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Suzuki ATV LT 250 Quad Sport 2003 Factory Service Repair Manual

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The 2003 Suzuki LT-F250 Quad Sport is a capable and reliable mid-size utility all-terrain vehicle designed for recreational riding, light work, and trail exploration. It offers a balanced combination of...
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Type: Atv
Vendor:
Sku: 50621
Suzuki ATV LT 250 Quad Sport 2003 Factory Service Repair ManualSuzuki ATV LT 250 Quad Sport 2003 Factory Service Repair ManualSuzuki ATV LT 250 Quad Sport 2003 Factory Service Repair ManualSuzuki ATV LT 250 Quad Sport 2003 Factory Service Repair Manual
The 2003 Suzuki LT-F250 Quad Sport is a capable and reliable mid-size utility all-terrain vehicle designed for recreational riding, light work, and trail exploration. It offers a balanced combination of performance, comfort, and durability, featuring a shaft drive system, a comfortable seating position, and a robust chassis. Key features include front and rear racks for cargo, dual headlights and a taillight for visibility, and ergonomically designed handlebars for control and reduced fatigue. This factory service repair manual provides comprehensive workshop repair and service information for the 2003 Suzuki LT-F250 Quad Sport. It covers essential areas such as scheduled maintenance, engine and transmission overhauls, fuel system adjustments, suspension and brake system repairs, and detailed electrical system diagnostics. The manual includes step-by-step instructions, troubleshooting guides, and technical specifications, enabling owners and technicians to effectively maintain, diagnose, and repair the vehicle to ensure optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
LT-F250 Quad Sport
Year:
2003
Codes
Chassis Code:
Not specified in product info
Engine Code:
Not specified in product info
👋 Introduction
Market Position
Positioning:
The Suzuki LT-F250 Quad Sport 2003 was positioned as a capable and reliable mid-size utility ATV, suitable for recreational riding, light work, and trail exploration. It offered a balance of performance, comfort, and durability.
Competitive Analysis
Competitors:
Competed against models like the Honda FourTrax 300/350, Yamaha Wolverine 350, and Kawasaki Bayou 300/300.
Key Features
Features Of Atv:
Shaft drive, comfortable seating position, robust chassis, reliable engine, front and rear racks for cargo.
Manual Value
Value Proposition:
This manual provides factory-level data, enabling owners and technicians to perform all necessary maintenance and repairs, ensuring optimal performance and longevity of the ATV, mirroring the information used by official Suzuki dealerships.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete workshop repair and service
Secondary Coverage:
Maintenance, troubleshooting, diagnostics, rebuilds
Page Count
Estimated Page Count:
Estimated 300-500 pages (typical for factory service manuals)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Engine disassembly, assembly, component inspection, timing, valve clearance, cooling system, lubrication system
Fuel System:
Carburetor tuning and overhaul, fuel pump, fuel tank, fuel lines
Transmission:
Clutch operation and adjustment, gear shifting mechanism, gearbox disassembly and reassembly
Drivetrain:
Drive shafts, differentials (if applicable), axle components, chain/belt maintenance
Suspension:
Front and rear suspension systems, shock absorbers, control arms, bushings, alignment
Brakes:
Brake system diagnosis, hydraulic lines, brake calipers, master cylinder, brake pads, rotor replacement
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), ignition system, lighting, starter motor
Cooling System:
Radiator, fan, coolant hoses, thermostat (if applicable)
Exhaust System:
Muffler, exhaust pipes, gasket replacement
Body And Chassis:
Frame inspection and repair, body panels, seat, handlebars, controls, plastics
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, chain lubrication and adjustment, battery care
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues, fault code interpretation (if applicable)
Repair:
Step-by-step instructions for component removal, repair, and installation, including engine rebuilds, suspension work, and electrical system repairs
Diagnostics:
Detailed diagnostic flowcharts and procedures for identifying and resolving malfunctions
Specifications:
Torque specifications for all fasteners, engine clearances, fluid capacities, electrical resistance values
Technical Depth
Depth:
Comprehensive, covering all aspects from basic maintenance to complete engine and transmission overhauls, including detailed electrical diagnostics
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Likely searchable text within PDF for efficient information retrieval
Print Quality
Print Quality:
High-resolution, suitable for printing individual pages or the entire manual
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, air-cooled, single-cylinder
Displacement:
246 cc (Cubic Centimeters)
Bore X Stroke:
Not specified in product info, but typically around 70mm x 64mm for this class.
Compression Ratio:
Not specified in product info, likely around 9.2:1 to 9.5:1
Performance
Horsepower:
Estimated 16-18 HP (Horsepower) at approximately 6500 RPM.
Torque:
Estimated 15-17 lb-ft (Pound-feet) at approximately 5000 RPM.
Fuel System
Carburetor:
Mikuni VM Series (e.g., VM26SS or similar) - manual will detail specific model and tuning.
Fuel Type:
Unleaded gasoline (Octane rating 87 or higher recommended)
Lubrication
Oil Type:
SAE 10W-40 API SG or SH (Specific Suzuki recommendations in manual)
Oil Capacity:
Approx. 1.7 L (1.8 US qt) with filter change (refer to manual for precise capacity).
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition)
Spark Plug:
NGK CR7E or similar (Check manual for exact specification and gap)
🔧 Transmission
Standard
Transmission Type:
5-speed manual with Reverse
Clutch Type:
Wet multi-plate
Features
Drive System:
2WD (Rear Wheel Drive) via shaft drive
Gear Ratios:
Specific gear ratios will be detailed in the manual, crucial for understanding performance characteristics.
Fluid Specifications
Gear Oil Type:
SAE 80W API GL-4 (Specific Suzuki recommendations in manual)
Gear Oil Capacity:
Not specified in product info, manual will detail capacity for gearbox and differential.
📐 Dimensions
Exterior
Length:
Approx. 1995 mm (78.5 in)
Width:
Approx. 1070 mm (42.1 in)
Height:
Approx. 1100 mm (43.3 in)
Wheelbase:
Approx. 1245 mm (49.0 in)
Weights
Dry Weight:
Approx. 200 kg (441 lbs)
Curb Weight:
Not specified in product info, but typically slightly higher than dry weight.
Cargo
Front Rack Capacity:
Approx. 20 kg (44 lbs)
Rear Rack Capacity:
Approx. 40 kg (88 lbs)
Wheels And Tires
Front Tire Size:
AT 22x7-10
Rear Tire Size:
AT 22x10-10
Wheel Bolt Pattern:
Not specified in product info, but typically 4-stud with a common PCD.
🛡️ Safety Features
Ratings
Atv Safety Standards:
Designed to meet relevant ANSI safety standards for ATVs.
Active Features
Braking System:
Hydraulic disc brakes front and rear for reliable stopping power.
Throttle Limiter:
Not typically featured on this model, but manual may detail any governor settings.
Passive Features
Handlebars:
Comfortable, ergonomically designed handlebars for control and reduced fatigue.
Footwells:
Wide, anti-slip footwells for rider security.
Lighting:
Dual headlights and taillight for visibility.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable for this model. Basic instrumentation includes speedometer, odometer, and indicator lights.
Driver Assistance
Driver Assistance Features:
Not applicable for this model.
Connectivity
Connectivity Features:
Not applicable for this model.
Engine Management
Engine Control:
Basic CDI ignition and carburetor-based fuel delivery. No electronic engine management systems beyond ignition timing.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 100 hours or annually, whichever comes first (check manual for exact recommendation).
Spark Plug Inspection Replacement:
Inspect every 100 hours, replace as needed. Gap check is critical.
Air Filter Cleaning Replacement:
Clean every 20 hours, replace as needed, especially in dusty conditions. Critical for engine longevity.
Chain Lubrication Adjustment:
Lubricate every 10-15 hours or after wet riding. Adjust chain slack according to manual specifications (typically 15-25mm).
Valve Clearance Check:
Every 400 hours or annually. Crucial for engine performance and preventing damage.
Fluid Specifications
Engine Oil Specification:
SAE 10W-40, API SG or SH rated motorcycle oil.
Gear Oil Specification:
SAE 80W API GL-4 gear oil.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
Brake pads, tires, suspension bushings, drive chain and sprockets (if applicable), air filter, spark plug.
Carburetor Issues:
Potential for gumming or clogging if fuel is left in the system for extended periods without stabilizer. Manual details cleaning and adjustment.
Electrical Gremlins:
Corrosion in connectors or grounds can cause intermittent issues. Comprehensive wiring diagrams in the manual are essential for diagnosis.
Suspension Wear:
Bushings and seals in the front and rear suspension can wear over time, affecting ride quality and handling. Manual details replacement procedures.
📚 Vehicle History
Brand Heritage
Heritage:
Suzuki has a long-standing reputation in the powersports industry, known for producing reliable and durable motorcycles and ATVs. The 'Quad Sport' line has been a popular offering.
Model Evolution
Evolution:
The LT-F250 Quad Sport evolved from earlier Suzuki utility ATVs, incorporating incremental improvements in engine technology, suspension, and rider comfort. This 2003 model represents a mature iteration of the design.
Production
Manufacturing Location:
Likely manufactured in Japan or a Suzuki facility in North America.
Production Years:
The LT-F250 Quad Sport model was produced for several years in the early to mid-2000s, with variations in trim and minor updates.
🏆 Awards & Recognition
Recognitions
Atv Awards:
No specific major awards are typically highlighted for this particular model year's utility ATV, but Suzuki ATVs generally received positive reviews for reliability and value in their class.
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