🏷️ Basic Information

Make:

Suzuki

Model:

LT-Z400 QuadSport

Model Code:

LT-Z400K3

Year:

2003

Generation Designation:

First Generation

Vin Prefix:

JS1

👋 Introduction

Market Position:

The Suzuki LT-Z400 QuadSport was a highly popular sport ATV positioned for recreational riders and amateur racers, known for its agile handling and potent engine.

Competitors:

Competed directly with models like the Yamaha YFZ450, Kawasaki KFX400, and Arctic Cat DVX400 (many of which shared a similar platform).

Key Features Of Atv:

Sport-tuned suspension, powerful 4-stroke engine, lightweight chassis, aggressive styling, rider-friendly ergonomics.

Manual Value Proposition:

Empowers owners to perform maintenance and repairs, saving money and ensuring proper upkeep. Offers detailed insights for both novice and experienced mechanics.

📋 Manual Details

Coverage Areas:

General Information, Periodic Maintenance, Engine, Fuel System, Cooling and Lubrication, Chassis, Electrical System, Servicing Information, Parts

Page Count:

Not Specified (Digital PDF)

Manual Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered:

Engine internal components, carburetor/fuel delivery, ignition system, cooling system (radiator, fan, coolant), lubrication system (oil pump, filter, passages), transmission, clutch, drivetrain, suspension (front forks, rear shock), steering, brakes (hydraulic system, calipers, master cylinder), electrical system (wiring harness, battery, stator, lights, starter), chassis frame, body panels, wheels, tires.

Procedures Included:

Scheduled maintenance, diagnostic procedures, troubleshooting guides for common problems, component removal and installation, engine overhaul (top-end and bottom-end), carburetor adjustment and cleaning, clutch adjustment and replacement, brake bleeding and service, suspension adjustments and rebuilds, electrical system testing, general repair procedures, parts identification.

Technical Depth:

Comprehensive, covering basic maintenance, advanced diagnostics, troubleshooting, and complete mechanical overhauls. Includes detailed torque specifications, clearances, and step-by-step instructions with illustrations and diagrams.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Type:

Not Applicable (Digital Download)

Paper Type:

Not Applicable (Digital Download)

Operating Systems Compatibility:

Compatible with Windows PC OS, MAC OS, and Linux OS.

Compression Utility Requirement:

May require a compression utility (e.g., 7-Zip) if the PDF is located within an archive.

⚙️ Engine Specifications

Engine Type:

4-stroke, DOHC, 4-valve, Single-cylinder

Displacement:

398 cc (24.3 cu. in.)

Bore X Stroke:

90.0 mm x 78.5 mm (3.54 in. x 3.09 in.)

Horsepower:

Approx. 32-34 HP (Varies slightly based on specific tuning and region)

Torque:

Not explicitly specified in product info, but generally strong low-to-mid range torque for a single-cylinder.

Fuel Delivery:

Mikuni BSR36 carburetor

Fuel Type:

Unleaded gasoline

Cooling Method:

Liquid-cooled

Oil Type Specification:

Suzuki 4-stroke motorcycle oil (e.g., SAE 10W-40 API SG or higher) or equivalent.

Engine Starting System:

Electric Starter

🔧 Transmission

Transmission Type:

5-speed manual with reverse

Optional Transmissions:

None

Clutch Type:

Wet multi-plate

Final Drive:

O-ring sealed chain

📐 Dimensions

Overall Length:

Approx. 1820 mm (71.7 in.)

Overall Width:

Approx. 1170 mm (46.1 in.)

Overall Height:

Approx. 1085 mm (42.7 in.)

Dry Weight:

Approx. 177 kg (390 lbs.)

Fuel Tank Capacity:

10.0 L (2.6 US gal.)

Wheelbase:

Approx. 1270 mm (50.0 in.)

Ground Clearance:

Approx. 265 mm (10.4 in.)

🛡️ Safety Features

Safety Ratings:

N/A (ATVs are not subject to standardized automotive safety ratings like cars)

Active Safety Features:

Hydraulic disc brakes (front and rear), responsive steering, stable chassis design for sport riding.

Passive Safety Features:

Ergonomic design for rider control, durable frame construction.

Recommended Safety Gear:

Helmet, eye protection, gloves, long pants, long-sleeved shirt, sturdy boots.

💡 Technology Features

Infotainment System:

Not applicable (basic ATV electronics).

Driver Assistance Features:

None (focus is on rider input and control).

Connectivity Features:

None.

Lighting System:

Dual halogen headlights, LED tail light.

🔧 Maintenance

Initial Service:

Refer to manual for break-in service (typically around 10-15 hours or 500 miles).

Engine Oil Change:

Every 1000 km (600 mi) or 6 months, whichever comes first. Or every 20 hours of operation.

Oil Filter Replacement:

At each engine oil change.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (e.g., every 30-50 hours).

Spark Plug Inspection Replacement:

Inspect every 1000 km (600 mi) or 6 months; replace as needed.

Valve Clearance Check:

Every 1000 km (600 mi) or 6 months.

Engine Oil Capacity:

1.8 L (1.9 US qt.) with filter change.

Coolant Type:

Suzuki Super Long Life Coolant or equivalent ethylene glycol-based coolant, mixed with distilled water at a 50:50 ratio.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Transmission Oil Type:

Refer to manual; typically Suzuki Gear Oil SAE 80 or equivalent API GL-4.

Common Issues 2003 Ltz400:

Some early models might experience carburetor jetting issues needing adjustment for optimal performance; potential for wear in the cam chain tensioner; wheel bearing maintenance is crucial for longevity.

Spark Plug Torque:

Refer to manual (typically around 15-20 Nm).

Oil Drain Plug Torque:

Refer to manual (typically around 20-25 Nm).

📚 Vehicle History

Brand Heritage:

Suzuki has a long-standing reputation for producing capable and reliable motorcycles and ATVs, with a focus on performance and innovation.

Model Evolution Early:

The LT-Z400 was introduced in 2003 as Suzuki's entry into the high-performance sport ATV market. It was developed in conjunction with Kawasaki, sharing many components with the KFX400.

Production Era:

The LT-Z400 was produced for many years with updates and revisions. The 2003 model represents the initial iteration of this popular platform.

🏆 Awards & Recognition

Atv Industry Awards:

While specific awards for the 2003 model might not be documented, the LT-Z400 platform was widely acclaimed in the ATV community for its performance and handling, often winning shootouts and enthusiast polls in its class.