Segment:
Entry-level to mid-range sport/utility ATV segment.
Key Competitors:
Honda TRX250EX, Yamaha Warrior 350, Kawasaki Mojave 250.
Features:
Reliable air-cooled engine, lightweight chassis, capable suspension for its class, electric start.
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of all engine components.
Engine Management:
Ignition system, carburetor system, fuel delivery, cooling system.
Transmission Drivetrain:
Clutch operation, gear shifting mechanism, drive shaft, rear axle assembly, differential.
Chassis Suspension:
Front and rear suspension systems, shock absorbers, control arms, bearings.
Brakes:
Front and rear brake systems, hydraulic lines, calipers, pads, master cylinder, parking brake.
Electrical:
Wiring diagrams, lighting system, starting system, charging system, battery, fuses, relays, switches.
Steering:
Steering column, tie rods, steering knuckles, adjustments.
Wheels Tires:
Wheel replacement, tire pressure, mounting.
Bodywork:
Body panel removal and installation, fenders, seat, handlebars.
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, chain adjustment, lubrication points.
Troubleshooting:
Diagnostic procedures for common problems, symptom analysis, fault finding.
Repair Rebuild:
Detailed step-by-step instructions for component repair and overhaul (e.g., engine rebuild, transmission overhaul, brake caliper rebuild).
Adjustments:
Carburetor adjustment, clutch adjustment, throttle cable adjustment, brake adjustments.
Torque Specifications:
Precise torque values for all critical fasteners.
Depth:
Comprehensive (from basic maintenance to full engine/transmission rebuilds).
Digital Quality:
High-resolution scans for clarity, likely searchable if digitally provided.
Print Type:
Professional quality, designed for workshop use.
Binding:
Likely stapled or perfect bound for workshop durability.
Paper Quality:
Durable, often glossy or semi-gloss paper to resist dirt and moisture in a workshop environment.
Engine Type:
4-stroke, SOHC, air-cooled
Bore X Stroke:
66.0 mm x 72.0 mm
Valvetrain:
SOHC, 2 valves per cylinder
Horsepower Estimate:
Approx. 17-19 HP (at flywheel)
Torque Estimate:
Approx. 15-17 lb-ft (at flywheel)
Carburetor Model:
Mikuni VM26SS
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
3.2 US gallons
Oil Type:
SAE 10W-40 API SE, SF, or SG
Oil Capacity With Filter:
1.9 US quarts (1.8 L)
Atv Safety Standards:
Meets ANSI standards for recreational ATVs.
Braking System:
Front: Dual hydraulic disc; Rear: Single hydraulic disc, enclosed driveline brake (parking brake).
Lighting:
Headlights, taillight/brake light.
Chassis Design:
Steel frame construction.
Features:
N/A (Basic ATV design, no infotainment systems).
Features:
N/A (Basic ATV design, no electronic driver assistance features).
Features:
N/A (Basic ATV design, no connectivity features).
Engine Oil Change:
Every 1000 km (620 miles) or annually, whichever comes first. (Refer to manual for exact interval).
Air Filter Cleaning:
Every 1000 km (620 miles) or more frequently in dusty conditions.
Spark Plug Replacement:
Every 3000 km (1860 miles) or annually.
Valve Clearance Check:
Every 3000 km (1860 miles).
Engine Oil Specification:
SAE 10W-40 API SE, SF, or SG
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Chain Lube:
Specialized O-ring chain lubricant
Carburetor Issues:
Can be prone to clogging if fuel is not clean or if stored for extended periods without proper fuel stabilization. Carburetor jetting can be sensitive to altitude and modifications.
Starter Clutch:
Some models may experience wear on the starter clutch over time, leading to grinding noises or failure to engage the starter motor.
Rear Axle Bearings:
Rear axle bearings and seals can wear, especially with aggressive riding or improper washing techniques that force water into the seals.
Suspension Bushings:
Rubber bushings in the suspension and swingarm can degrade over time, leading to play and reduced handling performance.
Heritage:
Suzuki has a long history in motorsports, including ATVs, known for their reliable and performance-oriented machines.
Lineage:
The QuadSport line has been a staple for Suzuki, evolving from earlier models with a focus on affordability and trail riding.
Production Period:
The LT250 QuadSport was produced through various iterations from the late 1980s into the early 2000s. The 2004 model represents a mature iteration of this platform.
