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This workshop repair service manual PDF download for the 2004-2009 Suzuki LT-Z250 QuadSport has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
SUZUKI LT-Z250K4 (2004-MODEL)
SUZUKI LT-Z250K5 (2005-MODEL)
SUZUKI LT-Z250K6 (2006-MODEL)
SUZUKI LT-Z250K7 (2007-MODEL)
SUZUKI LT-Z250K8 (2008-MODEL)
SUZUKI LT-Z250K9 (2009 MODEL)
TABLE OF CONTENTS :
01 GENERAL INFORMATION
02 PERIODIC MAINTENANCE
03 ENGINE
04 DRIVE TRAIN
05 FUEL SYSTEM
06 LUBRICATION SYSTEM
07 CHASSIS
08 ELECTRICAL SYSTEM
09 SERVICING INFORMATION
10 LT-Z250K5 ('05-MODEL)
11 LT-Z250K6 ('06-MODEL)
12 LT-Z250K7 ('07-MODEL)
13 LT-Z250K8 ('08-MODEL)
14 LT-Z250K9 (’09 MODEL)
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 325
This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service Suzuki Vehicles. Apprentice mechanics and "do it yourself" mechanics will also find this manual to be an extremely useful guide.
This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.
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FOREWORD
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR
COMPONENT PARTS AND WORK TO BE DONE
SYMBOL
01 GENERAL INFORMATION
WARNING/CAUTION/NOTE
GENERAL PRECAUTIONS
SUZUKI LT-Z250K4 (2004-MODEL)
SERIAL NUMBER LOCATION
FUEL AND OIL RECOMMENDATION
FUEL (FOR CANADA AND USA)
FUEL (FOR THE OTHER COUNTRIES)
ENGINE OIL (FOR USA)
ENGINE OIL (FOR THE OTHER COUNTRIES)
REAR DRIVE GEAR OIL
BRAKE FLUID
BREAK-lN PROCEDURES
INFORMATION LABELS
SPECIFICATIONS
DIMENSIONS AND DRY MASS
ENGINE
DRIVE TRAIN
CHASSIS
ELECTRICAL
CAPACITIES
COUNTRY AND AREA CODES
02 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
PERIODIC MAINTENANCE CHART
MAINTENANCE AND TUNE-UP PROCEDURES
AIR CLEANER
EXHAUST PIPE NUTS AND MUFFLER BOLTS
VALVE CLEARANCE
SPARK PLUG
FUEL LINE
THROTTLE CABLE PLAY
ENGINE IDLE SPEED
ENGINE OIL AND OIL FILTER
FINAL GEAR OIL
SPARK ARRESTER
CLUTCH
BRAKES
BRAKE FLUID
BRAKE HOSE
TIRES
STEERING
SUSPENSIONS
CHASSIS BOLTS AND NUTS
GENERAL LUBRICATION
COMPRESSION PRESSURE CHECK
COMPRESSION TEST PROCEDURE
OIL PRESSURE CHECK
OIL PRESSURE TEST PROCEDURE
INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION
INITIAL ENGAGEMENT INSPECTION
CLUTCH LOCK-UP INSPECTION
03 ENGINE
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE
ENGINE REMOVAL AND INSTALLATION
ENGINE REMOVAL
ENGINE INSTALLATION
ENGINE DISASSEMBLY
ENGINE TOP SIDE
ENGINE BOTTOM SIDE
ENGINE COMPONENTS INSPECTION AND SERVICE
CYLINDER HEAD COVER
CYLINDER HEAD
CAMSHAFT
CAM CHAIN TENSION ADJUSTER
CAM CHAIN TENSIONER AND CAM CHAIN GUIDE
CYLINDER
PISTON AND PISTON RING
CONROD AND CRANKSHAFT
CLUTCH
TRANSMISSION
GEARSHIFT FORK
GENERATOR COVER
CLUTCH COVER
CRANKCASE
CRANKSHAFT
DRIVE TRAIN
SECONDARY GEAR SHIMS ADJUSTMENT
REASSEMBLY INFORMATION
ENGINE REASSEMBLY
ENGINE BOTTOM SIDE
ENGINE TOP SIDE
04 DRIVE TRAIN
REAR DRIVING SYSTEM
REAR DRIVE REMOVAL
REAR DRIVE DISASSEMBLY
REAR DRIVE INSPECTION
REAR DRIVE REASSEMBLY
REAR DRIVE INSTALLATION
SHIM ADJUSTMENT
REASSEMBLY INFORMATION
05 FUEL SYSTEM
FUEL TANK
CONSTRUCTION
FUEL LINE INSPECTION
REMOVAL
REMOUNTING
FUEL VALVE
REMOVAL AND INSPECTION
FUEL STRAINER
REMOUNTING
CARBURETOR
CONSTRUCTION
SPECIFICATIONS
I.D. NO. LOCATION
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
REASSEMBLY
REMOUNTING
06 LUBRICATION SYSTEM
LUBRICATION SYSTEM
ENGINE LUBRICATION CIRCUIT
ENGINE LUBRICATION FLOW CHART
OIL PRESSURE
OIL FILTER
OIL STRAINER
OIL PUMP
07 CHASSIS
EXTERIOR PARTS
CONSTRUCTION
REMOVAL
REMOUNTING
FRONT AND REAR WHEELS
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND REMOUNTING
TIRES
TIRE REPLACEMENT
FRONT BRAKE
CONSTRUCTION
BRAKE PAD REPLACEMENT
BRAKE FLUID REPLACEMENT
BRAKE CALIPER REMOVAL AND DISASSEMBLY
BRAKE CALIPER INSPECTION
BRAKE CALIPER REASSEMBLY AND REMOUNTING
BRAKE DISC REMOVAL AND DISASSEMBLY
BRAKE DISC INSPECTION
BRAKE DISC REASSEMBLY AND REMOUNTING
MASTER CYLINDER REMOVAL AND DISASSEMBLY
MASTER CYLINDER INSPECTION
MASTER CYLINDER REASSEMBLY AND REMOUNTING
FRONT SUSPENSION
CONSTRUCTION
REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND REMOUNTING
SUSPENSION SETTING
STEERING
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND REMOUNTING
TOE-IN ADJUSTMENT
FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION
REAR BRAKE
CONSTRUCTION
REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND REMOUNTING
REAR SHOCK ABSORBER
CONSTRUCTION
REMOVAL
INSPECTION
REASSEMBLY
REMOUNTING
SUSPENSION SETTING
REAR SHOCK ABSORBER DISPOSAL
REAR SUSPENSION
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY
REMOUNTING
REAR AXLE
CONSTRUCTION
REMOVAL
INSPECTION
REASSEMBLY AND REMOUNTING
REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWINGARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION
REVERSE LOCK RELEASE CABLE
REMOVAL
REMOUNTING
08 ELECTRICAL SYSTEM
CAUTIONS IN SERVICING
CONNECTORS
COUPLERS
CLAMPS
FUSES
SEMI-CONDUCTOR EQUIPPED PARTS
BATTERY
CONNECTING THE BATTERY
WIRING PROCEDURE
USING THE MULTI CIRCUIT TESTER
LOCATION OF ELECTRICAL COMPONENTS
CHARGING SYSTEM
TROUBLESHOOTING
INSPECTION
STARTER SYSTEM
TROUBLESHOOTING
STARTER MOTOR REMOVAL AND DISASSEMBLY
STARTER MOTOR INSPECTION
STARTER MOTOR REASSEMBLY AND REMOUNTING
STARTER RELAY INSPECTION
NEUTRAL RELAY INSPECTION
PARKING BRAKE SWITCH
IGNITION SYSTEM
TROUBLESHOOTING
INSPECTION
LAMPS
HEADLIGHT
BRAKE LIGHT/TAILLIGHT
INDICATOR LIGHT
INSPECTION
INDICATOR LIGHT POSITION
DIODE
SWITCHES
BATTERY
SPECIFICATIONS
INITIAL CHARGING
SERVICING
RECHARGING OPERATION
09 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
DRIVE TRAIN
CARBURETOR
CHASSIS
BRAKES
ELECTRICAL
BATTERY
WIRING DIAGRAM
WIRING HARNESS, CABLE, AND HOSE ROUTING
WIRING HARNESS ROUTING
CABLE ROUTING
STEERING SHAFT SET-UP
CARBURETOR HOSE ROUTING
FRONT BRAKE HOSE ROUTING
REAR BRAKE BREATHER HOSE ROUTING
FUEL HOSE ROUTING
REAR BRAKE CAM LEVER SET-UP
STEERING HEAD COVER SET-UP
TAILLIGHT SET-UP
SPECIAL TOOLS
TIGHTENING TORQUE
ENGINE
DRIVE TRAIN
CHASSIS
TIGHTENING TORQUE CHART
SERVICE DATA
10 LT-Z250K5 ('05-MODEL)
SPECIFICATIONS
SERVICE DATA
TIGHTENING TORQUE
FRONT BRAKE CALIPER MOUNTING BOLT
FRONT BRAKE HOSE ROUTING
11 LT-Z250K6 ('06-MODEL)
SPECIFICATIONS
SERVICE DATA
12 LT-Z250K7 ('07-MODEL)
INFORMATION LABEL INSTALLATION (For E-33)
13 LT-Z250K8 ('08-MODEL)
INFORMATION LABELS
14 LT-Z250K9 (’09 MODEL)
SPECIFICATIONS
SERVICE DATA
FUEL TANK CONSTRUCTION
CARBURETOR
INFORMATION LABELS
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Suzuki LT-Z250 QuadSport Repair Service Manual 2004-2009.pdf
Source : Sitelux.com