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

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The LT-Z250 QuadSport, often referred to as the Z250, is a sport All-Terrain Vehicle (ATV) produced from 2004 to 2009. Designed as a capable and user-friendly option in the sport...
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Suzuki LTZ250 Service Manual Repair 2004-2009 Z250 LT-Z250
The LT-Z250 QuadSport, often referred to as the Z250, is a sport All-Terrain Vehicle (ATV) produced from 2004 to 2009. Designed as a capable and user-friendly option in the sport ATV segment, it offers a balanced blend of performance and handling suitable for recreational riding and entry-level competition. Building on a strong ATV heritage, the LT-Z250 features a 249 cc, 4-stroke liquid-cooled engine with a 5-speed transmission and reverse, providing reliable power for various terrains. Its independent front double A-arm suspension and rear swingarm suspension, coupled with hydraulic disc brakes, contribute to its agile and stable platform, making it a popular choice for riders seeking a sporty yet accessible experience. This comprehensive Factory Service Manual provides essential information for the maintenance, repair, and servicing of your LT-Z250 QuadSport ATV. Covering the model years 2004 through 2009, this 323-page English-language manual details everything from routine scheduled maintenance, fluid changes, and filter replacements to in-depth troubleshooting guides and complete component rebuild procedures. It includes detailed technical specifications, torque values, system diagrams, and safety guidelines, empowering owners and professional technicians alike to keep their ATV in optimal condition and ensure safe operation. The manual is designed to facilitate efficient diagnostics and repairs across all major systems, including the engine, drivetrain, chassis, brakes, and electrical components.
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
LT-Z250 QuadSport
Model Nickname:
Z250
Vehicle Type:
ATV (All-Terrain Vehicle)
Generation
Covered Years:
2004, 2005, 2006, 2007, 2008, 2009
Codes
Chassis Code:
Z250
👋 Introduction
Market Position
Segment:
Sport ATV / Youth Sport ATV
Competitive Analysis
Key Competitors:
Yamaha YFZ450, Honda TRX450R, Kawasaki KFX450R (though LT-Z250 often positioned as a slightly less aggressive, more accessible sport quad).
Key Features
Design Philosophy:
The Suzuki LT-Z250 QuadSport was designed as a capable and user-friendly sport ATV, offering a good balance of performance and handling for recreational riding and entry-level racing. It often shares design elements and components with its larger sibling, the LT-Z400.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete repair and service for Suzuki LT-Z250 QuadSport ATVs
Page Count
Total Pages:
323
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine:
Full engine overhaul, carburetor tuning, valve clearance adjustment, ignition system, starting system, lubrication system, cooling system (radiator, coolant flush), fuel system (fuel pump, mixture screw, jets), exhaust system.
Drivetrain:
Transmission, primary reduction gear, drive shaft, clutch (operation, adjustment, replacement), rear axle, swingarm (swinger), wheel hub, chain maintenance.
Chassis And Body:
Frame inspection, suspension (front forks, rear shock absorber, linkage), steering system (triple clamps, handlebars), body panels, fenders, seat, fuel tank removal/installation.
Brakes:
Front and rear brake system maintenance, hydraulic system bleeding, brake pad replacement, rotor inspection, caliper service.
Electrical:
Charging system (stator, rectifier, battery), starter motor, ignition system (CDI, spark plug), lighting system, switches, wiring diagrams (schematic).
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes (engine oil, coolant, brake fluid), filter replacement, lubrication, tire pressure checks, chain adjustment.
Troubleshooting:
Comprehensive troubleshooting guides for common issues such as no spark, starting problems, engine performance issues, electrical faults, transmission problems, and braking system issues. Includes error code identification if applicable.
Repair And Rebuild:
Complete tear-down and rebuild procedures for all major components, including engine disassembly/assembly, transmission overhaul, suspension rebuild, and electrical component replacement.
Technical Data:
Detailed torque specifications for all fasteners, valve clearance specifications, fluid capacities, recommended oil viscosities, tire pressure specifications, engine specifications (bore, stroke, compression ratio).
Technical Depth
Depth:
Comprehensive, covering basic maintenance to full engine and component rebuilds. Suitable for DIY enthusiasts and professional mechanics.
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Print Quality
Print Permission:
Unlimited printing allowed
Binding Type
Digital Features:
Clickable chapters and search functionality
Paper Type
Digital Storage:
Save and burn to disc allowed
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, Liquid-cooled, DOHC, 4-valve
Displacement:
249 cc (15.2 cu. in.)
Performance
Bore X Stroke:
72.0 mm x 61.2 mm (2.83 in. x 2.41 in.)
Compression Ratio:
11.3:1
Fuel System
Carburetor:
Mikuni BSR36 (36 mm) with Accelerator Pump
Fuel Capacity:
2.9 US gal (11 L)
Lubrication System
Recommended Oil:
SAE 10W-40 API SG or higher (specific viscosity may vary with temperature, consult manual for precise recommendations).
Cooling System
Coolant Type:
Ethylene glycol based antifreeze coolant (50% mixture with distilled water recommended).
Ignition
Ignition System:
Electronic ignition (CDI)
🔧 Transmission
Standard
Type:
5-speed constant mesh with Reverse
Clutch Type:
Wet, multi-plate
Features
Final Drive:
O-ring sealed chain, Drive sprocket, Driven sprocket
📐 Dimensions
Exterior
Overall Length:
Approx. 70.1 in. (1780 mm)
Overall Width:
Approx. 45.1 in. (1145 mm)
Overall Height:
Approx. 43.5 in. (1105 mm)
Weights
Dry Weight:
Approx. 390 lbs (177 kg)
Ground Clearance:
Approx. 4.7 in. (120 mm)
Wheels And Tires
Front Tire Size:
AT22x7-10
Rear Tire Size:
AT20x10-9
Front Wheel Type:
Aluminum alloy
Rear Wheel Type:
Aluminum alloy
Suspension
Front Suspension Type:
Independent, double A-arm with oil-damped, coil-spring shocks
Front Suspension Travel:
Approx. 6.9 in. (175 mm)
Rear Suspension Type:
Swingarm type with oil-damped, coil-spring shock absorber
Rear Suspension Travel:
Approx. 7.1 in. (180 mm)
🛡️ Safety Features
Ratings
Atv Safety Considerations:
As with all ATVs, operation requires protective gear (helmet, eye protection, gloves, boots, long sleeves and pants) and responsible riding practices. Manual provides safety warnings and guidelines.
Active Features
Braking System:
Dual hydraulic disc front brakes, Single hydraulic disc rear brake.
Passive Features
Throttle Limiter:
Often equipped with a thumb throttle for controlled acceleration.
💡 Technology Features
Infotainment
Features:
Basic instrumentation (speedometer, odometer, neutral indicator, oil pressure indicator, high beam indicator). No advanced infotainment systems present on this model.
Driver Assistance
Features:
No electronic driver assistance features beyond the standard throttle control and braking systems.
Connectivity
Features:
No connectivity features available.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Recommended every 1,000 km (600 miles) or 6 months. Check manual for specific break-in period recommendations.
Air Filter Cleaning:
Inspect and clean/replace regularly, especially in dusty conditions. Consult manual for specific interval (e.g., every 300 miles or annually).
Spark Plug Replacement:
Recommended replacement interval typically around 2,000-3,000 miles or annually. Manual will specify exact interval and correct spark plug type (e.g., NGK CR9E).
Valve Clearance Check:
First check at 1,000 km (600 miles) or 6 months, then every 2,000 km (1,200 miles) or 12 months thereafter. Correct valve clearance is critical for engine performance and longevity.
Brake Fluid Change:
Recommended every 2 years to maintain braking performance and prevent corrosion.
Fluid Specifications
Engine Oil Capacity:
Approx. 1.7 L (1.8 US qt) without filter change, 1.9 L (2.0 US qt) with filter change. Consult manual for exact capacity.
Transmission Oil Type:
Suzuki Gear Oil (or equivalent API GL-4, SAE 80).
Brake Fluid Type:
DOT 4 brake fluid.
Known Issues
Carburetor Jetting:
Some owners report lean running conditions at higher altitudes or with aftermarket exhausts, requiring carburetor re-jetting. The manual covers carb tuning.
Oil Leaks:
Occasional reports of minor oil leaks from valve covers or crankcase seals, which are detailed repair procedures in the manual.
Suspension Wear:
As with any sport ATV, regular use can lead to wear in suspension bushings and bearings, covered by the manual's rebuild sections.
📚 Vehicle History
Brand Heritage
Suzuki Atv Legacy:
Suzuki has a strong history in the ATV market, particularly with the highly successful LT-Z400 (QuadRacer) and its variants. The LT-Z250 builds on this heritage with a focus on recreational sport riding.
Model Evolution
Ltz250 Positioning:
Introduced as a slightly smaller, lighter, and more accessible sport ATV compared to the LT-Z400, targeting riders seeking sporty performance without the extreme power and handling characteristics of larger displacement models. It filled a niche for a capable entry-level or intermediate sport quad.
Production
Production Period:
2004-2009
🏆 Awards & Recognition
Recognitions
Industry Perception:
While not often garnering specific "awards" in the traditional sense, the LT-Z250 was generally well-regarded by ATV enthusiasts and reviewers for its approachable performance and Suzuki's reputation for reliable powertrains. It served as a solid platform for many riders to enter the sport ATV segment.
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