Suzuki ATV LT 250 Quad Sport 2003 Digital Service Repair Man

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Stichworte: 2003 Atv LT 250 Quad Sport Misc Motorcycles Suzuki

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Beschreibung

This manual covers the 2003 Suzuki LT250 Quad Sport, a versatile All-Terrain Vehicle (ATV) designed for sporty performance and agility across various terrains. Building on Suzuki's strong legacy in off-road vehicles, the LT250 Quad Sport is recognized for its robust engineering and durable components, offering a reliable and engaging riding experience for enthusiasts. Its design emphasizes a balance of power and handling, making it a capable option in the recreational ATV segment. This comprehensive service and repair manual provides detailed information essential for maintaining and servicing your 2003 Suzuki LT250 Quad Sport. It covers all major systems, including the engine, transmission, drivetrain, suspension, brakes, and electrical system. Within its pages, you will find step-by-step procedures for routine maintenance, in-depth repair instructions, troubleshooting guides, and critical technical specifications. This manual is an invaluable resource for owners and technicians alike, empowering them to keep the ATV in optimal condition.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

LT250 Quad Sport

Year:

Type:

All-Terrain Vehicle (ATV)

Codes

Chassis Code:

LT250PF

👋 Introduction

Market Position

Segment:

Sport/Recreational ATV

Target Audience:

Enthusiasts and owners seeking in-depth maintenance and repair knowledge.

Competitive Analysis

Competitors 2003:

Yamaha Warrior 350, Honda TRX300EX, Kawasaki Mojave 250.

Key Features

Performance Focus:

Designed for agility and sporty performance on various terrains.

Reliability:

Known for its robust engineering and durable components.

Manual Value:

Empowers owners to perform a wide range of maintenance and repairs, saving on dealership costs.

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Drivetrain:

Suspension:

Brakes:

Electrical System:

Fuel System:

Cooling System:

Exhaust System:

Frame And Bodywork:

Steering:

Troubleshooting:

Maintenance:

Wiring Diagrams:

Specifications Charts:

Page Count

Estimated Pages:

300-400

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Overview:

Detailed breakdown of the LT250PF engine, including disassembly, inspection, and reassembly procedures.

Engine Internals:

Covers pistons, rings, cylinders, crankshaft, connecting rods, valves, camshafts, and timing components.

Carburetor System:

Comprehensive guide to carburetor overhaul, adjustment, jetting, and troubleshooting for optimal performance.

Ignition System:

Details on CDI unit, ignition coil, spark plug, stator, and troubleshooting ignition faults.

Cooling System:

Information on air cooling system, including fan operation and maintenance.

Transmission And Clutch:

Explains the operation and repair of the manual clutch and 5-speed sequential gearbox.

Drivetrain And Axles:

Covers rear axle, drive shaft, and related components for proper power delivery.

Suspension System:

Detailed procedures for front and rear suspension, including shock absorbers, A-arms, and bearings.

Braking System:

In-depth coverage of front and rear hydraulic disc brakes, including master cylinders, calipers, and bleeding procedures.

Electrical Components:

Covers starter motor, battery, lighting, switches, and fuses.

Fuel Delivery:

Details on fuel tank, fuel lines, and fuel filter.

Exhaust System:

Information on muffler and exhaust pipe maintenance and replacement.

Frame And Chassis:

Covers frame inspection, welding, and component mounting.

Bodywork And Plastics:

Instructions for removing, installing, and repairing body panels and plastics.

Wheels And Tires:

Specifications for tire sizes, inflation pressures, and wheel torque.

Steering System:

Covers handlebars, steering shaft, tie rods, and wheel alignment.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustments, spark plug service, and general inspections.

Engine Rebuild:

Complete step-by-step instructions for engine disassembly, inspection, component replacement, and reassembly.

Transmission Repair:

Gearbox disassembly, inspection of gears and shift forks, and reassembly.

Carburetor Tuning:

Detailed procedures for cleaning, rebuilding, and adjusting the carburetor for optimal air-fuel mixture.

Brake System Overhaul:

Steps for replacing brake pads, calipers, master cylinders, and bleeding the hydraulic system.

Suspension Adjustment:

Guidance on adjusting suspension settings for different riding conditions.

Electrical Diagnostics:

Troubleshooting common electrical issues, including testing components and reading wiring diagrams.

Troubleshooting Guides:

Specific diagnostic steps for identifying and resolving common mechanical and electrical problems.

Tire And Wheel Service:

Information on tire replacement and wheel balancing.

Frame And Suspension Alignment:

Procedures for checking and adjusting steering and suspension alignment.

Technical Depth

Level Of Detail:

Comprehensive, suitable for both novice mechanics and experienced technicians.

Diagnostic Capabilities:

Advanced diagnostic procedures for identifying subtle issues and performance problems.

Rebuild Procedures:

Detailed, step-by-step instructions for complete engine, transmission, and component rebuilds.

Torque Specifications:

Extensive list of critical torque specifications for all fasteners and components.

Tolerances And Clearances:

Precise measurements for engine components, bearings, and critical assemblies.

Wiring Diagrams:

Clear, detailed electrical wiring diagrams for all systems.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Fully searchable text for quick access to information.

Printability:

Printable pages for easy reference in the workshop.

Resolution:

High-resolution images and diagrams for clarity.

Print Quality

Illustration Quality:

High-quality diagrams, illustrations, and photographs.

Binding Type

Digital Access:

Instant download or online access

Paper Type

Digital Medium:

Electronic document

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, OHC

Displacement:

246 cc

Bore X Stroke:

66.0 mm x 72.0 mm

Compression Ratio:

9.2:1

Cooling Method:

Air-cooled

Performance

Horsepower Estimated:

Approx. 20-23 HP (Varies by tuning and specific model year adjustments)

Torque Estimated:

Approx. 17-19 lb-ft (Varies)

Fuel System

Carburetor Model:

Mikuni VM26SS

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

2.6 US gal (9.8 L)

🔧 Transmission

Standard

Type:

5-speed manual with automatic clutch

Clutch Type:

Wet, multi-plate

Features

Reverse Gear:

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

70.5 in (1790 mm)

Width:

42.7 in (1085 mm)

Height:

41.5 in (1055 mm)

Wheelbase:

49.2 in (1250 mm)

Ground Clearance:

7.1 in (180 mm)

Weights

Dry Weight:

366 lbs (166 kg)

Curb Weight:

386 lbs (175 kg)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Adheres to industry safety standards for ATVs.

Active Features

Braking System:

Front and rear hydraulic disc brakes for reliable stopping power.

Suspension:

Long-travel suspension for stable handling and ride comfort.

Passive Features

Frame Construction:

Durable steel frame designed for off-road use.

Tire Tread:

Aggressive tire tread pattern for enhanced traction.

💡 Technology Features

Infotainment

System:

N/A (Basic ATV)

Driver Assistance

Features:

N/A (Basic ATV, focus on rider control)

Connectivity

Features:

N/A (Basic ATV)

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1000 km or 6 months, whichever comes first.

Air Filter Cleaning:

Every 100 hours or annually, more frequently in dusty conditions.

Spark Plug Replacement:

Every 5000 km or annually.

Chain Lubrication And Adjustment:

Every 500 km, or more often if riding in wet or muddy conditions.

Brake Fluid Flush:

Every 2 years.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SE, SF, or SG

Engine Oil Capacity:

1.6 L (1.7 US qt) without filter change, 1.8 L (1.9 US qt) with filter change

Transmission Oil Type:

SAE 80W API GL-4

Transmission Oil Capacity:

0.6 L (0.63 US qt)

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid

Known Issues

Carburetor Performance:

Can be susceptible to dirt ingress or require fine-tuning for optimal operation.

Suspension Wear:

Bushings and ball joints can wear over time, particularly with heavy use.

Chain And Sprocket Wear:

Regular maintenance is crucial to prevent premature wear of the drive chain and sprockets.

Electrical Connections:

Corrosion or loose connections in the electrical system can cause intermittent faults.

📚 Vehicle History

Brand Heritage

Suzuki Atv Legacy:

Suzuki has a long-standing reputation for building reliable and high-performance off-road vehicles.

Model Evolution

Quad Sport Lineage:

The Quad Sport line represents Suzuki's commitment to sporty, agile ATVs, building on previous iterations.

Lt250 Updates:

The 2003 model likely incorporates refinements from earlier LT250 Quad Sport versions, focusing on performance and rider comfort.

Production

Manufacturing Region:

Primarily Japan, with potential assembly in other regions.

🏆 Awards & Recognition

Recognitions

Atv Magazine Reviews:

While specific awards for the 2003 model are scarce, the LT250 Quad Sport line was generally well-received for its performance and handling in its class.

Ratings

Industry Perception:

Considered a capable and fun recreational ATV by enthusiasts and reviewers of the era.