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LT-Z250
Suzuki LT-Z250 User Manual
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SE
R
VIC
ING
IN
F
ORM
A
TIO
N
9-23
S
PEC
IAL
T
O
OL
S
09900-00410
He
xagon wr
ench set
09900-06106
Snap ring
plier
s
09900-06107
Snap ring pliers
09900-06108
Snap rin
g pliers
09900-09004
Impact driver set
09900-20101
V
ernier calipers
09900-20202
Micrometer
(1/100 mm,
25îš–50 mm)
09900-20203
Micr
om
eter
(1/100 mm,
50îš–75 mm)
09900-20205
Micrometer
(1/1000 mm,
0îš–25 m
m)
09900-20508
Cylinder gau
ge set
(1/100 mm,
40îš–80 mm)
09900-20602
Dial gauge
(1/1000 mm)
09900-20605
Dial calipers
(1/100 mm,
10îš–34 mm)
09900-20607
D
ia
l ga
uge
(1/100 mm)
09900-20701
Magnetic stand
09900-20803
Tickness gauge
09900-20804
Tickness gauge
09900-20805
Tire depth g
auge
09900-21304
V
-
bloc
k set
(100 mm)
09900-22302
Plastigaug
e
09900-22401
Sm
all b
ore gau
ge
(10îš–18 mm)
09900-25008
Multi cir
cuit
tester
set
09900-26006
T
a
chometer
09910-32812
Crankshaft installer
09913-50121
Oil seal rem
over
09913-70210
Bearing installer set
PartShark.com
877-999-5686
280
282
Table of Contents
General Information 1
7
General Information
1
Periodic Maintenance
1
Fuel System
1
Electrical System
1
Servicing Information
1
How to Use this Manual
4
Table of Contents
7
Warning/Caution/Note
8
General Precautions
8
Suzuki Lt-Z250K4 (2004-Model)
10
Serial Number Location
10
Fuel and Oil Recommendation
10
Fuel (for Canada and Usa)
10
Fuel (for the Other Countries)
10
Engine Oil (for Usa)
11
Engine Oil (for the Other Countries)
11
Rear Drive Gear Oil
11
Brake Fluid
11
BREAK-Ln PROCEDURES
11
Information Labels
12
Specifications
13
Dimensions and Dry Mass
13
Engine
13
Drive Train
13
Chassis
14
Electrical
14
Capacities
14
Country and Area Codes
15
Periodic Maintenance
17
Periodic Maintenance Schedule
18
Periodic Maintenance Chart
18
Maintenance and Tune-Up Procedures
19
Air Cleaner
19
Exhaust Pipe Nuts and Muffler Bolts
21
Valve Clearance
21
Spark Plug
23
Fuel Line
24
Throttle Cable Play
25
Engine Idle Speed
25
Engine Oil and Oil Filter
26
Final Gear Oil
27
Spark Arrester
28
Clutch
29
Brakes
30
Brake Fluid
31
Brake Hose
33
Tires
33
Service Limit
33
Steering
35
Suspensions
35
Chassis Bolts and Nuts
36
General Lubrication
39
Compression Pressure Check
40
Compression Test Procedure
40
Oil Pressure Check
41
Oil Pressure Test Procedure
41
Initial Engagement and Clutch Lock-Up Inspection
42
Initial Engagement Inspection
42
Clutch Lock-Up Inspection
42
Engine
43
Engine Components Removable with Engine in Place
44
Engine Removal and Installation
45
Engine Removal
45
Engine Installation
50
Engine Disassembly
54
Engine Top Side
54
Engine Bottom Side
57
Engine Components Inspection and Service
65
Cylinder Head Cover
65
Cylinder Head
67
Camshaft
75
Cam Chain Tension Adjuster
76
Cam Chain Tensioner and Cam Chain Guide
76
Cylinder
77
Piston and Piston Ring
77
Piston Ring Thickness
78
Conrod and Crankshaft
80
Crankshaft Runout
80
Clutch
81
Transmission
84
Gearshift Fork
87
Generator Cover
87
Clutch Cover
88
Crankcase
89
Crankshaft
92
Drive Train
93
Secondary Gear Shims Adjustment
97
Reassembly Information
100
Engine Reassembly
101
Engine Bottom Side
101
Engine Top Side
112
Drive Train
119
Rear Driving System
120
Rear Drive Removal
121
Rear Drive Disassembly
122
Rear Drive Inspection
127
Rear Drive Reassembly
129
Rear Drive Installation
134
Shim Adjustment
136
Reassembly Information
139
Fuel System
141
Fuel Tank
142
Construction
142
Fuel Line Inspection
143
Removal
143
Remounting
143
Fuel Valve
144
Removal and Inspection
144
Fuel Strainer
144
Remounting
144
Carburetor
145
Construction
145
Specifications
146
I.D. No. Location
146
Removal
147
Disassembly
148
Cleaning
152
Inspection
152
Reassembly
153
Remounting
155
Lubrication System
157
Lubrication System
158
Engine Lubrication Circuit
158
Engine Lubrication Flow Chart
160
Oil Filter
161
Oil Pressure
161
Oil Pump
161
Oil Strainer
161
Chassis
163
Exterior Parts
165
Construction
165
Removal
167
Remounting
170
Front and Rear Wheels
172
Construction
172
Removal
173
Inspection and Disassembly
174
Reassembly and Remounting
175
Tires
178
Tire Replacement
178
Front Brake
180
Construction
180
Brake Pad Replacement
181
Brake Fluid Replacement
181
Brake Caliper Removal and Disassembly
182
Brake Caliper Inspection
183
Brake Caliper Reassembly and Remounting
185
Brake Disc Removal and Disassembly
186
Brake Disc Inspection
187
Brake Disc Reassembly and Remounting
187
Master Cylinder Removal and Disassembly
188
Master Cylinder Inspection
189
Master Cylinder Reassembly and Remounting
189
Front Suspension
191
Construction
191
Removal and Disassembly
192
Inspection
193
Reassembly and Remounting
195
Suspension Setting
196
Steering
197
Construction
197
Removal
198
Inspection and Disassembly
200
Reassembly and Remounting
202
Toe-In Adjustment
205
Front Wheel, Front Brake, Front Suspension and Steering Reassembling Information
206
Rear Brake
207
Construction
207
Removal and Disassembly
208
Inspection
210
Reassembly and Remounting
211
Rear Shock Absorber
215
Construction
215
Removal
215
Inspection
215
Reassembly
216
Remounting
216
Suspension Setting
217
Rear Shock Absorber Disposal
217
Rear Suspension
218
Construction
218
Removal
219
Inspection and Disassembly
219
Reassembly
220
Remounting
221
Rear Axle
222
Construction
222
Removal
223
Inspection
223
Reassembly and Remounting
224
Rear Wheel, Rear Brake, Rear Suspension, Rear Swingarm and Rear Axle Shaft Reassembling Information
225
Reverse Lock Release Cable
226
Removal
226
Remounting
227
Electrical System
229
Cautions in Servicing
230
Connectors
230
Couplers
230
Clamps
230
Fuses
230
Semi-Conductor Equipped Parts
230
Battery
231
Connecting the Battery
231
Wiring Procedure
231
Using the Multi Circuit Tester
231
Location of Electrical Components
232
Charging System
234
Trouble Shooting
234
Inspection
236
Starter System
239
Trouble Shooting
239
Starter Motor Removal and Disassembly
241
Starter Motor Inspection
241
Starter Motor Reassembly and Remounting
242
Starter Relay Inspection
243
Neutral Relay Inspection
244
Parking Brake Switch
244
Ignition System
245
Troubleshooting
245
Inspection
247
Lamps
250
Headlight
250
Brake Light/Taillight
251
Indicator Light
252
Inspection
252
Indicator Light Position
252
Diode
253
Switches
254
Battery
255
Specifications
255
Initial Charging
255
Servicing
257
Recharging Operation
257
Servicing Information
259
Troubleshooting
260
Engine
260
Drive Train
263
Carburetor
263
Chassis
264
Brakes
265
Electrical
266
Battery
267
Wiring Diagram
268
Wiring Harness, Cable, and Hose Routing
269
Wiring Harness Routing
269
Cable Routing
271
Carburetor Hose Routing
274
Front Brake Hose Routing
275
Rear Brake Breather Hose Routing
276
Fuel Hose Routing
277
Rear Brake Cam Lever Set-Up
278
Steering Head Cover Set-Up
279
Taillight Set-Up
280
Special Tools
281
Tightening Torque
284
Engine
284
Drive Train
285
Chassis
285
Tightening Torque Chart
286
Service Data
287
Lt-Z250K5 ( 05-Model)
295
Lt-Z250K6 ( 06-Model)
307
Lt-Z250K7 ( 07-Model)
316
Lt-Z250K8 ( 08-Model)
318
Lt-Z250K9 ( 09-Model)
321
5
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Suzuki LT-Z250 Specifications
General
Brand
Suzuki
Model
LT-Z250
Category
Motorcycle
Language
English
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