Target Audience:
Owners, DIY mechanics, and professional technicians working on the Suzuki LT-Z250 QuadSport.
Purpose:
To provide comprehensive instructions for the repair, maintenance, and servicing of the Suzuki LT-Z250 QuadSport.
Completeness:
Covers all aspects of the vehicle, from basic maintenance to complete overhaul procedures.
Detail Level:
Detailed step-by-step instructions with clear diagrams and illustrations.
Diagnostic Focus:
Emphasis on troubleshooting and identifying the root cause of problems.
Engine Mechanical:
Full disassembly, inspection, repair, and reassembly of all engine components (e.g., cylinder head, piston, crankshaft, camshaft).
Engine Fuel System:
Carburetor (Mikuni BSR36) service, cleaning, adjustment, and troubleshooting; fuel pump, fuel filter, and fuel tank maintenance.
Engine Ignition System:
Ignition timing, spark plug specifications, CDI unit, and troubleshooting of ignition-related issues.
Engine Cooling System:
Radiator, fan, thermostat, coolant, and related hoses; flushing and refilling procedures.
Transmission System:
Clutch inspection, adjustment, and replacement; gearbox disassembly, inspection, and lubrication; gear shift mechanism.
Drivetrain System:
Drive shaft, rear axle, differential, and hub maintenance; U-joint inspection and lubrication.
Suspension System:
Front and rear suspension components (A-arms, shocks, springs), ball joints, tie rods, steering knuckles, and alignment procedures.
Braking System:
Front and rear hydraulic disc brakes, caliper service, pad replacement, brake fluid bleeding, master cylinder, and hose inspection.
Electrical System:
Battery, starter, charging system (stator, regulator/rectifier), lighting (headlight, taillight, brake lights), fuses, wiring diagrams, and troubleshooting.
Frame And Bodywork:
Frame inspection, front and rear fenders, seat, handlebars, controls, and plastic body panel removal/installation.
Routine Maintenance:
Oil changes, filter replacement, air filter cleaning/replacement, spark plug service, chain adjustment, tire pressure checks, and lubrication points.
Troubleshooting:
Diagnostic procedures for common problems related to starting, running, electrical systems, and performance issues.
Rebuild Procedures:
Step-by-step instructions for complete engine, transmission, and carburetor rebuilds.
Specifications Data:
Torque specifications, clearances, fluid capacities, electrical values, and wear limits for all components.
Wiring Diagrams:
Detailed electrical system wiring schematics for easy troubleshooting.
Diagnostic Capabilities:
Advanced diagnostics for ignition, fuel, electrical, and mechanical systems, including specific fault codes and their meanings (where applicable).
Repair Complexity:
Covers everything from basic adjustments and fluid changes to complete engine and transmission overhauls.
Special Tools:
Lists any specific Suzuki specialty tools required for certain procedures.
Engine Type:
Four-stroke, DOHC, single-cylinder, liquid-cooled
Displacement:
249.2 cc (15.2 cu. in.)
Bore X Stroke:
72.0 mm x 61.2 mm (2.83 in. x 2.41 in.)
Compression Ratio:
11.3:1
Estimated Horsepower:
Approximately 20-25 HP (varies by specific year and tune)
Estimated Torque:
Approximately 15-18 lb-ft (varies by specific year and tune)
Fuel Delivery:
Mikuni BSR36 CV carburetor
Fuel Type:
Unleaded gasoline, 87 octane or higher
Oil Type:
Suzuki 4-stroke motorcycle oil SAE 10W-40 API SE, SF or SG, or ACEA A1/A2/B1
Oil Capacity With Filter:
1.5 L (1.6 US qt)
Coolant Type:
Suzuki Long Life Coolant (or equivalent ethylene glycol-based coolant with distilled water, 50:50 mixture)
Infotainment System:
N/A (Basic ATV, no integrated infotainment system)
Driver Assistance Features:
N/A (Basic ATV, no electronic driver assistance systems)
Connectivity Features:
N/A (Basic ATV, no connectivity features)
Lighting Type:
Halogen bulbs for headlights and taillight.
Instrument Cluster:
Digital/analog combination meter with speedometer, odometer, tripmeter, clock, and indicator lights (e.g., neutral, oil pressure, high beam).
Engine Oil Change:
Every 1,000 km (600 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
Replace at every engine oil change.
Air Filter Cleaning:
Every 500 km (300 miles) or as needed in dusty conditions.
Spark Plug Check And Gap:
Every 1,000 km (600 miles).
Chain Tension Adjustment:
Every 500 km (300 miles).
Brake Fluid Level Check:
Regularly, and flush/replace every 2 years.
Engine Oil Specification:
SAE 10W-40 API SE, SF or SG, or ACEA A1/A2/B1
Transmission Oil Specification:
API GL-4, SAE 80W hypoid gear oil
Brake Fluid Specification:
DOT 3 or DOT 4 hydraulic brake fluid
Carburetor Fouling:
Can be prone to fouling if not properly maintained or if fuel quality is poor, leading to hard starting or poor idling.
Clutch Wear:
Normal wear and tear, especially with aggressive riding; proper adjustment is key to longevity.
Suspension Bushings:
Bushings can wear over time, leading to play in the suspension; regular inspection is recommended.
Manufacturer:
Suzuki Motor Corporation, a Japanese multinational corporation known for its wide range of automotive, motorcycle, and marine products.
Positioning:
Positioned as a sporty, mid-size ATV offering a balance of performance and usability for recreational trail riding.
Key Updates:
Minor cosmetic and specification updates across the model run, with the core platform remaining consistent.
Production Period:
2002-2009
Manufacturing Location:
Typically produced in Japan or other Suzuki global manufacturing facilities.
