The LT-Z250 Quad Sport, produced from 2004 to 2009, is a sport All-Terrain Vehicle (ATV) engineered for recreational riding and performance. Building on a strong heritage in sport ATVs, the LT-Z250 offers a robust single-cylinder, 4-stroke, 249cc liquid-cooled engine, paired with a 5-speed manual transmission and reverse. Its design emphasizes agility and control, featuring independent front double A-arm suspension and a swingarm rear suspension, complemented by dual hydraulic disc brakes at the front and a single hydraulic disc brake at the rear. The vehicle's construction prioritizes durability and a balanced power-to-weight ratio, making it a capable machine for various off-road terrains.
This comprehensive workshop service manual provides in-depth technical information and procedures for the LT-Z250 Quad Sport models from 2004 through 2009. It covers all essential aspects of maintenance, diagnosis, and repair, including detailed instructions for engine, transmission, fuel, ignition, lubrication, exhaust, electrical systems, and bodywork. The manual offers step-by-step guidance for routine maintenance, assembly, disassembly, and advanced troubleshooting, enabling both mechanical technicians and knowledgeable owners to perform professional-quality service. It also references special tools and emphasizes safety precautions, ensuring the vehicle is maintained to optimal standards for performance and longevity.
Model:
LT-Z250 Quad Sport
Vehicle Type:
All-Terrain Vehicle (ATV)
Target Audience:
Primarily mechanical technicians familiar with ATV service procedures, as well as knowledgeable owners
Manual Advantage:
Provides information and procedures equivalent to authorized dealer service departments, enabling professional-quality service
Information Reliability:
Strives for accuracy, providing the most reliable information for repairs
User Benefit:
Enables owners to get the best value from their vehicle and perform maintenance/repairs like a professional
Safety Emphasis:
Highlights safety equipment usage and precautions, including the importance of torque wrenches
Special Tool Reference:
Refers to and illustrates recommended or required special tools with Suzuki part numbers
Covered Years:
2004, 2005, 2006, 2007, 2008, 2009
Manual Type:
Workshop Service Manual / Repair Manual
Engine:
Complete repair and overhaul, including disassembly and assembly
Transmission:
Complete repair and overhaul, including disassembly and assembly
Fuel System:
Detailed procedures for diagnosis and repair
Ignition System:
Diagnosis and repair procedures
Lubrication System:
Maintenance and repair procedures
Exhaust System:
Repair and maintenance information
Electrical System:
Comprehensive coverage including wiring diagrams and troubleshooting
Bodywork:
Repair and maintenance procedures
Routine Maintenance:
Detailed instructions for tune-ups and regular servicing
Troubleshooting:
Diagnostic procedures for common and uncommon issues
Repair Overhaul:
In-depth repair and overhaul instructions for all major components
Assembly Disassembly:
Step-by-step guidance for component removal and installation
Proprietary Components:
Includes instructions for proprietary parts as sourced from component manufacturers
Depth:
Advanced diagnostics, complete rebuilds, and specialized adjustments
Printability:
Yes, printable pages
Delivery Method:
Electronic delivery via Email
Physical Format:
Not a hard copy
Engine Type:
Single-cylinder, 4-stroke
Cooling System:
Liquid-cooled
Estimated Horsepower:
Approx. 22.5 HP @ 7,500 rpm (for reference, not explicitly stated in product info, but typical for this engine)
Estimated Torque:
Approx. 16.4 lb-ft @ 6,000 rpm (for reference, not explicitly stated in product info, but typical for this engine)
Fuel Delivery:
Carburetor (Mikuni BSR32)
Fuel Type:
Unleaded gasoline
Oil Type:
Refer to manual for specific Suzuki recommendations (e.g., SAE 10W-40 API SG or higher)
Oil Capacity:
Refer to manual for exact capacity with filter change (typically around 1.5-2.0 liters)
Transmission Type:
5-speed manual with reverse
Clutch Type:
Wet multi-plate
Final Drive:
O-ring sealed chain
Transmission Oil Type:
Refer to manual for specific Suzuki recommendations (e.g., Suzuki Gear Oil, SAE 80)
Overall Length:
Approx. 1835 mm (72.2 in)
Overall Width:
Approx. 1120 mm (44.1 in)
Overall Height:
Approx. 1070 mm (42.1 in)
Dry Weight:
Approx. 183 kg (403.4 lbs)
Fuel Tank Capacity:
10 L (2.6 US gal)
Ground Clearance:
Approx. 240 mm (9.4 in)
Atv Classification:
Sport ATV
Braking System Front:
Dual hydraulic disc brakes
Braking System Rear:
Single hydraulic disc brake
Suspension Front:
Independent, double A-arm, oil-damped, coil spring
Suspension Rear:
Swingarm type, oil-damped, coil spring
Lighting:
Dual halogen headlights, LED taillight/brake light
Dashboard:
Basic digital/analog display for speed, RPM, odometer, trip meter, neutral indicator, oil warning, etc.
Atv Features:
None beyond standard mechanical systems
Connectivity Features:
N/A
Oil Change Interval:
Refer to manual for specific mileage/hours (typically every 1000 miles or 6 months)
Air Filter Cleaning:
Refer to manual for specific intervals (dependent on operating conditions)
Spark Plug Replacement:
Refer to manual for specific intervals (e.g., every 4000 miles or annually)
Valve Adjustment Interval:
Refer to manual for specific intervals (e.g., every 4000 miles or annually)
Engine Oil Viscosity:
SAE 10W-40 recommended (verify in manual)
Coolant Type:
Ethylene glycol based antifreeze (50/50 mix with distilled water recommended)
Brake Fluid Type:
DOT 3 or DOT 4 (verify in manual)
Common Wear Items:
Brake pads, tires, chain and sprockets, wheel bearings (typical for sport ATVs)
Potential Carburetor Issues:
Carburetor may require periodic cleaning and adjustment due to fuel quality or usage
Electrical Connector Corrosion:
As with many powersports vehicles, electrical connectors can be susceptible to corrosion if exposed to moisture; manual covers inspection and cleaning
Manufacturer:
Suzuki Motor Corporation
Sport Atv Legacy:
Suzuki has a strong heritage in sport ATVs with iconic models like the LT250R and LT500R
Lt Z Series Introduction:
The LT-Z series represents Suzuki's modern generation of sport ATVs, building on previous successful platforms
Production Period:
2004-2009
Manufacturing Location:
Typically manufactured in Japan by Suzuki
Industry Reputation:
Suzuki's sport ATVs are generally well-regarded for their performance and reliability within their class.
Consumer Reviews:
Owner feedback often highlights its good balance of power and handling for recreational riding.
