1999-2002 Suzuki Quadrunner 250 (LT-F250/LT-F250F) Service & Repair Manual

99500-42143-01E -

FOREWORD This manual contains an introductory description on the SUZUKI LT-F250/LT-F250F and procedures for its inspection/service and overhaul of its main com- ponents. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its maintenance. Use this section as well as other sections as a guide for proper inspection and service. This manual will help you know the vehicle better so that you can assure your customers of fast and reli- able service. * This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual vehicle. * Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual vehicle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, includ- ing special tools, for servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. A WARNING Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the rider. GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE SHAFT DRIVE AND DIFFERENTIAL GEARS (LT-F250F) FUEL AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION L T-F250Y /250FY(2000-MODEL) L T-F250K1 /250FK1(,01-MODEL) L T-F250FK2('02-MODEL)

HOWTO USETHIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on the first page of each section to help you find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit there is an exploded view which provides work instructions and other service information (e.g.; tightening torque, lubricating pOints, and locking agent points). Example: Front brake CD Master cylinder reservoir cap ® Diaphragm @ Boot @ Piston/cup set ® Master cylinder ® Master cylinder clamp . (J) Gasket ~~ \ ® Air bleeder valve @ra ~~4 ~ ® Dust seal (II @ Piston ® Cup @ Spring @ Wheel cylinder @ Pin @ Brake panel @ Brake shoe ® Strut @l Shoe holder spring No.1 @) Shoe holder spring No.2 ® Front wheel hub @ Dustseal @ Brake drum ITEM N·m ® 10 ® 12 © 23 @ 7.5 kg-m Ib-ft 1.0 7.0 1.2 8.5 2.3 16.5 0.75 5.0

SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION SYMBOL DEFINITION ~ Torque control required. • Apply THREAD LOCK SUPER "1303". Data beside it indicates specified 99000-32030 torque. llr Apply oil. Use engine oil unless .. Apply THREAD LOCK SUPER "1305". otherwise specified. 99000-32100 i l Apply molybdenum oil solution ~ Apply THREAD LOCK SUPER "1322". (mixture of engine oil and SUZUKI 99000-32110 (Except USA) MOLY PASTE in a ratio of 1 : 1) ~ Apply SUZUKI SUPER GREASE "A". mlJ Apply or use brake fluid. 99000-25030 (for USA) 99000-25010 (for the other countries) ~ Apply SUZUKI SILICONE GREASE. ~ Measure in voltage range. 99000-251 00 ~ Apply SUZUKI MOLY PASTE. ~ Measure in current range. 99000-25140 -412078J Apply SUZUKI BOND "1207B". ~ Measure in diode test range 99104-31140 (for USA) ~ Apply SUZUKI BOND "1215". ijiJ Measure in continuity test range. 99000-31110 (Except USA) -4 1216 J Apply SUZUKI BOND "1216". r400Li Use special tool. 99104-31160 (for USA) 99000-31160 (for the other countries) • Apply THREAD LOCK "1342" . 99000-32050

GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE •••••••••••••••••••••••.•••.•••••••••.•••• ...... • ...... • ..... ••• 1- 1 GENERAL PRECAUTIONS ................................................................. 1- 1 SUZUKI LT-F250XlLT-F250FX ('99-MODEL) ...................................... 1- 3 SERIAL NUMBER LOCATION ............................................................ 1- 3 FUEL AND OIL RECOMMENDATION ................................................. 1- 3 FUEL ................................................................................................ 1- 3 ENGINE OIL ...................................................... ........ ~..................... 1- 4 DIFFERENTIAL GEAR OIL ............................................................. 1- 4 BRAKE FLUID ................................................................................. 1- 4 BREAK-IN PROCEDURES ................................................................. 1- 4 INFORMATION LABELS................................................ ...................... 1- 5 SPECIFICATIONS ................................................................................ 1- 6 COUNTRY AND AREA CODES .......................................................... 1- 8

1-1 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasi:le special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. A WARNING Indicates a potential hazard that could result in death or injury. I A CAUTION I Indicates a potential hazard that could result in vehicle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice. GENERAL PRECAUTIONS A WARNING * Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the vehicle. * When two or more persons work together, pay attention to the safety of each other. * When it is necessary to run the engine indoors, make sure that exhaust gas is forced out- doors. * When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the manufacturer's instructions. * Never use gasoline as a cleaning solvent. * To avoid getting burned, do not touch the engine, engine oil, and exhaust system until they have cooled. * After servicing the fuel, oil, exhaust or brake systems, check all of the lines and fittings related to the system for leaks.

GENERAL INFORMATION 1·2 [ A CAUTION [ * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order. * Be sure to use special tools when instructed. * Make sure that all parts used in reassembly are clean. Lubricate them when specified. * Use the specified lubricant, bond, or sealant. * When removing the battery, disconnect the negative cable first and then the positive cable. * When reconnecting the battery, connect the positive cable first and then the negative cable, and cover the positive terminal with the terminal cover. * When performing service to electrical parts, disconnect the battery negative cable unless the service procedure requires the battery power. * When tightening cylinder head and crankcase bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts from the inside working out, diagonally and to the specified tightening torque. * Whenever you remove oil seals, gaskets, packing, O-rings, self-locking nuts, locking wash- ers, cotter pins, circlips, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. * Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. * Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. * After reassembling, check parts for tightness and proper operation. * To protect the environment, do not unlawfully dispose of used motor oil and all other fluids, batteries and tires. * To protect the earth's natural resources, properly dispose of used vehicles and parts.

1·3 GENERAL INFORMATION SUZUKI LT-F2S0XlLT-F2S0FX ('99-MODEL) RIGHT SIDE LEFT SIDE * Difference between photographs and the actual vehicles depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) CD is stamped on the left side of the frame. The engine serial number ® is located on the right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts. FUEL AND OIL RECOMMENDATION FUEL (For USA) 1. Use only unleaded gasoline of at least 87 pump octane ( R ~ M) method or 91 octane or higher rated by the research method. 2. Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% eth- anol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhib- itors are present in it. 5. If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. 6. Failure to follow these guideline could possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above.

GENERAL INFORMATION 1-4 FUEL (For CANADA) Use only unleaded gasoline of at least 87 pump octane (R ~ M) or 91 octane or higher rated by the Research Method. FUEL (For the other countries) Use unleaded gasoline that is graded 91 octane or higher (Research Method). ENGINE OIL (For USA) SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (America Petroleum Institute) service classification. The recommended viscosity is SAE 10W/40. If an SAE 10W/40 oil is not available, select an alternative according to the chart. ENGINE OIL (For the other countries) Use a premium quality 4-stroke motor oil to ensure longer service life of your motorcycle. Use only oils which are rated SF or SG under the API classification. The recommended viscosity is SAE 10W-40. If SAE 10W/40 engine oil is not available, select an alternative according to the chart. DIFFERENTIAL GEAR OIL MULTIGRADE • •• • TEMP. I J I I lOW-30 DC -30 -20 -10 0 10 20 30 40 OF -22 -4 14 32 60 68 86 104 Use SEA #90 hypoid gear oil which is rated GL-5 under API classification system. If you operate the vehicle where ambient temperature is below O°C (32°F), use SAE #80 hypoid gear oil. BRAKE FLUID Use DOT 4 brake fluid. A WARNING This vehicle uses a glycol-based brake fluid. Do not use or mix different types of brake fluid such as silicone-based and petroleum-based fluids for refilling the system, otherwise serious damage will result to the brake system. Never use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or which has been stored for a long period of time. BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to "BREAK-IN" before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. Refer to the following break-in engine speed recommendations. • Keep to these brake-in engine speed limits. Break-in engine speeds Initial 500 km (300 miles): Less than J-2 throttle • Upon reaching an odometer reading of 500 km (300 miles) you can subject the vehicle to full throttle operation, for short periods of time.

1·5 GENERAL INFORMATION INFORMATION LABELS CD Certification plate (For E-03, 24, 33) @ Manual notice label (For E-03, 33) ® Compliance label (For E-28) @ Maximum-amperage caution label ® @ Information label (For E-33) ® Maximum-amperage caution label ® (For E-28) @ Gearshift pattern label ® (Except for E-28) @) Fuel caution label (For E-24) ® Gearshift pattern label ®, ® (For E-28) ®l Gearshift label ® ® Tire air pressure label ® ® Gearshift label ® (For E-28) (]) Tire air pressure label ® (For E-28) @ Front carrier warning label ® ® Attention center plate (For E-28) @ Front carrier warning label ® (For E-28) ® General warning label ® @ Rear carrier warning label ® ®l General warining label ® (For E-28) @ Rear carrier warning label ® (For E-28) ® No-passenger warning label ® ® Trailer warning label ® @ No-passenger warning label ® (For E-28) @ Trailer warning label ® (For E-28) @ AGE 16 label ® @ Handle carrier warning label (For E-24) @ AGE 16 label ® (For E-28) @ ICES canada label (For E-28) ®: English ®:French

1999-2002 Suzuki Quadrunner 250 (LT-F250/LT-F250F) Service & Repair Manual

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