Suzuki LTZ400 Quad Sport LT-Z400 Complete Workshop Service Repair Manual 2003 2004 2005 2006

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Tipo: Atv

Proveedor:

SKU: 86537

Etiquetas: 2003 2004 2005 2006 ATV LT-Z400 LTZ400 Quad Sport Powersports Quadsport Suzuki

Variantes de producto

Descripción

The Suzuki LT-Z400 QuadSport is a high-performance sport ATV renowned for its potent 398cc liquid-cooled engine and agile handling. Introduced in 2003, this first-generation model has established itself as a formidable competitor in the sport ATV segment, offering enthusiasts a thrilling riding experience. Its robust construction, featuring a durable chassis and reliable mechanicals, makes it a popular choice for both recreational riding and competitive use. The QuadSport's design prioritizes performance and rider control, incorporating features like hydraulic disc brakes, a responsive suspension system, and a smooth 5-speed transmission with reverse, all contributing to its reputation for quality and capability. This comprehensive workshop service repair manual covers all Suzuki LT-Z400 QuadSport models from 2003 to 2006. It provides detailed, step-by-step instructions for a wide range of maintenance, repair, and diagnostic procedures. Within these pages, you will find in-depth coverage of engine mechanicals, fuel and ignition systems, transmission, drivetrain, electrical systems, suspension, steering, and braking systems. The manual also includes essential routine maintenance schedules, troubleshooting guides for common issues, component replacement instructions, and precise torque specifications. This resource is designed to empower owners and technicians alike, enabling efficient upkeep and repair to ensure the optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

LT-Z400 QuadSport

Product Name:

Suzuki LTZ400 Quad Sport LT-Z400 Complete Workshop Service Repair Manual 2003 2004 2005 2006 PDF Download

Generation

Generation:

First Generation

Codes

Chassis Code:

K4, K5, K6 (Representative codes for model years)

👋 Introduction

Market Position

Market Segment:

Performance Sport ATV

Target Audience:

Enthusiasts, recreational riders, DIY mechanics looking for in-depth repair and maintenance information.

Competitive Analysis

Competitors:

Yamaha YFZ450, Honda TRX450R, Kawasaki KFX450R.

Key Features

Value Proposition:

Enables significant cost savings through DIY repairs and maintenance.

Ease Of Use:

User-friendly, step-by-step instructions with clear visuals.

Accessibility:

Downloadable to multiple devices (PC, Mac, tablets, smartphones).

📋 Manual Details

Coverage Areas

Models Covered:

All LT-Z400 QuadSport models

Model Years Covered:

2003, 2004, 2005, 2006

Engine Variants Covered:

All engine types and variants for the specified model years

Trim Levels Covered:

All trim levels

Transmission Types Covered:

All transmission types

Page Count

Page Count Estimate:

Comprehensive (Exact page count not specified, typical for workshop manuals of this scope)

Manual Type

Manual Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full engine overhaul, including cylinder head, pistons, crankshaft, lubrication system, cooling system, timing system.

Fuel System:

Carburetor tuning, disassembly, cleaning, and reassembly; fuel tank, lines, and pump (if applicable).

Ignition System:

CDI unit, ignition coil, spark plug specifications and testing.

Transmission Drivetrain:

Clutch operation, maintenance, and adjustment; gearbox disassembly, inspection, and reassembly; final drive and chain maintenance.

Electrical System:

Wiring diagrams, component testing, battery, starter motor, charging system, lighting, instrumentation.

Suspension Steering:

Front and rear suspension components, shock absorbers, A-arms, steering system, tie rods, wheel alignment.

Braking System:

Hydraulic brake system, brake pads, discs, calipers, master cylinder, brake fluid specifications and bleeding procedures.

Chassis Frame:

Frame inspection, component mounting, and general chassis maintenance.

Bodywork Plastics:

Body panel removal, installation, and minor repair.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement, tire pressure checks.

Troubleshooting:

Step-by-step diagnostic procedures for common issues related to starting, running, and electrical problems.

Repair Overhaul:

Detailed instructions for disassembling, inspecting, repairing, and reassembling major vehicle components.

Component Replacement:

Instructions for replacing wear items and faulty components such as bearings, seals, cables, and brake parts.

Torque Specifications:

Precise torque values for all critical fasteners across various systems.

Technical Depth

Depth Of Coverage:

Comprehensive, from basic scheduled maintenance to complete engine and transmission rebuilds.

Diagnostic Capabilities:

Advanced diagnostic flowcharts and explanations for identifying and resolving complex mechanical and electrical faults.

Rebuild Procedures:

Detailed step-by-step instructions for rebuilding major sub-assemblies like the engine and transmission.

📊 Manual Specifications

File Format

File Format:

Searchable Text:

Likely Yes (Standard for quality PDF manuals)

Print Quality

Print Quality:

High-resolution images and clear text for easy readability and printing.

Illustration Quality:

Clear, step-by-step diagrams and photographs.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Software Requirements

Required Software:

Adobe Reader (or compatible PDF viewer)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-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

Compression Ratio:

11.3:1

Starting System:

Electric starter

Performance

Horsepower Estimate:

Approx. 35-40 HP (Varies slightly by year and specific tuning)

Torque Estimate:

Approx. 34-37 Nm (Varies slightly)

Fuel System

Carburetor Type:

Mikuni BSR36, 36 mm flat-slide with accelerator pump

Fuel Capacity:

9.5 L (2.5 US gal)

🔧 Transmission

Standard

Transmission Type:

5-speed, constant mesh, wet multi-plate clutch

Final Drive:

O-ring sealed chain, 520 pitch

Features

Reverse Gear:

Clutch Operation:

Hydraulic, wet multi-plate

📐 Dimensions

Exterior

Overall Length:

1845 mm (72.6 in)

Overall Width:

1130 mm (44.5 in)

Overall Height:

1050 mm (41.3 in)

Wheelbase:

1260 mm (49.6 in)

Ground Clearance:

250 mm (9.8 in)

Weights

Dry Weight:

170 kg (375 lbs)

Curb Weight:

Not specified in product description, typically around 180 kg.

🛡️ Safety Features

Ratings

Safety Ratings:

Not Applicable (ATV classification differs from automotive safety ratings).

Active Features

Braking System Type:

Hydraulic disc brakes (Front and Rear)

Parking Brake:

Mechanical disc brake (Rear axle)

Passive Features

Hand Guards:

Standard

Kill Switch:

Thumb throttle with safety switch, tethered kill switch (standard safety feature).

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic instrument cluster only)

Driver Assistance

Driver Assistance Features:

N/A (Manual operation)

Connectivity

Connectivity Features:

Instrumentation

Instrument Cluster:

Digital LCD display (Speedometer, odometer, trip meter, clock) and warning lights.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1000 km (600 miles) or 6 months, whichever comes first.

Clutch Adjustment:

Check and adjust every 2000 km (1200 miles) or as needed.

Air Filter Cleaning:

Every 500 km (300 miles) or more frequently in dusty conditions.

Spark Plug Replacement:

Inspect every 2000 km (1200 miles), replace as needed. Use NGK CR9E or equivalent.

Fluid Specifications

Engine Oil Type:

SAE 10W-40, API SE, SF or SG classification (API SJ or SL recommended for newer standards if compatible).

Engine Oil Capacity:

1.8 L (1.9 US qt) with filter change.

Brake Fluid Type:

DOT 4

Coolant Type:

Antifreeze coolant with a 50/50 mix of ethylene glycol and distilled water.

Known Issues

Common Wear Items:

Brake pads, clutch plates, wheel bearings, steering stem bearings, chain and sprockets.

Carburetor Issues:

Can be susceptible to clogging from debris or ethanol-related issues; requires regular cleaning and adjustment.

Engine Idle Instability:

Often related to carburetor adjustment, vacuum leaks, or spark plug condition.

📚 Vehicle History

Brand Heritage

Brand Focus:

Suzuki has a long history in motorsports and powersports, known for performance and reliability in motorcycles and ATVs.

Model Evolution

Introduction Year:

Key Updates Pre 2007:

Minor revisions, typically graphics and color schemes. Core mechanicals remained consistent.

Production

Manufacturing Location:

Japan (Primary manufacturing location for this generation).

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for this exact model year manual are not listed, the LT-Z400 platform is widely recognized as a dominant force in the sport ATV market during its era, influencing many subsequent designs.

Ratings

Consumer Ratings:

Consistently high ratings from riders for performance, handling, and reliability.