Suzuki 250 Ozark 2002-2009 Manuals

Manuals and User Guides for Suzuki 250 Ozark 2002-2009. We have 1 Suzuki 250 Ozark 2002-2009 manual available for free PDF download: Service Manual

Suzuki 250 Ozark 2002-2009 Service Manual

Suzuki 250 Ozark 2002-2009 Service Manual (374 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 48.1 MB

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
- 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

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