2002-2009 Suzuki LT-F250 Ozark Service Manual
This manual contains an introductory description on the SUZUKI LT-F250 and procedures for its inspection, service, and overhaul of its main components.
Manual chapters:
01 GENERAL INFORMATION
02 PERIODIC MAINTENANCE
03 ENGINE
04 DRIVE TRAIN
05 FUEL SYSTEM
06 LUBRICATION SYSTEM
07 CHASSIS
08 ELECTRICAL SYSTEM
09 SERVICING INFORMATION
10 LT-F250K3 ('03-MODEL)
11 LT-F250K4 ('04-MODEL)
12 LT-F250K5 ('05-MODEL)
13 LT-F250K6 ('06-MODEL)
14 LT-F250K7 ('07-MODEL)
15 LT-F250K8 ('08-MODEL)
16 LT-F250K9 ('09 MODEL)
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Full list of manual chapters:
FOREWORD
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR
COMPONENT PARTS AND WORK TO BE DONE
SYMBOL
01 GENERAL INFORMATION
WARNING/CAUTION/NOTE
GENERAL PRECAUTIONS
SUZUKI LT-F250K2 (2002-MODEL)
SERIAL NUMBER LOCATION
FUEL AND OIL RECOMMENDATION
FUEL
ENGINE OIL
REAR DRIVE GEAR OIL
BRAKE FLUID
BREAK-lN PROCEDURES
INFORMATION LABELS
SPECIFICATIONS
COUNTRY AND AREA CODES
02 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
PERIODIC MAINTENANCE CHART
MAINTENANCE AND TUNE-UP PROCEDURES
AIR CLEANER
EXHAUST PIPE NUTS AND MUFFLER BOLTS
VALVE CLEARANCE
SPARK PLUG
FUEL HOSE
THROTTLE CABLE PLAY
ENGINE IDLE SPEED
ENGINE OIL AND OIL FILTER
FINAL BEVEL GEAR OIL
SPARK ARRESTER
CLUTCH
BRAKES
BRAKE FLUID
BRAKE HOSE
TIRES
STEERING
SUSPENSIONS
CHASSIS BOLTS AND NUTS
GENERAL LUBRICATION
COMPRESSION PRESSURE CHECK
COMPRESSION TEST PROCEDURE
OIL PRESSURE CHECK
OIL PRESSURE TEST PROCEDURE
INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION
INITIAL ENGAGEMENT INSPECTION
CLUTCH LOCK-UP INSPECTION
03 ENGINE
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE
ENGINE LEFT SIDE
ENGINE RIGHT SIDE
ENGINE CENTER
ENGINE REMOVAL AND INSTALLATION
ENGINE REMOVAL
ENGINE INSTALLATION
ENGINE DISASSEMBLY
ENGINE TOP SIDE
ENGINE BOTTOM SIDE
ENGINE COMPONENTS INSPECTION AND SERVICING
CYLINDER HEAD COVER
CYLINDER HEAD
CAMSHAFT
CAM CHAIN TENSION ADJUSTER
CYLINDER
PISTON
CONROD/CRANKSHAFT
CLUTCH
TRANSMISSION
GEARSHIFT FORK
GENERATOR COVER
CLUTCH COVER
CRANKCASE
CRANKSHAFT
RECOIL STARTER
DRIVE TRAIN
SECONDARY GEAR SHIMS ADJUSTMENT
REASSEMBLY INFORMATION
ENGINE REASSEMBLY
ENGINE BOTTOM SIDE
ENGINE TOP SIDE
04 DRIVE TRAIN
REAR DRIVING SYSTEM
REAR DRIVE REMOVAL
REAR DRIVE DISASSEMBLY
REAR DRIVE INSPECTION
REAR DRIVE REASSEMBLY
REAR DRIVE INSTALLATION
SHIM ADJUSTMENT
REASSEMBLY INFORMATION
05 FUEL SYSTEM
FUEL TANK
CONSTRUCTION
FUEL LINE INSPECTION
REMOUNTING
FUEL VALVE
REMOVAL AND INSPECTION
FUEL STRAINER
REMOUNTING
CARBURETOR
CONSTRUCTION
SPECIFICATIONS
I.D. NO. LOCATION
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
REASSEMBLY
REMOUNTING
06 LUBRICATION SYSTEM
LUBRICATION SYSTEM
ENGINE LUBRICATION CIRCUIT
ENGINE LUBRICATION FLOW CHART
OIL PRESSURE
OIL FILTER
OIL STRAINER
OIL PUMP
07 CHASSIS
EXTERIOR PARTS
CONSTRUCTION
REMOVAL
REMOUNTING
FRONT AND REAR WHEELS
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REMOUNTING AND REMOUNTING
TIRES
TIRE REPLACEMENT
FRONT BRAKE
CONSTRUCTION
BRAKE PAD REPLACEMENT
BRAKE FLUID REPLACEMENT
BRAKE CALIPER REMOVAL AND DISASSEMBLY
BRAKE CALIPER INSPECTION
BRAKE CALIPER REASSEMBLY AND REMOUNTING
BRAKE DISC REMOVAL AND DISASSEMBLY
BRAKE DISC INSPECTION
BRAKE DISC REASSEMBLY AND REMOUNTING
MASTER CYLINDER REMOVAL AND DISASSEMBLY
MASTER CYLINDER INSPECTION
MASTER CYLINDER REASSEMBLY AND REMOUNTING
FRONT SUSPENSION
CONSTRUCTION
REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND REMOUNTING
STEERING
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND REMOUNTING
TOE-IN ADJUSTMENT
FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION
REAR BRAKE
CONSTRUCTION
REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND REMOUNTING
REAR SUSPENSION
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND REMOUNTING
REAR AXLE
CONSTRUCTION
REMOVAL
INSPECTION
REASSEMBLY AND REMOUNTING
REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWINGARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION
REVERSE LOCK RELEASE CABLE
REMOVAL AND INSTALLATION
08 ELECTRICAL SYSTEM
CAUTIONS IN SERVICING
CONNECTORS
COUPLERS
CLAMPS
FUSES
SEMI-CONDUCTOR EQUIPPED PARTS
BATTERY
CONNECTING THE BATTERY
WIRING PROCEDURE
USING THE MULTI CIRCUIT TESTER
LOCATION OF ELECTRICAL COMPONENTS
CHARGING SYSTEM
TROUBLESHOOTING
INSPECTION
STARTER SYSTEM
TROUBLESHOOTING
STARTER MOTOR REMOVAL AND DISASSEMBLY
STARTER MOTOR INSPECTION
STARTER MOTOR REASSEMBLY AND REMOUNTING
STARTER RELAY INSPECTION
NEUTRAL RELAY INSPECTION
PARKING BRAKE SWITCH
IGNITION SYSTEM
TROUBLESHOOTING
INSPECTION
LAMPS
HEADLIGHT
BRAKE LIGHT/TAILLIGHT
INDICATOR LIGHT
INSPECTION
INDICATOR LIGHT POSITION
DIODE
SWITCHES
BATTERY
SPECIFICATIONS
INITIAL CHARGING
SERVICING
RECHARGING OPERATION
09 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
DRIVE TRAIN
CARBURETOR
CHASSIS
BRAKES
ELECTRICAL
BATTERY
WIRING DIAGRAM
WIRING HARNESS, CABLE, AND HOSE ROUTING
WIRING HARNESS ROUTING
CABLE ROUTING
FUEL HOSE ROUTING
CARBURETOR HOSE ROUTING
FRONT BRAKE HOSE ROUTING
REAR BRAKE BREATHER HOSE ROUTING
SPECIAL TOOLS
TIGHTENING TORQUE
ENGINE
DRIVE TRAIN
CHASSIS
TIGHTENING TORQUE CHART
SERVICE DATA
10 LT-F250K3 ('03-MODEL)
SPECIFICATIONS
SERVICE DATA
TIGHTENING TORQUE
CHASSIS
CLUTCH
11 LT-F250K4 ('04-MODEL)
SPECIFICATIONS
SERVICE DATA
TIGHTENING TORQUE
DRIVE TRAIN
CHASSIS
ENGINE
CLUTCH SLEEVE HUB NUT TIGHTENING TORQUE
REASSEMBLY
DRIVE TRAIN
UNIVERSAL JOINT
GEARSHIFT LINKAGE
12 LT-F250K5 ('05-MODEL)
SPECIFICATIONS
SERVICE DATA
TIGHTENING TORQUE
FRONT BRAKE CALIPER MOUNTING BOLT
WIRING DIAGRAM
13 LT-F250K6 ('06-MODEL)
E-17, 24, 28, 33
SPECIFICATIONS
SERVICE DATA
E-04
SPECIFICATIONS
SERVICE DATA
SPEEDOMETER/ODOMETER GEAR
EXTERIOR PARTS
STEERING
LAMPS
SWITCHES
CABLE ROUTING
REGULATOR/RECTIFIER INSTALLATION
WIRING DIAGRAM
14 LT-F250K7 ('07-MODEL)
SPECIFICATIONS
INFORMATION LABEL INSTALLATION (For E-33)
FRONT BRAKE HOSE ROUTING
15 LT-F250K8 ('08-MODEL)
INFORMATION LABELS
CAMSHAFT DRIVE CHAIN
16 LT-F250K9 ('09 MODEL)
SPECIFICATIONS
SERVICE DATA
FUEL
CARBURETOR
INFORMATION LABELS
