2004-2009 Suzuki LT-Z250 Quadsport Service Repair Manual

$9.95

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Covers: 2004, 2005, 2006, 2007, 2008, 2009 Suzuki LT-Z250 ATV
Pages: 325
Format: PDF
Compatibility: Windows/Mac/Tablet

This service manual contains all the necessary instructions needed for any repair your 2004-2009 Suzuki LT-Z250 ATV may require. This is the same manual technicians use to diagnose and repair your 2004-2009 Suzuki LT-Z250. Whether its routine maintenance, such as tune-ups and brake service, or more extensive repairs involving engine and transmission disassembly, this manual provides the most reliable information to perform the job.

The following is a list of topics contained in the 2004-2009 Suzuki LT-Z250 Quadsport Service Repair Manual

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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