Download 2004-2009 Suzuki LT-Z250 Quad Sport Repair Manual PDF

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Type: Atv

Vendor:

Sku: 50102

Tags: 2004 2005 2006 2007 2008 2009 ATV LT-Z250 Quad Sport Powersports Quadsport Suzuki

Product variants

Description

The LT-Z250 QuadSport, produced from 2004 to 2009, is a capable all-terrain vehicle known for its reliable performance and agile handling. Featuring a 246 cm³ liquid-cooled, single-cylinder engine with a 5-speed transmission and reverse, this model offers a balanced blend of power and control suitable for recreational riding. Its design emphasizes rider comfort and operational efficiency, with tapered handlebars and a robust suspension system. The QuadSport lineage is recognized for providing dependable powersports experiences, making the LT-Z250 a popular choice for those seeking a well-rounded ATV. This factory service manual provides comprehensive guidance for the maintenance, repair, and overhaul of the 2004-2009 LT-Z250 QuadSport. It covers all major systems, including the engine, transmission, fuel, electrical, suspension, brakes, and drivetrain, offering detailed step-by-step instructions, diagnostic procedures, and technical specifications. With factory-level detail and clear illustrations, this manual is an essential resource for technicians and owners alike, ensuring the longevity and optimal performance of the vehicle through proper care and repair.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

LT-Z250 QuadSport

Product Name:

2004-2009 Suzuki LT-Z250 Quad Sport Repair Manual PDF

Codes

Model Codes:

LTZ250, Z250

👋 Introduction

Market Position

Target Audience:

Designed for factory service technicians, apprentice mechanics, and experienced DIY owners.

Competitive Analysis

Manual Advantage:

Provides instant download access, offering the same quality and detail as a printed factory manual.

Key Features

Visual Aids:

Includes detailed illustrations, diagrams, exploded views, and photographs to guide repairs.

Accuracy Reliance:

Considered the sole authoritative source for repair advice for the specified model years.

Tool Recommendation:

Emphasizes the use of exact special tools as specified within the manual for optimal results and safety.

📋 Manual Details

Coverage Areas

Covered Years:

2004, 2005, 2006, 2007, 2008, 2009

Page Count

Estimated Page Count:

N/A (Digital Download)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Digital Format:

PDF (Downloadable)

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, disassembly, reassembly, inspection, maintenance, troubleshooting, specifications.

Transmission:

Complete overhaul, disassembly, reassembly, inspection, maintenance, troubleshooting, specifications.

Fuel System:

Carburetor tuning, fuel pump, fuel lines, fuel tank inspection and maintenance.

Electrical System:

Ignition system, lighting, charging system, battery, wiring diagrams, troubleshooting.

Suspension:

Front and rear suspension inspection, adjustment, repair, fork seals, shock absorbers.

Brakes:

Brake system inspection, pad replacement, caliper service, fluid bleeding, master cylinder.

Drivetrain:

Chain maintenance, sprocket inspection, final drive unit service.

Cooling System:

Radiator inspection, fan operation, coolant specifications and replacement.

Frame And Bodywork:

Chassis inspection, body panel removal and installation, seat, handlebars.

Wheels And Tires:

Tire inspection, pressure specifications, wheel bearing service.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, lubrication.

Troubleshooting:

Diagnostic procedures for common and uncommon issues across all systems.

Repair:

Detailed step-by-step instructions for component removal, repair, and reassembly.

Overhaul:

Comprehensive procedures for complete engine and transmission rebuilds.

Inspection:

Visual and functional inspection guidelines for all major components.

Technical Depth

Depth:

Factory level detail, suitable for professional technicians and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

Digital Quality:

High-resolution PDF with searchable text and clear, legible illustrations.

Print Quality

Printability:

Designed for easy printing of individual sections or the entire manual.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Single-cylinder, SOHC, 4-valve

Displacement:

246 cm³ (15.0 cu. in.)

Bore X Stroke:

72.0 mm x 60.0 mm (2.83 in x 2.36 in)

Compression Ratio:

9.7:1

Performance

Estimated Horsepower:

Approximately 18-20 HP (subject to tuning and specific model year variations)

Estimated Torque:

Approximately 14-16 lb-ft (subject to tuning and specific model year variations)

Fuel System

Fuel Delivery:

Mikuni BSR32 flat-slide carburetor

Fuel Tank Capacity:

2.9 US gal (11.0 L)

Ignition

Ignition System:

Digital CDI (Capacitor Discharge Ignition)

Cooling System

Cooling Method:

Liquid-cooled

Lubrication

Lubrication System:

Wet sump

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh with reverse

Features

Clutch Type:

Multi-plate wet clutch

Drive System:

2WD (Rear wheel drive)

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Overall Length:

1790 mm (70.5 in)

Overall Width:

1140 mm (44.9 in)

Overall Height:

1150 mm (45.3 in)

Weights

Dry Weight:

183 kg (403 lbs)

Curb Weight:

N/A (Typically includes fluids, but not always quoted for ATVs)

Wheelbase

Wheelbase:

1240 mm (48.8 in)

Ground Clearance

Ground Clearance:

250 mm (9.8 in)

🛡️ Safety Features

Ratings

Safety Features Note:

ATVs are not typically rated by organizations like NHTSA or IIHS in the same way as cars; safety relies on proper operation and maintenance.

Active Features

Braking System:

Hydraulic disc brakes front and rear

Passive Features

Lighting:

Dual 35W headlights, 15W taillight

Handlebars:

Tapered handlebars for improved rider control and comfort.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic powersports instrumentation: speedometer, odometer, neutral indicator, high-beam indicator).

Driver Assistance

Driver Assistance:

Connectivity

Connectivity:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1000 km or 6 months, whichever comes first. More frequent changes recommended for severe use.

Air Filter Cleaning:

Every 1000 km or 6 months. Inspect more frequently in dusty conditions.

Spark Plug Replacement:

Check at 1000 km, replace as needed or recommended interval.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or higher

Engine Oil Capacity:

Approx. 1.7 L (1.8 US qt) without filter change, 1.9 L (2.0 US qt) with filter change.

Coolant Type:

Ethylene glycol-based antifreeze solution (50% mixture with distilled water)

Brake Fluid Type:

SAE J1703 or DOT 3

Known Issues

Common Wear Items:

Brake pads, clutch plates, chain and sprockets, wheel bearings, suspension bushings.

Potential Electrical Issues:

Stator or rectifier failure (less common but possible with age), corrosion in connectors.

Engine Performance:

Carburetor adjustments may be needed over time due to altitude or fuel changes; valve clearance checks are important.

📚 Vehicle History

Brand Heritage

Brand Focus:

Suzuki has a strong heritage in powersports, including a long history of producing reliable and capable ATVs.

Model Evolution

Quadsport Lineage:

The LT-Z250 QuadSport is part of Suzuki's popular line of sport ATVs, known for performance and agility, often positioned as a more accessible alternative to higher-performance models.

Production

Production Period:

2004-2009

🏆 Awards & Recognition

Recognitions

Industry Standing:

The LT-Z250 QuadSport is generally well-regarded in its class for its balance of performance, reliability, and value, making it a popular choice for recreational riders.