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Suzuki QuadSport 250 LT-Z250 LTZ250 2004-2009 Service Repair Manual

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The QuadSport 250, also known by its chassis code LT-Z250, is a versatile sport ATV designed for enthusiasts and recreational riders. Produced between 2004 and 2009, this model is celebrated...
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Suzuki QuadSport 250 LT-Z250 LTZ250 2004-2009 Service Repair Manual
The QuadSport 250, also known by its chassis code LT-Z250, is a versatile sport ATV designed for enthusiasts and recreational riders. Produced between 2004 and 2009, this model is celebrated for its agile handling, robust 249cc liquid-cooled engine, and reliable performance on varied terrain. Its design philosophy emphasizes a balance of power and maneuverability, making it a competitive choice in the sport ATV segment. The QuadSport 250 features a 5-speed manual transmission with reverse, dual hydraulic front disc brakes, and a single hydraulic rear disc brake, all contributing to its sporty capability and control. This comprehensive service repair manual provides detailed information for the maintenance, troubleshooting, and repair of your QuadSport 250. Covering all essential systems including the engine, transmission, chassis, steering, brakes, and electrical components, this guide offers step-by-step procedures, technical specifications, and diagnostic information. Whether you are performing routine maintenance like oil changes and filter replacements or undertaking more complex repairs such as engine overhauls or electrical system diagnostics, this manual equips owners and technicians with the knowledge needed to keep the vehicle in optimal condition. It includes detailed wiring diagrams, torque values, and specific fluid recommendations to ensure accurate and effective service.
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
QuadSport 250
Model Variant:
LT-Z250 / LTZ250
Production Years Covered:
2004, 2005, 2006, 2007, 2008, 2009
Codes
Chassis Code:
LT-Z250
👋 Introduction
Market Position
Segment:
Sport ATV (ATV)
Target Audience:
Enthusiasts, Recreational Riders, DIY Mechanics
Competitive Analysis
Key Competitors:
Yamaha Raptor 250, Honda TRX250X, Kawasaki KFX250
Key Features
Manual Advantage:
Provides dealership-level repair information, instant access, cost-effective alternative to physical manuals
Vehicle Focus:
Designed for performance and agility in sport riding
📋 Manual Details
Coverage Areas
Manual Type:
Complete Service Repair Manual
Language:
English
Format:
Adobe Acrobat PDF
Delivery Method:
Instant Digital Download
📖 Manual Coverage
Systems Covered
Engine:
Complete Engine Overhaul, Maintenance, Troubleshooting, Specifications
Transmission:
Gearbox Service, Clutch Operation, Maintenance, Repair
Chassis:
Frame Inspection, Suspension Adjustments, Wheel Bearing Service
Steering:
Handlebar Assembly, Tie Rods, Steering Knuckle Service
Brakes:
Hydraulic System, Disc Brake Service, Bleeding Procedures, Pad Replacement
Electrical:
Wiring Diagrams, Lighting System, Ignition System, CDI Unit, Charging System
Fuel System:
Carburetor Service, Fuel Tank Maintenance, Fuel Lines
Lubrication:
Lubrication Points, Oil Change Procedures, Fluid Specifications
Bodywork:
Body Panel Removal, Seat Assembly, Fender Maintenance
Battery:
Battery Testing, Charging, Replacement
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Chain Adjustment
Troubleshooting:
Diagnostic Procedures for Common Issues, Symptom-Based Fault Finding
Repair:
Component Disassembly, Reassembly, Component Replacement
Specifications:
Torque Values, Clearances, Timing Specifications
Technical Depth
Diagnostic Capabilities:
Comprehensive fault code diagnosis and troubleshooting guides
Rebuild Procedures:
Detailed instructions for complete engine and transmission rebuilds
Electrical Diagrams:
Detailed and accurate wiring diagrams for all electrical systems
📊 Manual Specifications
File Format
File Type:
PDF
Compatibility:
PC and Mac compatible
Searchability:
Searchable text for quick information retrieval
Print Quality
Printable:
Yes, individual sections or entire manual can be printed
Binding Type
User Binding:
Recommended for 3-ring binder for organized reference
Paper Type
Physical Format:
Digital - no physical manual is shipped
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, 4-valve
Displacement:
249cc (250cc class)
Bore X Stroke:
72.0 mm x 61.2 mm
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approximately 20-22 HP (Varies slightly by year and testing) - specific value not listed, but common for this class.
Torque:
Approximately 15-17 lb-ft (Varies slightly by year and testing) - specific value not listed.
Fuel System
Fuel Delivery:
Mikuni BSR32 carburetor
Fuel Type:
Unleaded gasoline
Ignition
Ignition System:
CDI (Capacitor Discharge Ignition)
🔧 Transmission
Standard
Transmission Type:
5-speed manual with reverse
Clutch Type:
Wet multi-plate
Features
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approximately 1760 mm (69.3 in)
Width:
Approximately 1115 mm (43.9 in)
Height:
Approximately 1040 mm (40.9 in)
Wheelbase:
Approximately 1240 mm (48.8 in)
Weights
Dry Weight:
Approximately 177 kg (390 lbs)
Fuel Tank Capacity:
10.0 L (2.6 US gal)
🛡️ Safety Features
Ratings
Safety Standards:
Designed to meet ANSI/SVIA 1-2003 and OSHA standards for recreational use
Active Features
Braking System:
Dual hydraulic disc front brakes, Single hydraulic disc rear brake
Passive Features
Handlebars:
Tapered handlebars with comfortable grip design
💡 Technology Features
Infotainment
Display:
Digital multi-function display (speedometer, odometer, trip meter, clock)
Driver Assistance
Lighting:
Dual 35W headlights, 5W brake/taillight
Connectivity
Charging System:
12V DC output for battery charging
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 20 hours or 6 months (refer to manual for precise details)
Air Filter Cleaning:
Every 10 hours or as needed based on conditions
Spark Plug Replacement:
Refer to manual, typically every 100-150 hours or as needed
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SE, SF or SG (refer to manual for exact specification)
Engine Oil Capacity:
Approximately 1.7 L (1.8 US qt) with filter change (refer to manual)
Coolant Type:
Antifreeze coolant (mixture of 50% ethylene glycol and 50% distilled water)
Known Issues
Common Wear Items:
Brake pads, tires, chain and sprockets, wheel bearings
Carburetor Tuning:
May require occasional adjustment due to altitude or fuel variations
Suspension Maintenance:
Regular cleaning and lubrication of suspension components is advised
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation, established 1909
Model Evolution
Previous Models:
Successor to models like the Suzuki QuadSport 250 LT-F250
Design Philosophy:
Emphasis on performance, light weight, and maneuverability for sport riding
Production
Production Location:
Typically manufactured in Japan or other Suzuki global facilities.
🏆 Awards & Recognition
Recognitions
Industry Perception:
Generally well-regarded in its class for reliability and performance. Specific awards not readily available, but consistently a popular choice in the sport ATV market.
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