Suzuki LTZ400 Quad Sport 2003 2004 2005 2006 Service Repair Manual

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The Suzuki LT-Z400 QuadSport, also known as the QuadSport, is a versatile All-Terrain Vehicle (ATV) produced for the 2003, 2004, 2005, and 2006 model years. As a key player in...

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Tipo: Atv

Proveedor:

SKU: 88126

Etiquetas: 2003 2004 2005 2006 Atv LTZ400 Quad Sport Misc Motorcycles Suzuki

Variantes de producto

Descripción

The Suzuki LT-Z400 QuadSport, also known as the QuadSport, is a versatile All-Terrain Vehicle (ATV) produced for the 2003, 2004, 2005, and 2006 model years. As a key player in the sport ATV segment, it was engineered for enthusiasts and recreational riders seeking agile handling and a powerful engine. Its first-generation design, featuring a 398 cc liquid-cooled engine, 5-speed manual transmission with reverse, and hydraulic disc brakes, established it as a strong competitor in its class, praised for its aggressive styling and performance on trails and in recreational racing. This comprehensive service repair manual covers all essential aspects of the Suzuki LT-Z400 QuadSport from 2003 to 2006. It provides detailed procedures for engine overhaul, fuel system maintenance, cooling and ignition system service, transmission and drivetrain repair, suspension adjustments, brake system servicing, and electrical system diagnostics. The manual also includes scheduled maintenance guidelines, troubleshooting charts for common issues, and in-depth wiring diagrams. This resource is designed to assist owners, technicians, and mechanics in maintaining, diagnosing, and repairing the QuadSport, ensuring its optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

LT-Z400 QuadSport

Model Nickname:

QuadSport

Vehicle Type:

ATV (All-Terrain Vehicle)

Chassis Code:

LT-Z400

Generation

Generation Identifier:

First Generation

👋 Introduction

Market Position

Segment:

Sport ATV, Recreational Off-Road

Target Audience:

Enthusiasts, recreational riders, racers

Competitive Analysis

Key Competitors:

Yamaha Warrior/Banshee, Honda TRX series, Kawasaki KFX series

Key Features

Performance Focus:

Aggressive styling, agile handling, powerful engine for its class

📋 Manual Details

Coverage Areas

Applicable Years:

2003, 2004, 2005, 2006

Page Count

Estimated Page Count:

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, disassembly, assembly, tuning, diagnostics

Fuel System:

Carburetor adjustment and cleaning, fuel pump, fuel lines, fuel tank

Cooling System:

Radiator, fan, thermostat, coolant replacement

Ignition System:

Spark plugs, ignition coil, CDI unit, timing

Transmission:

Clutch operation, gear shifting, internal components, fluid change

Drivetrain:

Chain adjustment and replacement, sprocket wear, drive axle

Suspension:

Front and rear suspension, shock absorbers, A-arms, linkages, adjustment

Brakes:

Hydraulic brake system, brake pads, rotors, calipers, bleeding procedure

Electrical System:

Wiring diagrams, battery, starter motor, lighting, charging system

Frame And Bodywork:

Chassis inspection, plastics, seat, handlebars, footpegs

Wheels And Tires:

Tire pressure, wheel bearing maintenance, rim inspection

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, inspections

Troubleshooting:

Diagnostic charts, common problems and solutions, fault finding

Repair:

Step-by-step repair procedures for all major components

Overhaul:

Complete engine and transmission overhaul instructions

Wiring Diagrams:

Detailed electrical system schematics

Technical Depth

Depth:

Comprehensive: Covers basic maintenance to complete engine rebuilds and diagnostics

📊 Manual Specifications

File Format

Quality:

High-resolution, searchable PDF

Printability:

Printable pages for workshop use

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, DOHC, 4-valve

Displacement:

398 cc (24.3 cu in)

Bore X Stroke:

90.0 mm x 78.0 mm

Compression Ratio:

11.3:1

Cooling Method:

Liquid-cooled

Performance

Horsepower Est:

30-34 hp (at crank)

Torque Est:

22-25 lb-ft (at crank)

Fuel System

Carburetor:

Mikuni BSR36, CV (Constant Velocity)

Fuel Type:

Unleaded gasoline, 87-91 octane

Ignition System

Ignition:

Electronic ignition (CDI)

Oil Specifications

Engine Oil Type:

SAE 10W-40 API SG or higher, JASO MA certified

Engine Oil Capacity:

1.7 L (1.8 US qt) without filter change, 1.9 L (2.0 US qt) with filter change

🔧 Transmission

Standard

Type:

5-speed manual with reverse

Clutch Type:

Wet multi-plate

Features

Gear Ratios:

Detailed in manual (e.g., 1st: 3.182, 2nd: 2.000, 3rd: 1.579, 4th: 1.273, 5th: 1.050)

Fluid Specifications

Transmission Oil Type:

SAE 80W API GL-4 Gear Oil

Transmission Oil Capacity:

0.7 L (0.74 US qt)

📐 Dimensions

Exterior

Overall Length:

1820 mm (71.7 in)

Overall Width:

1170 mm (46.1 in)

Overall Height:

1105 mm (43.5 in)

Wheelbase:

1270 mm (50.0 in)

Ground Clearance:

260 mm (10.2 in)

Weights

Dry Weight Est:

170 kg (375 lbs)

Curb Weight Est:

181 kg (399 lbs)

Suspension Travel

Front Suspension Travel:

230 mm (9.1 in)

Rear Suspension Travel:

252 mm (9.9 in)

Wheels Tires

Front Tire Size:

AT21x7-10

Rear Tire Size:

AT20x10-9

Bolt Pattern:

4x110 mm

🛡️ Safety Features

Ratings

Atv Safety Standards:

Adherence to ANSI/SVIA standards for recreational ATVs

Active Features

Braking System:

Hydraulic disc brakes front and rear

Throttle Limiter:

Adjustable thumb throttle for control

Passive Features

Chassis Design:

Steel frame, integrated grab bar, footwells with heel guards

Lighting:

Dual halogen headlights, LED tail/brake light

💡 Technology Features

Infotainment

Display:

Digital multi-function meter (speedometer, odometer, trip meter, clock, neutral indicator, high-beam indicator, oil pressure indicator)

Driver Assistance

Throttle Control:

Ergonomic thumb throttle for precise acceleration control.

Connectivity

Charging System:

Stator and battery charging system

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1000 km (600 miles) or 6 months, whichever comes first. Also after every 20 hours of operation.

Oil Filter Replacement:

At every engine oil change.

Air Filter Cleaning Or Replacement:

Every 20 hours or 6 months; replace if damaged.

Spark Plug Check And Cleaning:

Every 1000 km (600 miles) or 6 months.

Chain Lubrication And Tension Adjustment:

Every 500 km (300 miles) or after riding in wet/muddy conditions.

Brake Fluid Level Check:

Monthly or every 10 hours.

Coolant Level Check:

Monthly or every 10 hours.

Fluid Specifications

Brake Fluid Type:

DOT 4 hydraulic brake fluid

Coolant Type:

High-quality ethylene glycol-based coolant (50/50 mix with distilled water)

Known Issues

Common Wear Items:

Clutch plates, brake pads, wheel bearings, drive chain and sprockets

Carburetor Tuning:

Can be sensitive to altitude and temperature changes, requiring occasional adjustment.

Engine Cooling:

Overheating can occur under sustained heavy load or if cooling system maintenance is neglected.

Starter Clutch:

Some early models reported potential starter clutch wear; manual provides diagnostic steps.

📚 Vehicle History

Brand Heritage

Company Origin:

Suzuki Motor Corporation, founded in 1909 in Japan

Atv Division:

Long-standing reputation in powersports, including motorcycles and ATVs

Model Evolution

Introduction Year:

Design Basis:

Developed as a competitor to the Yamaha Warrior and Honda TRX series, sharing some components with the Kawasaki KFX400.

Production

Manufacturing Location:

Often manufactured in Japan or other global Suzuki facilities. (Specific to this generation, often associated with Japanese production.)

🏆 Awards & Recognition

Recognitions

Market Reputation:

Highly regarded for its performance and handling in the sport ATV segment during its production years.

Ratings

Review Highlights:

Praised for its potent engine, adjustable suspension, and stable chassis, making it a popular choice for trail riding and recreational racing.