Suzuki LT-Z250 User 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 inspec-
tion, 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 mainte-
nance. 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.

' COPYRIGHT SUZUKI MOTOR CORPORATION 2003
* 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.
99500-42175-03E
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03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM
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03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM
SUPPLEMENTS
LT-Z250K5 (05-MODEL) 10
LT-Z250K6 (06-MODEL) 11
12
LT-Z250K7 (07-MODEL)
LT-Z250K8 (08-MODEL) 13
14
LT-Z250K9 (09-MODEL)
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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
A 78 7.8 55.0
B 60 6.0 43.5
C 85 8.5 61.5
D 60 6.0 43.5
EF 65 6.5 47.0
@
1 Rear shock absorber
2 Swingarm
3 Bearing
A Rear shock absorber mounting nut (Upper)
B Rear shock absorber mounting nut (Lower)
C Swingarm pivot nut
D Axle housing mounting nut (RH)
E Axle housing bolt
F Axle housing mounting nut (LH)
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SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing. 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
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
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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
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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.
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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 bat-
tery 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 speci-
fied 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.
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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)
1is stamped on the left side of the rear
frame pipe. The engine serial number
2is 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.
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