Engine Mechanical:
Complete engine overhaul, cylinder head, cylinder block, pistons, crankshaft, camshafts, valve train, lubrication system, cooling system, fuel system (carburetor).
Engine Electrical:
Ignition system, starting system, charging system (stator, regulator/rectifier), CDI unit, spark plug, wiring diagrams.
Transmission Drivetrain:
Clutch (wet multi-plate), gearbox (5-speed), final drive (chain), reverse gear (if applicable to specific sub-model), lubrication.
Chassis Suspension:
Frame inspection and repair, front suspension (A-arms, shocks, steering), rear suspension (swingarm, shock absorber, linkage), wheel bearings, hubs.
Brakes:
Front and rear hydraulic disc brakes, brake caliper servicing, master cylinders, brake lines, bleeding procedures.
Electrical System:
Lighting (headlight, taillight, brake lights), battery, fuses, relays, switches, handlebar controls, speedometer, wiring schematics.
Fuel System:
Carburetor (Mikuni BSR36) disassembly, cleaning, adjustment, jetting, fuel tank, fuel petcock.
Bodywork Trim:
Body panels, fenders, seat, handlebars, footpegs, plastics.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, brake checks, tire pressure, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnosis of common problems, fault finding for engine, electrical, and mechanical systems.
Repair Rebuild:
Step-by-step instructions for engine rebuilds, transmission overhauls, suspension repairs, brake caliper overhauls.
Diagnostics:
Wiring diagrams for electrical fault finding, component testing procedures.
Disassembly Assembly:
Complete procedures for dismantling and reassembling all major vehicle components.
Depth Of Information:
Factory detailed, comprehensive, A-Z coverage for all repairs and maintenance.
Diagrams Illustrations:
Includes detailed diagrams, exploded views, and step-by-step illustrations.
Schematics:
Complete wiring schematics for electrical system diagnostics.
File Type:
PDF (Portable Document Format)
Printability:
All pages printable, ability to blow up images for enlarged copies.
Binding:
Digital Download (Printable PDF)
Paper Type Recommendation:
Standard printer paper for printable sections.
Operating Systems:
Compatible with Windows 7, Vista (32/64-bit), XP, ME, 98, NT, 2000, and Mac computers.
Required Software:
Adobe PDF Reader
Engine Type:
Four-stroke, DOHC, 4-valve, single-cylinder
Displacement:
398 cc (24.3 cu in)
Bore X Stroke:
90.0 mm x 78.0 mm (3.54 in x 3.07 in)
Cooling System:
Liquid-cooled
Horsepower Peak:
Approx. 30-33 HP (Varies by region and tuning)
Torque Peak:
Approx. 32-35 Nm (Varies by region and tuning)
Carburetor Model:
Mikuni BSR36, CV type with TPS (Throttle Position Sensor)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Display:
Digital multi-function display including speedometer, odometer, trip meter, clock, and neutral indicator.
Throttle Position Sensor:
TPS on the carburetor aids in optimizing fuel delivery for emissions and performance.
No Specific Connectivity:
As an off-road focused ATV, it does not feature modern connectivity technologies like Bluetooth or smartphone integration.
Engine Oil Change:
Every 1,000 km (600 miles) or 6 months, whichever comes first. Inspect level more frequently.
Oil Filter Replacement:
At every engine oil change.
Air Filter Cleaning:
Every 1000 km (600 miles) or more frequently in dusty conditions. Replace if damaged.
Spark Plug Inspection:
Every 1,000 km (600 miles)
Chain Lubrication Adjustment:
Every 500 km (300 miles) or more frequently in adverse conditions. Adjust slack to specification (typically 10-15mm).
Engine Oil Type:
Suzuki genuine 4-stroke engine oil, API SG or higher, SAE 10W-40 or 20W-50 depending on ambient temperature. Fully synthetic recommended.
Engine Oil Capacity:
Approx. 1.7 L (1.8 US qt) without filter change, 1.9 L (2.0 US qt) with filter change.
Coolant Type:
Suzuki Super Long Life Coolant or equivalent ethylene glycol-based coolant (50% solution with distilled water).
Brake Fluid Type:
DOT 4 brake fluid.
Common Wear Items:
Brake pads, wheel bearings, chain and sprockets, and clutch plates are typical wear items that may require periodic replacement.
Carburetor Tuning:
Carburetor may require periodic cleaning and adjustment to maintain optimal performance, especially after modifications or prolonged storage.
Manufacturer:
Suzuki Motor Corporation is a well-established Japanese multinational corporation known for its range of motorcycles, automobiles, ATVs, and marine engines.
Predecessor:
The LT-Z400 evolved from earlier Suzuki sport ATVs, incorporating advancements in engine technology and chassis design. It was initially developed in collaboration with Kawasaki (as the KFX400).
Updates 2009-2010:
Models from 2009-2010 typically received minor updates and refinements based on rider feedback and emissions regulations. The core platform remained robust.
Production Period:
The LT-Z400 platform was produced for many years, with the 2009-2010 models representing a specific iteration within its lifecycle.
