The LT-Z250, produced from 2004 to 2009, is a capable and versatile sport ATV designed for recreational riders. Positioned to balance power and handling, it features a 249cc liquid-cooled, fuel-injected engine with electric start, providing consistent performance and ease of use. Notable features include front and rear hydraulic disc brakes, adjustable suspension, and a robust frame construction, all contributing to its reputation for durability and a comfortable riding experience. This model competed effectively in its class by offering a blend of sport and recreational capabilities, making it a popular choice for those seeking an engaging ATV experience.
This comprehensive service repair manual provides detailed information for the maintenance, diagnosis, and repair of the LT-Z250 for model years 2004 through 2009. It covers a wide range of systems, including general information, periodic maintenance, engine, fuel injection, exhaust, cooling, lubrication, chassis, and electrical systems. The manual includes procedures for troubleshooting, component-level repair, disassembly and assembly, technical specifications, and essential safety guidelines. This resource is designed to assist owners, mechanics, and technicians in ensuring the optimal performance and longevity of their LT-Z250.
Generation:
First Generation
Model Years Covered:
2004, 2005, 2006, 2007, 2008, 2009
Chassis Code:
K4/K5/K6/K7/K8/K9
Market Position:
The Suzuki LT-Z250 was positioned as a capable and versatile sport ATV, bridging the gap between entry-level and high-performance models. It offered a balance of power, handling, and reliability for recreational riders.
Competitive Analysis:
Competed directly with models like the Yamaha Raptor 250, Honda TRX250EX, and Kawasaki KFX250. Its key selling points included a fuel-injected engine for consistent performance and ease of use, a comfortable chassis, and Suzuki's reputation for durability.
Key Features:
Fuel Injection, Electric Start, Disc Brakes (Front and Rear), Adjustable Suspension, Comfortable Seating Position, Robust Frame Construction.
Coverage Areas:
General Information, Periodic Maintenance, Engine, FI System Diagnosis, Fuel System and Throttle Body, Exhaust System, Cooling and Lubrication System, Chassis, Electrical System, Servicing Information, Emission Control Information, Wiring Diagram
Page Count:
Estimated 400-600 pages (typical for comprehensive service manuals)
Manual Type:
Service Repair Manual
Systems Covered:
Engine (internal components, assembly/disassembly), Fuel Injection (FI) System, Throttle Body, Exhaust System, Cooling System, Lubrication System, Chassis (frame, suspension, steering, wheels, brakes), Electrical System (ignition, lighting, starting, charging, wiring harnesses), Emission Control System
Procedures Included:
Diagnosis of FI system issues, Fuel system inspection and repair, Throttle body cleaning and adjustment, Engine tune-up, Valve clearance adjustment, Piston and cylinder inspection, Cooling system flush and refill, Brake system bleeding and service, Suspension adjustment and repair, Steering system service, Electrical component testing and replacement, Wiring diagram interpretation, Routine maintenance procedures, Troubleshooting guides
Technical Depth:
Comprehensive: Covers detailed diagnostics, component-level repair, disassembly, assembly, specifications, and procedures for both routine maintenance and major repairs. Suitable for professional technicians and experienced DIYers.
Print Quality:
High Resolution, allowing for clear reproduction of text, diagrams, and illustrations.
Binding Type:
Digital Download (Printable)
Paper Type:
N/A (Digital PDF, printable)
Compatibility:
Windows and Mac operating systems
Engine Type:
4-stroke, DOHC, Single Cylinder
Bore X Stroke:
72.0 mm x 61.2 mm
Cooling System:
Liquid-cooled
Horsepower:
Approximately 19-20 HP (estimated, varies by model year and tuning)
Torque:
Approximately 14-15 lb-ft (estimated)
Fuel Delivery:
Fuel Injection (Suzuki's digital fuel injection system)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Oil Type:
API SG or SH, SAE 10W-40 motorcycle oil
Oil Capacity:
Approximately 1.7 L (1.8 US qt) without filter change; 1.9 L (2.0 US qt) with filter change
Transmission Type:
5-speed manual with reverse
Clutch Type:
Wet multi-plate
Final Drive:
O-ring sealed chain
Overall Length:
Approximately 71.3 inches (1810 mm)
Overall Width:
Approximately 45.3 inches (1150 mm)
Overall Height:
Approximately 42.7 inches (1085 mm)
Wheelbase:
Approximately 49.2 inches (1250 mm)
Dry Weight:
Approximately 370 lbs (168 kg)
Fuel Tank Capacity:
3.2 gallons (12 Liters)
Front Tire Size:
AT21 x 7-10
Rear Tire Size:
AT20 x 10-9
Front Suspension Travel:
Approximately 7.1 inches (180 mm)
Rear Suspension Travel:
Approximately 7.1 inches (180 mm)
Ground Clearance:
Approximately 4.3 inches (110 mm)
Safety Ratings:
Not applicable for ATVs in the same manner as passenger vehicles. Focus is on rider safety and operational stability.
Active Features:
Front and rear hydraulic disc brakes for reliable stopping power, Wide track stance for stability.
Passive Features:
Full floorboards with heel guards for foot protection, Thumb throttle for precise control, Comfortable and secure seating position.
Infotainment System:
N/A (Basic instrument cluster with speedometer, odometer, trip meter, and indicator lights)
Driver Assistance Features:
N/A
Connectivity Features:
N/A
Engine Management System:
Suzuki's digital ignition system (CDI) with electronic fuel injection (EFI)
Initial Break In Service:
Recommended at 600 miles or 3 months (check manual for specifics on oil change, filter change, and basic inspections)
Engine Oil And Filter Change:
Every 1,000 miles or 6 months (whichever comes first)
Air Filter Cleaning Or Replacement:
Every 1,000 miles or as needed based on operating conditions
Spark Plug Inspection And Replacement:
Every 2,000 miles or annually
Valve Clearance Check:
Every 4,000 miles or 2 years
Engine Oil Specification:
API SG or SH, SAE 10W-40 motorcycle oil
Coolant Type:
Suzuki Long Life Coolant or equivalent (50/50 mix of antifreeze and distilled water)
Gear Oil Type:
SAE 80W API GL-4
Known Issues:
Occasional issues with the fuel pump relay failing, leading to no-start conditions. Throttle body cleaning can be beneficial for maintaining smooth engine operation. Chain and sprocket wear is typical with regular use.
Brand Heritage:
Suzuki has a long-standing reputation in the powersports industry, known for producing reliable and performance-oriented motorcycles and ATVs. The LT-Z line is a continuation of this heritage.
Model Evolution:
The LT-Z250 was introduced as a successor to the LT-F250 QuadRunner and a more accessible option compared to the high-performance LT-Z400. It focused on a balance of sport and recreational riding capabilities.
Production Period:
2004-2009
Manufacturing Location:
Japan
Recognitions:
While specific awards for the LT-Z250 are not widely documented, it was generally well-regarded in its class for its performance and reliability.
User Ratings:
Generally positive user reviews for its ease of use, comfortable ride, and the benefits of fuel injection.
