count Estimated Page Count: High (detailed service manuals typically range from 300-600+ pages) Manual Type Manual Type: Service Repair Manual Content Focus: Repair, maintenance, troubleshooting, diagnostics Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, specifications Fuel System: Carburetor tuning and rebuilding, fuel pump, fuel lines, fuel tank Cooling System: Radiator, fan, thermostat, coolant specifications Ignition System: Spark plugs, ignition coil, CDI unit, timing specifications Transmission: Clutch operation, gear shifting mechanisms, internal components, fluid types Drivetrain: Drive shafts, differentials (if applicable), axle components, lubrication Suspension: Front and rear suspension systems, shock absorbers, control arms, bushings, adjustments Steering: Steering column, tie rods, linkage, wheel alignment specifications Brakes: Hydraulic brake system, calipers, master cylinder, brake pads, brake fluid specifications, bleeding procedures Electrical System: Wiring diagrams, battery, charging system, lighting, starting system, fuses, relays Frame And Body: Frame inspection and repair, body panels, fenders, seat, handlebars Wheels And Tires: Tire pressure, rim specifications, lug nut torque Procedures Included Maintenance Procedures: Oil changes, filter replacements, chain adjustment, lubrication points, spark plug replacement Troubleshooting Guides: Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts Repair Procedures: Step-by-step instructions for component removal, installation, and rebuilding Diagnostic Charts: Flowcharts and tables to identify and resolve problems Assembly Disassembly: Detailed instructions for taking apart and putting back together various vehicle components Technical Depth Depth Level: Comprehensive Diagnostic Capabilities: Advanced diagnostics, including electrical system troubleshooting Rebuild Instructions: Full engine and transmission rebuild procedures Special Tools: Identification of specific tools required for certain repairs 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text content Print Quality Print Readability: High resolution images and text for clear printing Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder Displacement: Approximately 250cc (exact displacement may vary slightly by specific model year, typically around 246cc) Bore X Stroke: Typically 66.0 mm x 72.0 mm (subject to verification in manual) Cooling Method: Liquid-cooled Valve Train: SOHC, 4-valve (common configuration for this era Suzuki) Compression Ratio: Typically around 10.2:1 (subject to verification) Performance Horsepower: Estimated 20-25 HP (subject to verification in manual) Torque: Estimated 15-18 lb-ft (subject to verification in manual) Fuel System Fuel Delivery: Carburetor (likely Mikuni VM series, e.g., VM26) Fuel Type: Unleaded gasoline Fuel Capacity: Approximately 2.6 US gallons (subject to verification) 🔧 Transmission Standard Transmission Type: 5-speed manual with reverse Clutch Type: Wet, multi-plate Optional Optional Transmission: N/A (standard configuration) Features Drive System: 2WD (Rear Wheel Drive) Final Drive: Chain drive 📐 Dimensions Exterior Overall Length: Approximately 70.1 inches (1780 mm) (subject to verification) Overall Width: Approximately 46.5 inches (1180 mm) (subject to verification) Overall Height: Approximately 43.1 inches (1095 mm) (subject to verification) Wheelbase: Approximately 48.8 inches (1240 mm) (subject to verification) Weights Dry Weight: Approximately 390 lbs (177 kg) (subject to verification) Curb Weight: Typically around 400+ lbs (subject to verification) Ground Clearance: Approximately 8.3 inches (210 mm) (subject to verification) 🛡️ Safety Features Ratings Safety Standards: Designed to meet industry standards for ATVs, but specific crash ratings are not typical for this vehicle type. Active Features Braking System: Hydraulic disc brakes front and rear Lighting: Dual headlights and taillight for visibility Passive Features Chassis Design: Robust frame construction for durability Ergonomics: Designed for rider control and comfort 💡 Technology Features Infotainment Infotainment System: N/A (Basic ATV functionality) Driver Assistance Assistance Features: N/A (Mechanical controls) Connectivity Connectivity Options: N/A 🔧 Maintenance Service Intervals Engine Oil Change: Every 1,000 km or 6 months (typical, refer to manual for exact) Spark Plug Inspection: Every 2,000 km or annually (typical, refer to manual for exact) Air Filter Cleaning: As needed based on riding conditions, or every 6 months (typical) Chain Lubrication Adjustment: Every 500 km or as needed (typical) Fluid Specifications Engine Oil Type: Suzuki recommends API SF, SG, SH, SJ or higher, SAE 10W-40 (confirm in manual) Engine Oil Capacity: Approximately 1.7 US quarts (1.6 liters) without filter change, 1.8 US quarts (1.7 liters) with filter change (confirm in manual) Brake Fluid Type: DOT 3 or DOT...
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts
Repair Procedures:
Step-by-step instructions for component removal, installation, and rebuilding
Diagnostic Charts:
Flowcharts and tables to identify and resolve problems
Assembly Disassembly:
Detailed instructions for taking apart and putting back together various vehicle components
Technical Depth
Depth Level:
Comprehensive
Diagnostic Capabilities:
Advanced diagnostics, including electrical system troubleshooting
Rebuild Instructions:
Full engine and transmission rebuild procedures
Special Tools:
Identification of specific tools required for certain repairs
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text content
Print Quality
Print Readability:
High resolution images and text for clear printing
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, single-cylinder
Displacement:
Approximately 250cc (exact displacement may vary slightly by specific model year, typically around 246cc)
Bore X Stroke:
Typically 66.0 mm x 72.0 mm (subject to verification in manual)
Cooling Method:
Liquid-cooled
Valve Train:
SOHC, 4-valve (common configuration for this era Suzuki)
Compression Ratio:
Typically around 10.2:1 (subject to verification)
Performance
Horsepower:
Estimated 20-25 HP (subject to verification in manual)
Torque:
Estimated 15-18 lb-ft (subject to verification in manual)
Fuel System
Fuel Delivery:
Carburetor (likely Mikuni VM series, e.g., VM26)
Fuel Type:
Unleaded gasoline
Fuel Capacity:
Approximately 2.6 US gallons (subject to verification)
🔧 Transmission
Standard
Transmission Type:
5-speed manual with reverse
Clutch Type:
Wet, multi-plate
Optional
Optional Transmission:
N/A (standard configuration)
Features
Drive System:
2WD (Rear Wheel Drive)
Final Drive:
Chain drive
📐 Dimensions
Exterior
Overall Length:
Approximately 70.1 inches (1780 mm) (subject to verification)
Overall Width:
Approximately 46.5 inches (1180 mm) (subject to verification)
Overall Height:
Approximately 43.1 inches (1095 mm) (subject to verification)
Wheelbase:
Approximately 48.8 inches (1240 mm) (subject to verification)
Weights
Dry Weight:
Approximately 390 lbs (177 kg) (subject to verification)
Curb Weight:
Typically around 400+ lbs (subject to verification)
Ground Clearance:
Approximately 8.3 inches (210 mm) (subject to verification)
🛡️ Safety Features
Ratings
Safety Standards:
Designed to meet industry standards for ATVs, but specific crash ratings are not typical for this vehicle type.
Active Features
Braking System:
Hydraulic disc brakes front and rear
Lighting:
Dual headlights and taillight for visibility
Passive Features
Chassis Design:
Robust frame construction for durability
Ergonomics:
Designed for rider control and comfort
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic ATV functionality)
Driver Assistance
Assistance Features:
N/A (Mechanical controls)
Connectivity
Connectivity Options:
N/A
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 1,000 km or 6 months (typical, refer to manual for exact)
Spark Plug Inspection:
Every 2,000 km or annually (typical, refer to manual for exact)
Air Filter Cleaning:
As needed based on riding conditions, or every 6 months (typical)
Chain Lubrication Adjustment:
Every 500 km or as needed (typical)
Fluid Specifications
Engine Oil Type:
Suzuki recommends API SF, SG, SH, SJ or higher, SAE 10W-40 (confirm in manual)
Engine Oil Capacity:
Approximately 1.7 US quarts (1.6 liters) without filter change, 1.8 US quarts (1.7 liters) with filter change (confirm in manual)
Brake Fluid Type:
DOT 3 or DOT 4 (confirm in manual)
Coolant Type:
Ethylene glycol-based antifreeze and water mixture (50/50 recommended, confirm in manual)
Known Issues
Carburetor Issues:
Can be prone to clogging from old fuel or debris; requires regular cleaning and adjustment.
Electrical Connectors:
Corrosion or loose connections can cause intermittent electrical problems.
Suspension Wear:
Bushing and ball joint wear can occur with heavy use.
Chain And Sprocket Wear:
Regular maintenance is crucial to prevent premature wear.
📚 Vehicle History
Brand Heritage
Suzuki Atv Legacy:
Suzuki has a long history in ATV manufacturing, known for performance and reliability.
Model Evolution
Quadsport Lineage:
The LT-F250 QuadSport was part of Suzuki's popular line of sport-oriented ATVs, often positioned as a more accessible alternative to higher-performance models.
Production
Manufacturing Country:
Likely manufactured in Japan or North America
🏆 Awards & Recognition
Recognitions
Industry Accolades:
While specific awards for the 2002-2009 QuadSport are not widely documented, Suzuki ATVs generally received positive reviews for their performance and value in their respective classes during this period.
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