Positioning:
The Suzuki LT250 Quad Sport was positioned as a capable and versatile sport ATV, offering a balance of performance and maneuverability for recreational riding and trail exploration. It competed in a segment with models from Yamaha, Honda, and Kawasaki.
Competitors:
Yamaha Warrior 350, Honda TRX300EX, Kawasaki Mojave 250.
Features:
Reliable engine, comfortable suspension, agile handling, durable construction, suitable for a wide range of riders.
Purpose:
To provide comprehensive diagnostic, repair, maintenance, and service information equivalent to that used by authorized Suzuki dealerships.
Model Years:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Specific Variants:
All LT250 Quad Sport models within the specified year range.
Estimated Pages:
Extensive (typical for a full factory service manual, often 500+ pages)
Type:
Factory Service Repair Manual
Powertrain:
Engine, transmission, driveline, cooling system, exhaust system, fuel system.
Chassis:
Frame, suspension (front and rear), steering, wheels, tires.
Brakes:
Front and rear brake systems (hydraulic disc brakes).
Electrical:
Ignition system, lighting, starting system, charging system, battery, wiring diagrams, sensors, ECU.
Bodywork:
Body panels, fenders, seat, handlebars, controls, decals.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning/replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides.
Repair:
Detailed step-by-step repair instructions for all major components and systems, including disassembly and reassembly.
Overhaul:
Complete engine and transmission overhaul procedures, including specifications and tolerances.
Adjustments:
Carburetor tuning, clutch adjustment, brake bleeding, suspension adjustments.
Depth:
Comprehensive, covering everything from basic user maintenance to complete engine rebuilds and advanced electrical diagnostics.
Type:
4-stroke, SOHC, single-cylinder
Displacement:
246cc (approximate, specific designation LT250 may vary slightly based on market tuning)
Bore X Stroke:
Refer to manual for exact specifications, typically around 72.0 mm x 61.2 mm.
Cooling System:
Liquid-cooled
Horsepower:
Estimated 20-25 HP (varies by tuning and market).
Torque:
Refer to manual for exact specifications.
Carburetor:
Mikuni VM32SS (typical, refer to manual for exact model and jetting).
Fuel Type:
Unleaded gasoline
Compression Ratio:
Refer to manual for exact specifications, typically around 9.5:1.
Ignition Type:
CDI (Capacitor Discharge Ignition)
Oil Type:
Refer to manual for specific Suzuki brand or SAE viscosity recommendations (e.g., SAE 10W-40 or 20W-50).
Capacity:
Refer to manual for exact capacity (typically 1.0-1.2 Liters).
Type:
5-speed manual with reverse
Options:
N/A for this model; 5-speed manual was standard.
Drive System:
2WD (Rear Wheel Drive)
Transmission Oil Type:
Refer to manual for specific Suzuki gear oil or SAE viscosity recommendations (e.g., SAE 80W-90).
Transmission Oil Capacity:
Refer to manual for exact capacity.
Length:
Refer to manual for exact specifications (typically around 1800-1850 mm).
Width:
Refer to manual for exact specifications (typically around 1100-1150 mm).
Height:
Refer to manual for exact specifications (typically around 1050-1100 mm).
Dry Weight:
Refer to manual for exact specifications (typically around 200-215 kg).
Curb Weight:
Refer to manual for exact specifications.
Payload Capacity:
Refer to manual for exact specifications.
Front Tire Size:
AT22x7-10 (typical, refer to manual for exact).
Rear Tire Size:
AT22x10-9 (typical, refer to manual for exact).
Front Wheel Size:
10x5.5 (typical, refer to manual for exact).
Rear Wheel Size:
9x8 (typical, refer to manual for exact).
Bolt Pattern:
Refer to manual for exact specifications.
Atv Safety Standards:
Manufactured to meet relevant industry safety standards for ATVs. Specific ratings like NHTSA or IIHS are not applicable to ATVs in the same way as passenger vehicles.
Braking System:
Hydraulic disc brakes front and rear, providing strong stopping power.
Throttle Limiter:
Some models may have adjustable throttle limiters for younger or less experienced riders (check manual for details).
Handlebar Protectors:
Standard on most sport ATVs for rider protection.
Footwells:
Provide protection for rider's feet.
Safety Equipment:
Helmet, eye protection, gloves, long sleeves and pants, sturdy boots (as recommended in the manual).
Infotainment System:
Not applicable; this is a utility/sport ATV with no complex infotainment features.
Driver Assistance Features:
Not applicable; designed for direct rider control.
Connectivity Features:
Not applicable.
ECU:
Engine Control Unit (ECU) manages ignition timing and fuel delivery parameters based on sensor inputs. Refer to manual for detailed diagnostics.
Initial Service:
Break-in service recommended around 500 miles or 10 hours (refer to manual for exact break-in procedure and schedule).
Engine Oil Change:
Every 1000 miles or 100 hours, or every 6 months (whichever comes first, refer to manual for specific conditions).
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions. Refer to manual for specific intervals.
Spark Plug Service:
Inspect and clean/gap every 600 miles or 60 hours; replace as needed. Refer to manual for correct gap.
Chain Lubrication Adjustment:
Lubricate and check tension at frequent intervals, especially after riding in wet conditions. Refer to manual for correct tension.
Engine Oil Viscosity:
SAE 10W-40 or SAE 20W-50 API SE, SF, SG or SH (refer to manual for exact Suzuki recommendation and API service classification).
Coolant Type:
Permanent antifreeze coolant (ethylene glycol based) with distilled water (50:50 mixture). Refer to manual for specific Suzuki coolant type.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for exact specification).
Common Wear Items:
Brake pads, tires, spark plug, air filter, chain and sprockets, wheel bearings.
Potential Performance Issues:
Carburetor gumming if not run regularly, clutch wear, suspension wear with high mileage use. Overheating if cooling system is not maintained.
Starting Problems:
Check fuel, spark, compression, and battery. Refer to manual's diagnostic section.
Oil Filter Part Number:
Refer to manual or Suzuki parts fiche for exact part number (e.g., 16510-03G00 or equivalent).
Air Filter Part Number:
Refer to manual or Suzuki parts fiche for exact part number.
Heritage:
Suzuki has a long and successful history in the powersports industry, including a strong legacy in ATV manufacturing, known for its innovative and reliable machines.
Predecessors:
The LT250 Quad Sport evolved from earlier Suzuki sport ATVs, inheriting design cues and technical advancements.
Generation Overview:
This generation of the LT250 Quad Sport (2002-2009) represents a refinement of Suzuki's sport ATV platform, focusing on performance, rider comfort, and reliability.
Manufacturing Location:
Primarily manufactured in Japan or at Suzuki's overseas facilities.
