2004-2009 Suzuki LT-Z250 QuadSport 250 Service Manual (P/N 99000-25030)

• Covers 2004–2009 Suzuki LT-Z250 QuadSport 250 ATV models, detailing complete engine, chassis, and electrical service procedures
• Official Suzuki publication 99000-25030 for all model variants from K4 through K9
• Contains 28 detailed exploded-view diagrams with tightening torque specifications and 16 electrical system reference charts
• Spans 323 pages and includes specific supplement sections for individual year models from 2005 through 2009

Engine and Mechanical Coverage

This 2004–2009 Suzuki LT-Z250 service manual details the maintenance of the 246 cm³ four-stroke engine, from component disassembly and inspection to final reassembly. It outlines the exact technical procedures for valve clearance adjustments, carburetor tuning, and full transmission overhauls. Mechanics will find specific tolerances for piston-to-cylinder clearances and rod deflection limits. The documentation groups data by system. This layout allows for quick reference to MIKUNI BSR29 carburetor specifications or centrifugal clutch engagement settings. Working on ATV powertrains carries inherent risks. Proper workshop safety protocols and a solid mechanical background are required before starting any disassembly.

Specification Highlights

Precision work requires exact numbers. The cylinder head specification table lists the intake valve clearance at 0.03–0.08 mm. During a filter change, the engine requires exactly 2.3 liters of oil. You will also find the clutch lock-up speed specified at 3,100–3,700 r/min. Throughout the text, reference tables provide chassis bolt torques, cooling system parameters, and electrical diagnostic thresholds to support comprehensive rebuilds.