Ltz250 repair manual

The text of this manual is divided into sections. Holding the manual as shown at the right will allow you to find the first page of the section easily.

The contents are listed on the first page of each section to help you find the item and page you need. The meaning of each symbol is also included in the table. Data beside it indicates specified torque. Use engine oil unless otherwise specified. Add to cart Become an eManualOnline member today to read and access full manuals.

The store will not work correctly in the case when cookies are disabled. Toggle Nav. Aircraft Aeroplanes Buses Golf Carts. My Cart 0 Cart. Skip to the end of the images gallery. Skip to the beginning of the images gallery. Add to Cart. Secure transaction. SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servic- ing.

Measure the valve seat width W after every cut. NOTE: After cutting the 15 angle, it is possible that the valve seat 45 is too narrow. Weak- ened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. Check the valve springs for proper strength by measuring their free length and also by the force required to compress them. Page 74 Be sure to restore each spring, valve and spring retainer to their original positions.

Page Camshaft To properly measure the oil clearance with plastigauge, all gas- ket material must be removed from fitting surfaces of cylinder head and cover. Tighten the cylinder head cover bolts evenly and diagonally to the specified torque. Replace either the cylinder head set or the camshaft if the clear- ance is incorrect.

Standard: If any clearance reading exceeds the service limit, replace the cylinder with a new one. If any clearance reading exceeds the ser- vice limit, replace both the piston and piston rings. They bear the fol- lowing identification numbers. SIZE 0. Oversize oil ring The following oversize oil ring is available as optional parts.

They bear the following identification mark. Measure the conrod small end inside diameter with the small bore gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod with a new one. Service Limit: Measure the thickness of drive plates with a vernier calipers. If each drive plate is not within the standard range, replace it with a new one. Also, check the depth of the grooves on the clutch shoes. If there is no groove at any part of the shoes, replace the shoes as a set.

NOTE: The clutch shoes must always be changed as a set. Remove the 2nd drive gear by a hydraulic press. Reverse driven gear Reverse gear dog " After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed.

Measure the gearshift fork clearance in the groove of its respec- tive gear with the thickness gauge. If the clearance exceeds specification, replace the fork, its respective gear, or both.

Remove the bearing with the special tool. Replace the bearing in the following procedure if there is any- thing unusual. NOTE: Refer to the following pages for the details of each step. Remove the rear wheel. Hold the bearings with the special tool. Measure the backlash by turning the driven bevel gear shaft in For driven bevel gear each direction, reading the total backlash on the dial gauge. Pay attention to the following procedures: Remove the driven bevel gear.

Clean and degrease several teeth of the drive and driven bevel gears. Apply a coating of machinist s layout dye or paste to several teeth of the driven bevel gear. Shim thickness 0.

Pay special attention to the following points: NOTE: Apply engine oil to each running and sliding part before reas- sembling. NOTE: Use proper bars. Install the reverse driven gear and washer 2. Install the gearshift forks and shafts as shown. NOTE: Each fork differs in shape. Install the snap ring 5, washer 6 and spacer 7. Install the reverse idle gear 8 and washer 9.

Page Fit the dowel pins onto the left half on the crankcase. Apply engine oil to the conrod big end and gears. Install the key 2. NOTE: Degrease the tapered portion of the generator rotor assembly and also the crankshaft.

Install the washer 1 and pin 2. Install the oil pump driven gear and E-ring. Install the oil pump drive gear. NOTE: Flange side of the gear is positioned inside. Install the washer 7 and gearshift arm. Align the clutch drive plates in line to facilitate later assembly.

Install the washer 3 onto the countershaft. Install the primary driven gear assembly. Install the washer 4. Install the clutch sleeve hub assembly into the primary driven gear assembly. Install the clutch springs and clutch release plate.

Install the washer as its convex side faces outside. Before installing the clutch shoe nut, apply engine oil to the thread and inside surface of the nut. Install the spring 1 and oil filter 2. Use new O-rings to prevent oil leakage. NOTE: 1st ring and 2nd ring differ in shape. Be sure to bring the marked side to the top when fitting it to the piston. Use a new gasket to prevent gas leakage. Hold each piston ring with proper position, insert the piston into the cylinder.

Install the washers and cylinder head nuts M8 as shown. Tighten the cylinder head nuts M8 diagonally to the speci- fied torque. Engage the hole of the sprocket C with the locating pin on the camshaft as shown. Align the lines D on the camshaft so that they are parallel with the surface of the cylinder head.

Page Clean the mating surface of the cylinder head and head cover before matching. Install the dowel pins to the cylinder head. Drain gear oil. Remove the final gear case together with the propeller shaft.

Remove the O-ring 4. Pry the cover at the arrows as shown by tapping with a plastic mallet. Remove the O-ring 1. Drive out the bearing from the other side with the special tool. The removed bearing must be replaced with a new one. Remove the pinion gear shaft coupling joint with the special tools.

Remove the stopper ring 1 and O-ring 2. Remove the bearing with a commercially available bearing puller or a hydraulic press. NOTE: If there is no abnormal condition, the bearing removal is not nec- essary. Replace the removed C-rings with new ones. Remove the bearings by tapping with the special tool and a hammer. Also, inspect the boot for cuts or damage. If any defects are found, replace the propeller shaft and its boot with new ones. Inspect the pinion gear for wear or damage.

If the pinion gear is damaged, inspect the ring gear also. If any defects are found, replace the bearing and gear with the new ones. Install the shim, pinion gear assembly and new bearing locknut. Install new oil seal to the gear case with the special tool. Pay attention to the fol- lowing procedures: Remove the ring gear. Clean and degrease several teeth on the ring gear and pinion Incorrect gear, and then apply a coating of machinist s layout dye or paste to several teeth of the pinion gear.

If any dam- ages are found, replace the defective parts with the new ones. Remove the fuel valve. Keep heat, sparks and flames away from gasoline. Disconnect the fuel hose 2 and vacuum hose 3.

Disconnect the starter cable 4. Loosen the carburetor clamp screws. Pull out the carburetor from between the engine and air cleaner. Remove the throttle stop screw 5. Remove the carburetor top cap. Do not use compressed air on the carburetor body before removing the diaphragm; this may damage the diaphragm.

Remove the coasting enrichment valve cover D and spring. Remove the coasting enrichment valve E. Remove the O-ring G. Replace the removed O-ring with a new one to prevent leakage of fuel. Remove the float pin H, float I and needle valve J. Remove the valve seat K. Always follow the chemical man- ufacturer s instructions on proper use, handling and storage.

Clean all jets with a spray-type carburetor cleaner and dry them using compressed air. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve sticks, the gasoline will not flow into the float chamber.

Pay attention to the following points: Fit the lug on the carburetor with the intake pipe s projection. Position the carburetor clamps as shown in the illustration. Left Right Left Above Remove the fuel tank side covers 1 and 2. Open the fuel tank cap and remove the fuel tank top cover 1.

Remove the reverse lock release knob 2. Remove the screws that connect the front fender with the head light. Above Remove the footrest 1 and 2. Pull out the taillight assembly 2 with the bracket. Remove the rear fender mounting bolts. Remove the footrest mud guards. Remove the rear fender. Support the vehicle with a jack or wooden block.

Remove the wheel. Above Remove the front hub plate 1. Remove the cotter pin and loosen the wheel hub nut with applying the front brake. If any damages are found, replace the dust seal with a new one.

Remove the dust seals with the special tool. Page Install the front wheel. NOTE: The convex side of the washer faces outside. Dismount the bead from the rim completely as shown. Separate the tire from the rim by using a set of tire levers and rim protectors. Also, make sure the outer side of the wheel rim is facing outward. NOTE: For inspecting the tire refer to page Inspect the valve core, before installation. Remove the brake pads. Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system.

Close the air bleeder valve and disconnect the clear hose. Do not use high pressure air to prevent brake caliper piston damage. Remove the dust seal and piston seal.

Do not reuse the dust seal and piston seal to prevent fluid leakage. If any damages are found, replace the piston with a new one. If any damages are found, replace them with new ones. If any damages are found or if the thickness is less than the service limit, replace the brake disc with a new one. Remove the brake hose union bolt and disconnect the brake hose.

Immediately wipe off any brake fluid contacting any part of the vehicle. If any damages are found, replace the master cylinder with a new one. Page CHASSIS Align the master cylinder holder s mating surface 1 with the punched mark 2 on the handlebars and tighten the upper clamp bolt first.

Disconnect the brake hose from the brake hose clamp 2. Remove the front disc cover 3. Remove the cotter pin, tie rod end nut and washer.

Disconnect the tie rod end with a commercially available ball bearing joint remover 4. Remove the cotter pins, knuckle nuts and washers. Disconnect the steering knuckle 8 with a commercially avail- able ball bearing joint remover. If any damages are found, replace the front shock absorber with a new one. If any damages are found, replace the knuckle with a new one.

If any dam- ages are found, replace the wishbone arm with a new one. Pay attention to the following points: Degrease the tapered portions of the knuckle, knuckle end and tie rod end with nonflammable cleaning solvent.

Install the wishbone arms to the knuckle. Tghten the upper and lower front shock absorber mounting nuts 2 and the wishbone arm pivot nuts 3 to the specified torque.

Disconnect the rear brake cable 3 and remove the handlebar switch 4. Disconnect the fuel vent hose and remove the steering head cover 5. Remove the cotter pin and steering shaft nut 9, washer 0 and dust seal A.

Replace the removed cotter pins with new ones. Remove the O-ring B. Remove the steering shaft holder bolts. Remove the dust seal F from the steering shaft. If any damages are found, replace the dust seals with new ones. If any damages are found, replace the steering shaft with a new one. If any damages are found, replace the steering shaft holders with new ones. NOTE: The indicator light position on the steering head cover is shown on page Install the handle switch with the lug 5 on the switch half inserted into the hole 6 on the handlebars.

Make sure all the tires are inflated to the standard pressure. Forward Loosen the locknuts 1, 2 on each tie rod. Remove the right rear wheel hub. Remove the drum cover bolts. Remove the drum cover 1 with a flat head screwdriver. Remove the brake panel and panel cover 6. Remove the O-ring 7. Remove the brake cam lever 8. Remove the brake lining indicator prate 9, washer 0 and spring A. Remove the brake camshaft B and O-rings C from the brake panel.

If the measurement value exceeds the service limit, replace the brake drum with a new one. Install new dust seal 2 to the drum cover 3 by using the removed dust seal 1. Install the O-rings and brake camshaft to the anchor panel. Page Install new O-ring to the brake panel. Replace the removed O-ring with a new one. Do not apply grease to the spline portion of brake drum. NOTE: Before installing the brake drum, make sure that the brake drum is clean and free of any greasey matter.

Install the drum cover and tighten the bolts. NOTE: When installing the drum cover, make sure that the O-ring must be fitted into the groove on the brake panel securely.

Remove the rear shock absorber 1. The removed dust seals must be replaced with new ones. Inspect the spacers for any flaws or other damage.

If any dam- ages are found, replace the spacers with new ones. Insert the spacer into the rear shock absorber bearing and then check the play by moving the spacer up and down. This adjust- ment is performed by changing spring set length. Loosen the locknut 1. Adjust the spring set length by turning the adjuster 2. Remove the swingarm. Page Reassembly 5. Install the swingarm pivot bolts and upper and lower shock absorber mounting bolts temporarily.

Remove the rear axle housing 3 and rear axle 4. Remove the O-ring 5. Page Reassembly And Remounting Reassemble and remount the rear axle in reverse order of removal and disassembly.

Open the fixed clamp. Remove the clip 2 and pin 3. Loosen the locknuts 4 and remove the reverse lock release cable. Remove the bracket 5. Page Remounting Pay attention to the following points: Install the spring so that the spring end A matches the groove B on the housing.

Loosen the locknuts 1.