Suzuki ATV LT 250 Quad Sport 2003 Digital Service Repair Man

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🏷️ Basic Information Identification Make: Suzuki Model: LT250 Quad Sport Year: 2003 Type: All-Terrain Vehicle (ATV) Codes Chassis Code: LT250PF 👋 Introduction Market Position Segment: Sport/Recreational ATV Target Audience: Enthusiasts...

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Type: Atv

Vendor:

Sku: 50667

Tags: 2003 Atv LT 250 Quad Sport Misc Motorcycles Suzuki

Product variants

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

LT250 Quad Sport

Year:

Type:

All-Terrain Vehicle (ATV)

Codes

Chassis Code:

LT250PF

👋 Introduction

Market Position

Segment:

Sport/Recreational ATV

Target Audience:

Enthusiasts and owners seeking in-depth maintenance and repair knowledge.

Competitive Analysis

Competitors 2003:

Yamaha Warrior 350, Honda TRX300EX, Kawasaki Mojave 250.

Key Features

Performance Focus:

Designed for agility and sporty performance on various terrains.

Reliability:

Known for its robust engineering and durable components.

Manual Value:

Empowers owners to perform a wide range of maintenance and repairs, saving on dealership costs.

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Drivetrain:

Suspension:

Brakes:

Electrical System:

Fuel System:

Cooling System:

Exhaust System:

Frame And Bodywork:

Steering:

Troubleshooting:

Maintenance:

Wiring Diagrams:

Specifications Charts:

Page Count

Estimated Pages:

300-400

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Overview:

Detailed breakdown of the LT250PF engine, including disassembly, inspection, and reassembly procedures.

Engine Internals:

Covers pistons, rings, cylinders, crankshaft, connecting rods, valves, camshafts, and timing components.

Carburetor System:

Comprehensive guide to carburetor overhaul, adjustment, jetting, and troubleshooting for optimal performance.

Ignition System:

Details on CDI unit, ignition coil, spark plug, stator, and troubleshooting ignition faults.

Cooling System:

Information on air cooling system, including fan operation and maintenance.

Transmission And Clutch:

Explains the operation and repair of the manual clutch and 5-speed sequential gearbox.

Drivetrain And Axles:

Covers rear axle, drive shaft, and related components for proper power delivery.

Suspension System:

Detailed procedures for front and rear suspension, including shock absorbers, A-arms, and bearings.

Braking System:

In-depth coverage of front and rear hydraulic disc brakes, including master cylinders, calipers, and bleeding procedures.

Electrical Components:

Covers starter motor, battery, lighting, switches, and fuses.

Fuel Delivery:

Details on fuel tank, fuel lines, and fuel filter.

Exhaust System:

Information on muffler and exhaust pipe maintenance and replacement.

Frame And Chassis:

Covers frame inspection, welding, and component mounting.

Bodywork And Plastics:

Instructions for removing, installing, and repairing body panels and plastics.

Wheels And Tires:

Specifications for tire sizes, inflation pressures, and wheel torque.

Steering System:

Covers handlebars, steering shaft, tie rods, and wheel alignment.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustments, spark plug service, and general inspections.

Engine Rebuild:

Complete step-by-step instructions for engine disassembly, inspection, component replacement, and reassembly.

Transmission Repair:

Gearbox disassembly, inspection of gears and shift forks, and reassembly.

Carburetor Tuning:

Detailed procedures for cleaning, rebuilding, and adjusting the carburetor for optimal air-fuel mixture.

Brake System Overhaul:

Steps for replacing brake pads, calipers, master cylinders, and bleeding the hydraulic system.

Suspension Adjustment:

Guidance on adjusting suspension settings for different riding conditions.

Electrical Diagnostics:

Troubleshooting common electrical issues, including testing components and reading wiring diagrams.

Troubleshooting Guides:

Specific diagnostic steps for identifying and resolving common mechanical and electrical problems.

Tire And Wheel Service:

Information on tire replacement and wheel balancing.

Frame And Suspension Alignment:

Procedures for checking and adjusting steering and suspension alignment.

Technical Depth

Level Of Detail:

Comprehensive, suitable for both novice mechanics and experienced technicians.

Diagnostic Capabilities:

Advanced diagnostic procedures for identifying subtle issues and performance problems.

Rebuild Procedures:

Detailed, step-by-step instructions for complete engine, transmission, and component rebuilds.

Torque Specifications:

Extensive list of critical torque specifications for all fasteners and components.

Tolerances And Clearances:

Precise measurements for engine components, bearings, and critical assemblies.

Wiring Diagrams:

Clear, detailed electrical wiring diagrams for all systems.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Fully searchable text for quick access to information.

Printability:

Printable pages for easy reference in the workshop.

Resolution:

High-resolution images and diagrams for clarity.

Print Quality

Illustration Quality:

High-quality diagrams, illustrations, and photographs.

Binding Type

Digital Access:

Instant download or online access

Paper Type

Digital Medium:

Electronic document

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, OHC

Displacement:

246 cc

Bore X Stroke:

66.0 mm x 72.0 mm

Compression Ratio:

9.2:1

Cooling Method:

Air-cooled

Performance

Horsepower Estimated:

Approx. 20-23 HP (Varies by tuning and specific model year adjustments)

Torque Estimated:

Approx. 17-19 lb-ft (Varies)

Fuel System

Carburetor Model:

Mikuni VM26SS

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

2.6 US gal (9.8 L)

🔧 Transmission

Standard

Type:

5-speed manual with automatic clutch

Clutch Type:

Wet, multi-plate

Features

Reverse Gear:

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

70.5 in (1790 mm)

Width:

42.7 in (1085 mm)

Height:

41.5 in (1055 mm)

Wheelbase:

49.2 in (1250 mm)

Ground Clearance:

7.1 in (180 mm)

Weights

Dry Weight:

366 lbs (166 kg)

Curb Weight:

386 lbs (175 kg)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Adheres to industry safety standards for ATVs.

Active Features

Braking System:

Front and rear hydraulic disc brakes for reliable stopping power.

Suspension:

Long-travel suspension for stable handling and ride comfort.

Passive Features

Frame Construction:

Durable steel frame designed for off-road use.

Tire Tread:

Aggressive tire tread pattern for enhanced traction.

💡 Technology Features

Infotainment

System:

N/A (Basic ATV)

Driver Assistance

Features:

N/A (Basic ATV, focus on rider control)

Connectivity

Features:

N/A (Basic ATV)

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1000 km or 6 months, whichever comes first.

Air Filter Cleaning:

Every 100 hours or annually, more frequently in dusty conditions.

Spark Plug Replacement:

Every 5000 km or annually.

Chain Lubrication And Adjustment:

Every 500 km, or more often if riding in wet or muddy conditions.

Brake Fluid Flush:

Every 2 years.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SE, SF, or SG

Engine Oil Capacity:

1.6 L (1.7 US qt) without filter change, 1.8 L (1.9 US qt) with filter change

Transmission Oil Type:

SAE 80W API GL-4

Transmission Oil Capacity:

0.6 L (0.63 US qt)

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid

Known Issues

Carburetor Performance:

Can be susceptible to dirt ingress or require fine-tuning for optimal operation.

Suspension Wear:

Bushings and ball joints can wear over time, particularly with heavy use.

Chain And Sprocket Wear:

Regular maintenance is crucial to prevent premature wear of the drive chain and sprockets.

Electrical Connections:

Corrosion or loose connections in the electrical system can cause intermittent faults.

📚 Vehicle History

Brand Heritage

Suzuki Atv Legacy:

Suzuki has a long-standing reputation for building reliable and high-performance off-road vehicles.

Model Evolution

Quad Sport Lineage:

The Quad Sport line represents Suzuki's commitment to sporty, agile ATVs, building on previous iterations.

Lt250 Updates:

The 2003 model likely incorporates refinements from earlier LT250 Quad Sport versions, focusing on performance and rider comfort.

Production

Manufacturing Region:

Primarily Japan, with potential assembly in other regions.

🏆 Awards & Recognition

Recognitions

Atv Magazine Reviews:

While specific awards for the 2003 model are scarce, the LT250 Quad Sport line was generally well-received for its performance and handling in its class.

Ratings

Industry Perception:

Considered a capable and fun recreational ATV by enthusiasts and reviewers of the era.