Suzuki LT-Z250 Manuals

Suzuki LT-Z250 Manuals

Manuals and User Guides for Suzuki LT-Z250. We have 1 Suzuki LT-Z250 manual available for free PDF download: Service Manual

Suzuki LT-Z250 Service Manual

Suzuki LT-Z250 Service Manual (325 pages)

Brand: Suzuki | Category: Motorcycle | Size: 24.16 MB

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

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