Suzuki LT-Z400 LTZ400 Quad Sport 2008-2012 Service Repair Manual

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Taper: Atv

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UGS: 100358

Mots clés: 2008 2009 2010 2011 2012 ATV LT-Z400 LTZ400 Quad Sport Powersports Quadsport Suzuki

Variantes de produits

Description

This manual covers the ATVs manufactured between 2008 and 2012. As a performance sport ATV, the LT-Z400 is renowned for its powerful 398cc liquid-cooled, single-cylinder engine, agile handling, and rider-friendly ergonomics, making it a popular choice for trail riding and recreational racing. Building on a legacy of reliable and performance-oriented ATVs, this second-generation model offers a compelling blend of power and durability, designed to provide an exhilarating off-road experience. This comprehensive factory service repair manual provides extensive coverage for all aspects of the 2008-2012 Quad Sport. It details general information, engine systems including the fuel, cooling, and lubrication systems, drivetrain components such as the clutch and final drive, chassis systems like brakes and suspension, and the electrical system with wiring diagrams. The manual includes step-by-step instructions for regular maintenance, diagnostic procedures for troubleshooting common issues, and complete repair instructions for all major vehicle systems, enabling owners and technicians to effectively maintain, repair, and optimize their vehicle.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

LT-Z400 Quad Sport

Model Alias:

LTZ400

Years Covered:

2008, 2009, 2010, 2011, 2012

Vehicle Type:

ATV (All-Terrain Vehicle)

Generation

Generation Identifier:

Second Generation (post-2003 redesign)

👋 Introduction

Market Position

Market Segment:

Performance Sport ATV

Competitive Analysis

Key Competitors:

Yamaha YFZ450, Honda TRX450R/ER, Kawasaki KFX450R.

Key Features

Vehicle Selling Points:

Powerful engine, agile handling, rider-friendly ergonomics, popular for trail riding and recreational racing.

Manual Value Proposition

Cost Savings:

Potential to save $50-$60 per hour on shop labor costs by performing maintenance and repairs independently.

📋 Manual Details

Coverage Areas

Coverage Summary:

Complete factory service and repair coverage for all styles of the 2008-2012 Suzuki LT-Z400 Quad Sport.

Page Count

Estimated Page Count:

Hundreds of pages (actual count not specified but indicated as extensive).

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

General Information, Fuel System, Cooling System, Engine Top End, Engine Lubrication System, Crankshaft/Transmission.

Drivetrain Systems:

Clutch, Crankshaft/Transmission, Final Drive, Wheels/Tires.

Chassis Systems:

Brakes, Suspension, Steering, Frame.

Electrical Systems:

Electrical System, Wiring Diagrams.

Additional Systems:

Appendix.

Procedures Included

Maintenance Procedures:

Regular scheduled maintenance, fluid changes, filter replacements, lubrication.

Diagnostic Procedures:

Engine fault diagnosis, troubleshooting common issues, part testing techniques.

Repair Procedures:

Step-by-step repair instructions for all major vehicle systems, engine rebuilds, transmission overhauls.

Technical Guidance:

Engine management system analysis, wiring diagram tracing, component identification.

Tuning And Modification:

Implied coverage for understanding engine management systems and potential for tuning.

Technical Depth

Depth Of Coverage:

Comprehensive; covers fundamental maintenance to complete rebuilds, detailed diagnostics, and expert tips.

Diagnostic Tools Mentioned:

Implied use of standard automotive and ATV diagnostic tools; specific mention of 'secret techniques used by top mechanics'.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printability:

Fully printable without restriction; individual pages or entire manual.

Binding Type

Binding Type:

Digital Download (user printable)

Paper Type

Paper Type:

N/A (Digital)

Software Requirements

Software Requirements:

Adobe PDF Reader

Search Functionality

Search Functionality:

Enabled (PDF search function)

Delivery Method

Delivery Method:

Instant Download Link post-payment

File Quality

Resolution:

High resolution (stated for clarity of illustrations and diagrams).

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Engine Displacement:

398 cc

Bore X Stroke:

90.0 mm x 78.5 mm (typical for this generation)

Cooling System:

Liquid-cooled

Performance

Horsepower Estimate:

Approximately 40-45 HP (at crankshaft, varies with tuning and exhaust)

Torque Estimate:

Approximately 30-35 lb-ft (at crankshaft, varies)

Fuel System

Fuel Delivery:

Mikuni BSR36 carburetor (common across this generation)

Fuel Type:

Unleaded gasoline, 87 octane or higher recommended

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh, with reverse

Features

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain, drive sprocket, driven sprocket

📐 Dimensions

Exterior

Overall Length:

Approximately 70.5 inches (1790 mm)

Overall Width:

Approximately 45.1 inches (1145 mm)

Overall Height:

Approximately 43.9 inches (1115 mm)

Weights

Dry Weight:

Approximately 397 lbs (180 kg)

Fuel Capacity:

2.6 US gallons (9.8 L)

Dimensions

Wheelbase:

Approximately 49.2 inches (1250 mm)

Ground Clearance:

Approximately 10.0 inches (255 mm)

🛡️ Safety Features

Ratings

Safety Standards:

Manufactured to meet relevant ATV safety standards; specific ratings not typically published for this vehicle class.

Active Features

Braking System:

Front: Dual hydraulic disc; Rear: Single hydraulic disc.

Parking Brake:

Mechanical disc brake

Passive Features

Throttle Limiter:

Adjustable throttle limiter for novice riders (often user-configurable).

💡 Technology Features

Infotainment

Infotainment System:

N/A (Performance ATV, minimal electronics focus).

Driver Assistance

Driver Assistance Features:

N/A (Performance ATV).

Connectivity

Connectivity Features:

N/A (Performance ATV).

Engine Management

Ignition System:

CDI (Capacitor Discharge Ignition).

Lighting

Headlight Type:

Dual Halogen headlights.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 20 hours of operation or annually, whichever comes first (refer to manual for precise details).

Air Filter Cleaning:

Inspect every 10 hours of operation; clean or replace as needed, more frequently in dusty conditions.

Spark Plug Replacement:

Inspect every 20 hours, replace as needed (typical recommendation).

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or higher (specific Suzuki recommendation preferred).

Engine Oil Capacity:

Approximately 2.0 US quarts (1.9 L) with filter change (verify in manual).

Coolant Type:

Antifreeze coolant, 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4 recommended.

Known Issues

Common Wear Items:

Clutch wear, chain and sprockets, wheel bearings, brake pad wear.

Potential Performance Issues:

Carburetor jetting for altitude or modifications, ignition system components, exhaust system performance.

📚 Vehicle History

Brand Heritage

Suzuki Atv Legacy:

Suzuki has a long history of producing reliable and performance-oriented ATVs, including popular models like the LT-Z series.

Model Evolution

Ltz400 Development:

The LT-Z400 platform, introduced in 2003, was a significant evolution, offering a balance of performance, reliability, and rider comfort that made it a class leader.

Production

Production Location:

Typically manufactured in Japan or other Suzuki global facilities.

🏆 Awards & Recognition

Recognitions

Industry Reputation:

Highly regarded in the sport ATV segment for its blend of power, handling, and durability.