User Manuals: Suzuki LT-Z250K5 2005 QuadSport 250

Manuals and User Guides for Suzuki LT-Z250K5 2005 QuadSport 250. We have 2 Suzuki LT-Z250K5 2005 QuadSport 250 manuals available for free PDF download: Service Manual

Suzuki LT-Z250K5 2005 Service Manual

Suzuki LT-Z250K5 2005 Service Manual (374 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 48 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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Suzuki LT-Z250K5 2005 Service Manual

Suzuki LT-Z250K5 2005 Service Manual (325 pages)

Brand: Suzuki | Category: Motorcycle | Size: 24 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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