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2009 Suzuki 400 LTZ Quad Sport Master Service Manual

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🏷️ Basic Information Identification Make: Suzuki Model: LT-Z400 QuadSport Year: 2009 Vehicle Type: ATV (All-Terrain Vehicle) Common Designations: LT-Z400, QuadSport Z400 Codes Engine Code: F431 (Typical, may vary by specific...
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Tipo: Atv
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SKU: 44568
2009 Suzuki 400 LTZ Quad Sport Master Service Manual2009 Suzuki 400 LTZ Quad Sport Master Service Manual2009 Suzuki 400 LTZ Quad Sport Master Service Manual2009 Suzuki 400 LTZ Quad Sport Master Service Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
LT-Z400 QuadSport
Year:
2009
Vehicle Type:
ATV (All-Terrain Vehicle)
Common Designations:
LT-Z400, QuadSport Z400
Codes
Engine Code:
F431 (Typical, may vary by specific sub-model)
👋 Introduction
Market Position
Segment:
High-performance sport ATV
Target Audience:
Enthusiasts seeking agile handling, strong power, and versatile performance for recreational riding and competition.
Competitive Analysis
Key Competitors:
Yamaha YFZ450, Honda TRX450R, Kawasaki KFX450R
Key Features
Handling:
Renowned for its nimble and responsive handling, making it a favorite for trail riding and track use.
Engine Power:
Strong and reliable 398cc liquid-cooled engine providing ample power for its class.
Suspension:
Fully adjustable suspension components for precise tuning to rider preference and terrain.
📋 Manual Details
Coverage Areas
Manual Type:
Master Service Manual
Language:
English
Format:
PDF Download
Page Count
Page Count:
Estimated 300-400 pages (typical for master service manuals of this era)
Compatibility
Operating Systems:
Windows, macOS, Linux
Accessibility
Printability:
Yes
Download Method:
Instant High-Speed Download
Requirements
Software Requirement:
Adobe Acrobat Reader
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, disassembly, assembly, tuning, and troubleshooting.
Fuel System:
Carburetor (Mikuni BSR36) overhaul, adjustment, fuel pump, fuel tank, lines.
Ignition System:
CDI unit, spark plug, ignition coil, timing.
Cooling System:
Radiator, fan, coolant, hoses, thermostat.
Transmission:
Clutch operation, transmission overhaul, gear shifts, lubrication.
Drivetrain:
Chain drive, sprockets, axle assembly, bearings.
Brakes:
Front and rear disc brake systems, caliper overhaul, pad replacement, hydraulic lines, master cylinders.
Suspension:
Front A-arms, rear swingarm, shock absorbers (fully adjustable), bushings, bearings.
Steering:
Handlebar, steering stem, tie rods, steering knuckle.
Electrical System:
Wiring diagrams, battery, stator, rectifier/regulator, lighting, starter motor, switches.
Chassis And Bodywork:
Frame, plastics, seat, fenders, skid plates, mounting hardware.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, valve clearance checks.
Troubleshooting:
Diagnostic procedures for common issues, error code interpretation (if applicable), performance problems.
Repair:
Step-by-step repair instructions for all major and minor components.
Disassembly And Assembly:
Detailed instructions for component removal and reinstallation.
Torque Specifications:
Crucial torque values for critical fasteners and engine components.
Wiring Diagrams:
Comprehensive electrical system schematics.
Special Tools:
Identification of specific tools required for certain procedures.
Technical Depth
Depth:
Comprehensive, from basic maintenance to full engine rebuilds and electrical diagnostics.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Likely text-searchable PDF for efficient information retrieval.
Print Quality
Print Quality:
High-resolution, suitable for clear printing of text and diagrams.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, Single-cylinder, DOHC, 4-valve, TSCC (Twin Swirl Combustion Chamber)
Displacement:
398 cc (24.3 cu. in.)
Bore X Stroke:
90.0 mm x 76.0 mm (3.54 in x 2.99 in)
Cooling Method:
Liquid-cooled
Compression Ratio:
11.3:1
Performance
Horsepower:
Estimated 37-40 HP (at crank, varies with tuning and specific model year updates)
Torque:
Estimated 26-28 lb-ft (at crank)
Fuel System
Carburetor:
Mikuni BSR36, flat-slide, with accelerator pump
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Ignition
Ignition System:
Electronic ignition (CDI)
Starting System
Starter:
Electric starter
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 5-speed sequential
Clutch:
Wet, multi-plate
Optional
Optional Transmission:
N/A (All models featured the 5-speed manual)
Features
Drive System:
Chain drive
Final Drive:
O-ring sealed chain, 520 (typically) with 14T front and 38T rear sprocket (stock)
📐 Dimensions
Exterior
Overall Length:
1,845 mm (72.6 in)
Overall Width:
1,170 mm (46.1 in)
Overall Height:
1,070 mm (42.1 in)
Wheelbase:
1,270 mm (50.0 in)
Ground Clearance:
265 mm (10.4 in)
Weights
Dry Weight:
177 kg (390 lbs)
Curb Weight:
Estimated 186 kg (410 lbs) with fluids
Cargo
Rack Capacity Front:
N/A (Sport ATV design)
Rack Capacity Rear:
N/A (Sport ATV design)
Wheels And Tires
Front Tire Size:
AT 21 x 7-10
Rear Tire Size:
AT 20 x 10-9
Front Wheel Type:
Aluminum alloy
Rear Wheel Type:
Aluminum alloy
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (ATVs are not typically subjected to automotive crash testing standards)
Active Features
Braking System:
Dual hydraulic disc front brakes, Single hydraulic disc rear brake.
Parking Brake:
Mechanical parking brake on rear caliper.
Passive Features
Handlebars:
Tapered handlebars with reinforced grips for better control.
Footpegs:
Wide, serrated footpegs with heel guards for secure footing.
Throttle:
Thumb throttle with safety limiter function (adjustable).
💡 Technology Features
Infotainment
Infotainment Features:
N/A (Focus is on performance and utility, not typically equipped with advanced infotainment)
Driver Assistance
Driver Assistance Features:
N/A (No electronic driver aids like ABS or traction control)
Connectivity
Connectivity Features:
N/A
Engine Management
Efi System:
No, features a carburetor. (Later models may have received fuel injection updates, but the 2009 LT-Z400 is carburetor-based).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 1000 km (620 miles) or 6 months, whichever comes first. More frequently under severe use.
Air Filter Cleaning:
Every 500 km (310 miles) or monthly. Clean more often in dusty conditions.
Spark Plug Inspection:
Every 1000 km (620 miles) or 6 months.
Valve Clearance Check:
Every 2000 km (1240 miles) or 12 months.
Chain Lubrication Adjustment:
Every 500 km (310 miles) or after washing/wet riding.
Fluid Specifications
Engine Oil:
SAE 10W-40 API SG or higher. Suzuki recommends their own brand. Capacity: 2.1 L (2.2 US qt) without filter change, 2.3 L (2.4 US qt) with filter change.
Coolant:
Suzuki Super Long Life Coolant (50% mixture with distilled water) or equivalent ethylene glycol-based coolant.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Chain Lube:
Specific motorcycle chain lubricant.
Known Issues
Clutch Slippage:
Can occur with aggressive riding or prolonged use; regular inspection and adjustment are key.
Carburetor Issues:
Accelerator pump diaphragm can wear out, affecting low-end throttle response. Clogged jets are common with poor fuel maintenance.
Cam Chain Tensioner:
Some owners report the automatic cam chain tensioner can become weak over time, leading to a rattling noise. Manual tensioners are a common aftermarket upgrade.
Wheel Bearings:
Can wear prematurely with excessive water exposure or hard impacts.
📚 Vehicle History
Brand Heritage
Brand Focus:
Suzuki has a long-standing reputation for producing high-performance motorcycles and ATVs, emphasizing sportiness and reliability.
Model Evolution
Lineage:
The LT-Z400 platform, introduced in 2002, was a significant development in the sport ATV market, competing with Yamaha's successful YFZ450. It shared engineering with the Kawasaki KFX400 for several years.
2009 Updates:
The 2009 model year typically features minor refinements over previous generations, focusing on reliability and rider comfort, often including updated graphics and potentially minor internal engine revisions for emissions or performance.
Production
Manufacturing Location:
Primarily manufactured in Japan or through contract manufacturing arrangements.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 2009 model year might not be readily documented, the LT-Z400 as a platform consistently received praise in its segment for handling and performance from off-road publications during its production run.
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