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Suzuki LTZ250 LT-Z250 QUADSPORT Workshop Repair Manual All 2004-2009 ModelS COVERED

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This manual covers the QuadSport, a sport All-Terrain Vehicle (ATV) produced from 2004 to 2009. Known for its nimble handling and sporty design, the LT-Z250 was engineered for recreational riders...
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Suzuki LTZ250 LT-Z250 QUADSPORT Workshop Repair Manual All 2004-2009 ModelS COVERED
This manual covers the QuadSport, a sport All-Terrain Vehicle (ATV) produced from 2004 to 2009. Known for its nimble handling and sporty design, the LT-Z250 was engineered for recreational riders and positioned within the sport ATV segment. It features a 249 cc liquid-cooled, single-cylinder engine, a 5-speed manual transmission with reverse, and hydraulic disc brakes. The QuadSport line, including the LT-Z250, reflects a legacy of producing reliable and capable ATVs, offering a compelling blend of performance and value for trail riding and general recreational use. This comprehensive workshop repair manual provides detailed instructions and technical specifications essential for the maintenance and repair of your QuadSport. It covers all major systems, including engine, drivetrain, chassis, and electrical components, with in-depth procedures for disassembly, reassembly, adjustments, and troubleshooting. Regular maintenance schedules, fluid specifications, and guidance on common wear items are also included, empowering owners and technicians to keep the ATV in optimal condition. The manual is designed to facilitate efficient diagnostics and repairs, ensuring the longevity and performance of your vehicle.
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
LT-Z250 QuadSport
Model Alias:
LTZ250
Vehicle Type:
All-Terrain Vehicle (ATV)
Generation
Generation Identifier:
First Generation (LT-Z250)
Codes
Chassis Code Prefix:
K7
👋 Introduction
Market Position
Market Segment:
Sport ATV segment, targeting recreational riders and entry-level competition.
Competitive Analysis
Key Competitors:
Yamaha Warrior 350, Honda TRX300EX, Polaris Predator 500 (older models), Kawasaki Mojave 250.
Key Features
Quadsport Philosophy:
Suzuki's QuadSport line emphasized nimble handling, reliable performance, and a sporty design, making the LT-Z250 a popular choice for trail riding and recreational use.
Manual Value Proposition
Value For Buyers:
Provides essential technical data, diagnostic procedures, and repair instructions to empower owners and technicians for effective maintenance and repair, saving time and money.
📋 Manual Details
Coverage Areas
Model Years Covered:
2004, 2005, 2006, 2007, 2008, 2009
Page Count
Estimated Page Count:
Comprehensive (Exact count not specified, but described as extensive)
Manual Type
Manual Type:
Workshop Repair Manual / Service Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine assembly, disassembly, lubrication, cooling, fuel system (carburetor, fuel lines, petcock), ignition system, exhaust system, starting system, internal engine components (piston, rings, cylinder, valve train), engine torque specifications.
Drivetrain Systems:
Clutch operation and adjustment, transmission assembly and disassembly, gear shifting mechanism, drive chain, rear axle, differential (if applicable), wheel bearings.
Chassis Systems:
Frame inspection and repair, suspension (front and rear A-arms, shocks, springs), steering system (handlebars, tie rods, steering shaft), brake system (front and rear calipers, master cylinders, brake lines, brake pads, brake fluid), wheels and tires, skid plates.
Electrical Systems:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting system (headlights, taillights, brake lights), ignition switch, starter motor, fuses, relays, CDI unit, troubleshooting electrical faults.
Bodywork And Trim:
Body panel removal and installation, plastics, seat, fenders, handlebars, controls, decals.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacement (oil, air), spark plug replacement, valve clearance adjustment, chain adjustment and lubrication, brake bleeding, tire pressure checks, battery terminal cleaning.
Repair Procedures:
Engine rebuilds, carburetor overhaul, transmission rebuilds, suspension component replacement, brake caliper overhaul, steering bearing replacement, electrical component testing and replacement.
Troubleshooting Guides:
Diagnostic procedures for common problems, symptom-based troubleshooting, electrical fault finding, engine performance issues.
Adjustment Procedures:
Carburetor adjustments, clutch lever free play, throttle cable adjustment, brake lever adjustment, chain slack adjustment, steering alignment.
Technical Depth
Depth Of Coverage:
Comprehensive: Covers routine maintenance to full engine and transmission overhauls. Includes detailed disassembly and reassembly instructions with torque specifications and critical measurements.
📊 Manual Specifications
File Format
PDF Quality:
High-quality, searchable PDF for easy navigation and printing.
Print Quality
Printability:
Printable pages for workshop use.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, SOHC, single-cylinder
Displacement:
249 cc (249 cubic centimeters)
Bore X Stroke:
72.0 mm x 61.2 mm (2.83 in x 2.41 in)
Cooling System:
Liquid-cooled
Performance
Horsepower Estimate:
Approximately 20-22 HP (Engine output varies slightly by year and tuning)
Torque Estimate:
Approximately 14-16 lb-ft (Engine output varies slightly by year and tuning)
Fuel System
Fuel Delivery:
Carburetor
Carburetor Model:
Mikuni BSR33 (typically)
Ignition System
Ignition Type:
Digital CDI (Capacitor Discharge Ignition)
Lubrication System
Oil Capacity With Filter:
Approx. 1.8 L (1.9 US qt)
Starting System
Starting Method:
Electric start
🔧 Transmission
Standard
Transmission Type:
5-speed manual with reverse
Optional
Optional Transmissions:
None
Features
Clutch Type:
Wet multi-plate
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Overall Length:
Approx. 1790 mm (70.5 in)
Overall Width:
Approx. 1100 mm (43.3 in)
Overall Height:
Approx. 1070 mm (42.1 in)
Wheelbase:
Approx. 1275 mm (50.2 in)
Ground Clearance:
Approx. 245 mm (9.6 in)
Weights
Dry Weight:
Approx. 186 kg (410 lbs)
Curb Weight:
Not specified, but typically slightly higher than dry weight.
Cargo
Rack Capacity Front:
Not specified for carrying cargo, but typically designed for light loads or accessories.
Rack Capacity Rear:
Not specified for carrying cargo, but typically designed for light loads or accessories.
🛡️ Safety Features
Ratings
Atv Safety Standards:
Compliant with ANSI/SVIA standards for Class II ATVs.
Active Features
Braking System Type:
Hydraulic disc brakes, front and rear.
Parking Brake:
Mechanical parking brake (typically lever-actuated).
Passive Features
Throttle Limiter:
Some models may have adjustable throttle limiters for beginner riders.
Recoil Starter:
Manual recoil starter as a backup to electric start (check specific model variant).
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic recreational ATV, no integrated infotainment)
Driver Assistance
Driver Assistance Features:
N/A (Basic recreational ATV, no electronic driver aids)
Connectivity
Connectivity Features:
N/A (Basic recreational ATV, no electronic connectivity)
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 1000 km or 6 months (refer to manual for specific conditions).
Air Filter Cleaning Interval:
Every 20 hours of operation or as needed based on conditions.
Spark Plug Replacement Interval:
Every 3000 km or 18 months (check gap regularly).
Valve Clearance Check Interval:
Every 2000 km or 12 months.
Fluid Specifications
Engine Oil Type Recommendation:
SAE 10W-40 API SG or higher (check manual for specific viscosity based on temperature).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Type:
High-quality ethylene glycol-based coolant (50/50 mixture with distilled water).
Known Issues
Common Wear Items:
Brake pads, chain and sprockets, wheel bearings, tie rod ends, carburetor jets (clogging).
Potential Engine Concerns:
Valve seat wear (over time), carburetor cleaning due to fuel quality/storage.
Maintenance Tips
Storage Preparation:
Includes fuel stabilizer, carburetor draining, battery care, and proper cleaning.
📚 Vehicle History
Brand Heritage
Suzuki Atv Legacy:
Suzuki has a long-standing reputation for producing robust and capable ATVs, including the popular 'Quadsport' and 'Quadrunner' lines, known for their performance and reliability.
Model Evolution
Ltz250 Introduction:
Introduced as a successor to the LT-F250 Quadrunner, the LT-Z250 QuadSport offered a sportier, more performance-oriented platform with a focus on agile handling and a more powerful engine configuration.
Key Updates 2004-2009:
Minor revisions likely included color options, graphics, and potentially minor tuning adjustments for emissions or performance across the model years covered.
Production
Production Period:
2004-2009
🏆 Awards & Recognition
Recognitions
Atv Industry Accolades:
While specific awards are not readily documented for the LT-Z250, Suzuki's QuadSport line generally received positive reviews for its performance and value within its class.
Ratings
Consumer Reviews Trend:
Generally well-regarded for its handling, reliability, and affordability in the recreational sport ATV market.
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