Category:
Sport ATV / Utility ATV Crossover
Target Audience:
Recreational riders, trail riding, light sport use.
Competitors:
Honda TRX250EX, Yamaha Warrior 350 (earlier models), Kawasaki Mojave 250.
Vehicle Attributes:
User-friendly handling, reliable engine, good value for its class.
Years Covered:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Type:
Comprehensive Service and Repair Manual
Engine:
Complete engine overhaul, top-end and bottom-end rebuilds, valve adjustment, piston and cylinder inspection, camshaft timing.
Fuel System:
Carburetor tuning and rebuilding, fuel pump, fuel lines, fuel filter replacement.
Transmission:
Clutch operation and adjustment, gear inspection, lubrication, shifting mechanism.
Drivetrain:
Chain maintenance, sprocket inspection, rear axle and hub assembly.
Suspension:
Front and rear shock absorber service, spring replacement, A-arm bushings, steering linkage.
Brakes:
Hydraulic brake system, caliper overhaul, brake pad replacement, rotor inspection, brake fluid bleeding, parking brake adjustment.
Electrical System:
Battery testing and replacement, ignition system diagnosis, lighting circuits, starter motor, charging system (stator and regulator/rectifier).
Cooling System:
Radiator service, fan operation, coolant replacement, thermostat testing.
Lubrication System:
Oil pump operation, oil filter replacement, oil specifications and capacities.
Frame And Body:
Chassis inspection, body panel removal and installation, seat, handlebars, and footpeg maintenance.
Maintenance:
Routine maintenance checks, lubrication points, filter replacement intervals, valve lash adjustments, chain tensioning.
Troubleshooting:
Diagnostic flowcharts for common starting issues, running problems, electrical faults, and performance issues.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly.
Diagnostics:
Methods for diagnosing electrical circuits, fuel delivery problems, and mechanical failures.
Wiring Diagrams:
Detailed electrical wiring schematics for all circuits.
Level Of Detail:
Factory-level detail suitable for professional mechanics and experienced DIY enthusiasts.
Engine Type:
Four-stroke, SOHC, air-cooled
Bore X Stroke:
72.0 mm x 61.1 mm
Valve Clearance Intake:
0.08 - 0.12 mm (0.003 - 0.005 in)
Valve Clearance Exhaust:
0.10 - 0.14 mm (0.004 - 0.006 in)
Horsepower:
Approximately 18-20 HP (estimated, varies by region/tuning)
Torque:
Approximately 14-15 lb-ft (estimated)
Carburetor Model:
Mikuni BNS32 (likely)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
2.6 US gal (9.8 L)
Safety Features General:
Designed for off-road use; operator must wear appropriate safety gear.
Brakes:
Front disc brakes, Rear disc brake. Mechanical parking brake.
Lighting:
Halogen headlights, taillight/stoplight.
Handlebars:
Handlebar padding for rider safety.
Oil Change Interval:
Every 1000 km (600 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Clean every 500 km (300 miles) or more frequently in dusty conditions.
Spark Plug Replacement:
Replace every 5000 km (3000 miles) or as needed.
Valve Adjustment Interval:
Check/adjust every 4000 km (2500 miles).
Chain Maintenance:
Clean and lubricate every 500 km (300 miles); check tension regularly.
Engine Oil Type:
SAE 10W-40 API SE, SF, or SG.
Engine Oil Capacity:
1.8 L (1.9 US qt) with oil filter change.
Brake Fluid Type:
DOT 3 or DOT 4.
Coolant Type:
Ethylene glycol-based coolant with demineralized water (50/50 mix).
Common Wear Items:
Front brake pads, rear brake pads, chain and sprockets, wheel bearings.
Potential Failures:
Carburetor jetting issues in humid or high-altitude conditions, stator failure (less common than on some other models).
Suzuki Legacy:
Suzuki has a long-standing reputation for producing reliable and capable off-road vehicles, including ATVs.
Ltz250 Introduction:
The LT-Z250 QuadSport was introduced as a mid-range sport ATV, offering a balance of performance and user-friendliness.
Manufacturing Location:
Primarily manufactured in Japan.
Key Updates During Production:
While major overhauls were minimal during this generation, minor updates to graphics, tuning, and component sourcing occurred.
