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Ozark
Suzuki Ozark User Manual
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3-42 ENGINE
TRANSMISSION
DISASSEMBLY
•
Insert the special tool between the 2nd drive gear and 4th
drive gear.
•
Remove the 2nd drive gear by a hydraulic press.
09950-81910: Remover
•
Disassemble the transmission as shown.
1
Rev
erse dr
iven gear
2
Rev
erse gear dog
3
1st dr
iven gear
4
5th dr
iven gear
5
3rd dr
iven gear
6
4th dr
iven gear
7
2nd dr
iven gear
8
Dr
iveshaft
9
Countershaft
0
5th dr
ive gear
A
3rd dr
ive gear
B
4th dr
ive gear
C
2nd dr
ive gear
D
Rev
erse idle gear
E
Rev
erse idle shaft
81
83
Table of Contents
Supplements 10
3
General Information
1
Periodic Maintenance
1
Fuel System
1
Lubrication System
1
Electrical System
1
Servicing Information
1
Table of Contents
3
General Information 1
7
General Precautions
8
Warning/Caution/Note
8
Fuel and Oil Recommendation
10
Fuel
10
Engine Oil
11
Rear Drive Gear Oil
11
Brake Fluid
11
Serial Number Location
10
Suzuki Lt-F250K2 (2002-Model)
10
BREAK-Ln PROCEDURES
11
Information Labels
12
Specifications
13
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
20
Valve Clearance
21
Spark Plug
22
Fuel Hose
23
Throttle Cable Play
24
Engine Idle Speed
24
Engine Oil and Oil Filter
24
Final Bevel Gear Oil
26
Spark Arrester
27
Clutch
27
Brakes
28
Brake Fluid
29
Brake Hose
31
Tires
31
Steering
32
Suspensions
33
Chassis Bolts and Nuts
34
General Lubrication
37
Compression Pressure Check
38
Compression Test Procedure
38
Oil Pressure Check
39
Oil Pressure Test Procedure
39
Initial Engagement and Clutch Lock-Up Inspection
40
Initial Engagement Inspection
40
Clutch Lock-Up Inspection
40
Engine
41
Default Chapter
42
Engine Components Removable with Engine in Place
42
Engine Left Side
42
Engine Right Side
42
Engine Center
42
Engine Removal and Installation
43
Engine Removal
43
Engine Installation
48
Engine Components Removable with Engine in Place
52
Engine Left Side
52
Recoil Starter
52
Engine Bottom Side
55
Engine Disassembly
52
Engine Top Side
52
Neutral Switch
55
Starter Cup
55
Secondary Driven Bevel Gear
55
Starter Idle Gear
56
Engine Right Side
56
Oil Filter
56
Clutch
57
Gearshift 3-19
59
Oil Pump Drive Gear
60
Engine Components Inspection and Servicing
64
Cylinder Head Cover
64
Cylinder Head
65
Camshaft
73
Cam Chain Tension Adjuster
74
Cylinder
75
Piston
75
Cylinder 3-14
75
Piston Diameter
75
Piston Ring Groove Width
76
Piston Ring Thickness
76
Piston Ring End Gap
76
Conrod/Crankshaft
78
Crankshaft Runout
78
Clutch
79
Transmission
82
Gearshift Fork
85
Generator Cover
86
Clutch Cover
87
Crankcase
88
Crankshaft
90
Recoil Starter
91
Drive Train
94
Secondary Gear Shims Adjustment
98
Reassembly Information
100
Engine Reassembly
101
Engine Bottom Side
101
Engine Top Side
113
Drive Train
121
Rear Driving System
122
Rear Drive Removal
123
Rear Drive Disassembly
125
Rear Drive Inspection
129
Rear Drive Reassembly
131
Rear Drive Installation
136
Shim Adjustment
138
Reassembly Information
141
Fuel System
143
Fuel Tank
144
Construction
144
Fuel Line Inspection
145
Remounting
145
Fuel Valve
146
Removal and Inspection
146
Fuel Strainer
146
Remounting
146
Carburetor
147
Construction
147
Specifications
148
I.D. No. Location
148
Removal
149
Disassembly
150
Cleaning
154
Inspection
155
Reassembly
156
Remounting
158
Lubrication System
159
Chassis
165
Exterior Parts
166
Construction
166
Removal
168
Remounting
173
Front and Rear Wheels
174
Construction
174
Removal
174
Inspection and Disassembly
175
Remounting and Remounting
176
Tires
179
Tire Replacement
179
Front Brake
181
Construction
181
Brake Pad Replacement
182
Brake Fluid Replacement
183
Brake Caliper Removal and Disassembly
183
Brake Caliper Inspection
185
Brake Caliper Reassembly and Remounting
186
Brake Disc Removal and Disassembly
188
Brake Disc Inspection
188
Brake Disc Reassembly and Remounting
188
Master Cylinder Removal and Disassembly
189
Master Cylinder Inspection
190
Master Cylinder Reassembly and Remounting
190
Front Suspension
192
Construction
192
Removal and Disassembly
193
Inspection
194
Reassembly and Remounting
196
Steering
199
Construction
199
Removal
200
Inspection and Disassembly
202
Reassembly and Remounting
204
Toe-In Adjustment
207
Front Wheel, Front Brake, Front Suspension and Steering Reassembling Information
208
Rear Brake
209
Construction
209
Removal and Disassembly
210
Inspection
212
Reassembly and Remounting
213
Rear Suspension
217
Construction
217
Removal
218
Inspection and Disassembly
218
Reassembly and Remounting
219
Rear Axle
220
Construction
220
Removal
221
Inspection
222
Reassembly and Remounting
222
Rear Wheel, Rear Brake, Rear Suspension, Rear Swingarm and Rear Axle Shaft Reassembling Information
224
Reverse Lock Release Cable
225
Removal and Installation
225
Electrical System
227
Cautions in Servicing
228
Connectors
228
Couplers
228
Clamps
228
Fuses
228
Semi-Conductor Equipped Parts
228
Battery
229
Connecting the Battery
229
Wiring Procedure
229
Using the Multi Circuit Tester
229
Location of Electrical Components
230
Charging System
232
Troubleshooting
232
Inspection
234
Starter System
237
Troubleshooting
237
Starter Motor Removal and Disassembly
238
Starter Motor Inspection
239
Starter Motor Reassembly and Remounting
240
Starter Relay Inspection
241
Neutral Relay Inspection
242
Parking Brake Switch
242
Ignition System
243
Troubleshooting
243
Inspection
245
Lamps
248
Headlight
248
Brake Light/Taillight
249
Indicator Light
250
Inspection
250
Indicator Light Position
250
Diode
251
Switches
252
Battery
253
Specifications
253
Initial Charging
253
Servicing
255
Recharging Operation
255
Servicing Information
257
Troubleshooting
258
Engine
258
Drive Train
261
Carburetor
261
Chassis
262
Brakes
263
Electrical
264
Battery
265
Wiring Diagram
266
Wiring Harness, Cable, and Hose Routing
268
Wiring Harness Routing
268
Cable Routing
270
Fuel Hose Routing
272
Carburetor Hose Routing
273
Front Brake Hose Routing
274
Rear Brake Breather Hose Routing
275
Special Tools
276
Tightening Torque
279
Engine
279
Drive Train
280
Chassis
280
Tightening Torque Chart
281
Service Data
282
Lt-F250K3 ('03-Model)
289
Lt-F250K4 ('04-Model)
301
Lt-F250K5 ('05-Model)
316
Lt-F250K6 ('06-Model)
329
Specifications
330
Service Data
331
Specifications
338
Service Data
339
Speedometer/Odometer Gear
346
Exterior Parts
347
Steering
355
Switches
356
Cable Routing
357
Regulator/Rectifier Installation
358
Wiring Diagram
359
Lt-F250K7 ('07-Model)
362
Lt-F250K8 ('08-Model)
368
Swingarm
370
5
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Suzuki Ozark Specifications
General
Brand
Suzuki
Model
Ozark
Category
Offroad Vehicle
Language
English
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