2004-2009 Suzuki QuadSport 250 LT-Z250 LTZ250 Service & Repair Manual

GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE 2 ENGINE 3 DRIVE TRAIN 4 FUEL SYSTEM 5 LUBRICATION SYSTEM 6 CHASSIS 7 ELECTRICAL SYSTEM 8 SERVICING INFORMATION 9 FOREWORD This manual contains an introductory description on the SUZUKI LT-Z250 and procedures for its inspection, service and overhaul of its main components. 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 publi- cation. If modifications have been made since then, differences may exist between the con- tent 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, including special tools, for servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcy- cle dealer to help you. 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.

SUPPLEMENTS LT-Z250K5 ( 05-MODEL) 10 LT-Z250K6 ( 06-MODEL) 11 12 LT-Z250K7 ( 07-MODEL) L T-Z250K8 ( 08-MODEL) 13 14 LT-Z250K9 ( 09-MODEL)

HOW TO USE THIS 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: Rear suspension ITEM N•m kgf-m lb-ft 78 7.8 55.0 60 6.0 43.5 85 8.5 61.5 60 6.0 43.5 65 6.5 47.0 Rear shock absorber Swingarm Bearing Rear shock absorber mounting nut (Upper) Rear shock absorber mounting nut (Lower) Swingarm pivot nut Axle housing mounting nut (RH) Axle housing bolt Axle housing mounting nut (LH)

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. Data beside it indicates specified torque. Apply THREAD LOCK SUPER 1303 . 99000-32030 Indicates service data. Apply THREAD LOCK SUPER 1322 . 99000-32110 (Except USA) Apply oil. Use engine oil unless otherwise specified. Apply THREAD LOCK 1342 . 99000-32050 Apply hypoid gear oil. Apply THREAD LOCK SUPER 1360 . 99000-32130 Apply molybdenum oil solution. (mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply or use brake fluid. Apply SUZUKI SUPER GREASE A . 99000-25030 (USA) 99000-25010 (Others) Measure in voltage range. Apply SUZUKI SILICONE GREASE. 99000-25100 Measure in resistance range. Apply SUZUKI MOLY PASTE. 99000-25140 Measure in current range. Apply WATER RESISTANCE GREASE. 99000-25160 Measure in diode test range. Apply SUZUKI BOND 1207B 99104-31140 (USA) 99000-31140 (Others) Measure in continuity test range. Apply SUZUKI BOND 1215 . 99000-31110 (Except USA) Use special tool. Apply SUZUKI BOND 1216B . 99000-31230 H/O W 1216B

1 GENERAL INFORMATION 1-1 GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE .........................................................................1- 2 GENERAL PRECAUTIONS ...........................................................................1- 2 SUZUKI LT-Z250K4 (2004-MODEL) .............................................................1- 4 SERIAL NUMBER LOCATION ......................................................................1- 4 FUEL AND OIL RECOMMENDATION ..........................................................1- 4 FUEL (FOR CANADA AND USA) ..........................................................1- 4 FUEL (FOR THE OTHER COUNTRIES) ................................................1- 4 ENGINE OIL (FOR USA) ........................................................................1- 5 ENGINE OIL (FOR THE OTHER COUNTRIES) ....................................1- 5 REAR DRIVE GEAR OIL .......................................................................1- 5 BRAKE FLUID ........................................................................................1- 5 BREAK-lN PROCEDURES ...........................................................................1- 5 INFORMATION LABELS ...............................................................................1- 6 SPECIFICATIONS .........................................................................................1- 7 DIMENSIONS AND DRY MASS ............................................................1- 7 ENGINE ..................................................................................................1- 7 DRIVE TRAIN .........................................................................................1- 7 CHASSIS ................................................................................................1- 8 ELECTRICAL .........................................................................................1- 8 CAPACITIES ..........................................................................................1- 8 COUNTRY AND AREA CODES ....................................................................1- 9

1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize 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. ! Indicates a potential hazard that could result in death or injury. " 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 ! * 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 handling toxic or flammable materials, make sure that the area you work in is well ven- tilated 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, radiator 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 1-3 " * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * 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 and orientation. * 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 replace the terminal cover on the positive terminal. * When performing service to electrical parts, if the service procedures not require use of battery power, disconnect the negative cable the battery. * When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts diagonally from the inside toward outside and to the specified tightening torque. * Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, 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, all other fluids, bat- teries and tires. * To protect the earth s natural resources, properly dispose of used vehicles and parts.

1-4 GENERAL INFORMATION SUZUKI LT-Z250K4 (2004-MODEL) RIGHT SIDE LEFT SIDE * Difference between photographs and actual vehicles depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the left side of the rear frame pipe. The engine serial number 2 is located on the left side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts. FUEL AND OIL RECOMMENDATION FUEL (FOR CANADA AND USA) Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) method or 91 octane or higher rated by the Research Method. SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% etha- nol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibi- tors are present in it. If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. Failure to follow these guidelines 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. FUEL (FOR THE OTHER COUNTRIES) Use unleaded gasoline that is graded 91 octane or higher by the Research Method.

GENERAL INFORMATION 1-5 ENGINE OIL (FOR USA) SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or oils that meet API service classifications SF or SG and that have a viscosity rating of SAE 10W-40. If engine oil with a rating of SAE 10W-40 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 the vehicles. Use only oils that meet API service classifications SF or SG and that have a viscosity rating of SAE 10W-40. If engine oil with a rating of SAE 10W-40 is not available, select an alternative according to the chart. REAR DRIVE GEAR OIL Use hypoid gear oil that meets the API service classification GL-5 and is rated SAE #90. Use a hypoid gear oil with a rating of SAE #80 if the vehicle is operated where the ambient temperature is below 0 C (32 F). BRAKE FLUID # Specification and classification: DOT 4 ! BREAK-lN 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-lN 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 break-in engine speed limits. Break-in engine speeds Initial 10 hours: Less than ‰ throttle After the engine has been operated for 10 hours the engine to full throttle operation, for short periods of time. 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 reuse brake fluid left over from the last servicing or which has been stored for a long period of time.

1-6 GENERAL INFORMATION INFORMATION LABELS * E-28: Fuel caution label enclosed. E: English F: French A: Attached No. LABEL or PLATE NAME APPLIED SPECIFICATION E-19 E-28 E-33 1 Certification plate E A A 2 Information label E A 3 Gearshift pattern label E A 4 Gearshift pattern label E/F A 5 Tire air pressure label E A A A 6 Tire air pressure label and warning no-passenger label F A 7 General warning label E A A A 8 General warning label F A 9 Warning no-passenger label E A A A 0 Age, 16 Iabel E A A A A Age, 16 Iabel F A B Manual notice label E A C Gearshift label E A A A D Gearshift label F A E ICES Canada label E/F F Compliance label E A G EC approval mark A A Front of left side frame Left side frame

2004-2009 Suzuki QuadSport 250 LT-Z250 LTZ250 Service & Repair Manual

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