Suzuki LT-Z400 Quad Sport 2009-2012 Full Service & Repair Manual

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UGS: 71914

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

Variantes de produits

Description

The Suzuki LT-Z400 QuadSport is a performance sport ATV designed for recreational and competitive riding. Produced for the model years 2009 through 2012, this model is recognized for its liquid-cooled engine, robust chassis, and sporty suspension system, offering reliable performance. Building on a strong heritage in ATV manufacturing, the LT-Z400 QuadSport has been a consistent performer in its segment, praised for its balance of power, handling, and value. Its engineering quality and reliable performance make it a popular choice for riders seeking an engaging off-road experience. This comprehensive factory service repair workshop manual, written in English, provides in-depth guidance for all repairs and servicing of the Suzuki LT-Z400 QuadSport. It covers essential areas including engine overhaul, transmission repair, chassis and suspension maintenance, brake system servicing, and electrical system diagnostics. The manual includes step-by-step instructions, hundreds of detailed photos, and exploded diagrams to assist owners, mechanics, and technicians. Its purpose is to empower users to perform preventative maintenance, troubleshooting, and complex repairs, ensuring the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

LT-Z400 QuadSport

Model Variant:

QuadSport

Model Years Covered:

2009, 2010, 2011, 2012

👋 Introduction

Market Position

Market Segment:

Performance Sport ATV

Competitive Analysis

Competitors:

Yamaha YFZ450, Kawasaki KFX450R, Bombardier/Can-Am DS450.

Key Features

Atv Features:

Liquid-cooled engine, strong chassis, sporty suspension, reliable performance for recreational and competitive riding.

Manual Value

Value Proposition:

Provides comprehensive factory-level repair and maintenance information for owners and technicians, saving on professional service costs and enabling self-sufficiency.

📋 Manual Details

Coverage Areas

All Repairs:

Servicing:

Troubleshooting:

Page Count

Estimated Pages:

Hundreds

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, diagnostics, tuning, lubrication system, cooling system, fuel system, exhaust system, emissions control.

Transmission:

Clutch, gearbox, final drive, lubrication, adjustment, repair.

Chassis Suspension:

Front suspension (A-arms, shocks, steering), rear suspension (swingarm, linkage, shock), wheel bearings, steering system.

Brakes:

Front and rear disc brakes, hydraulic system, pad replacement, caliper service, bleeding.

Electrical System:

Battery, charging system (stator, regulator/rectifier), ignition system, lighting, starter motor, wiring diagrams, component testing.

Fuel System:

Carburetor (Mikuni BSR36), fuel lines, fuel tank, fuel pump (if applicable), jetting specifications.

Bodywork:

Frame, plastics, seat, handlebars, controls, body panel removal and installation.

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug service, valve clearance checks, general inspection.

Diagnostics:

Step-by-step troubleshooting guides for common and uncommon issues, error code interpretation (if applicable).

Repair Procedures:

Engine rebuild, transmission overhaul, suspension component replacement, electrical component repair, brake system service.

Adjustment Procedures:

Carburetor tuning, clutch adjustment, throttle cable adjustment, chain tension.

Technical Depth

Depth:

Comprehensive, suitable for professional mechanics and experienced DIY technicians.

Diagrams:

Hundreds of detailed photos and exploded diagrams.

Instructions:

Step-by-step instructions for all repair and maintenance tasks.

📊 Manual Specifications

File Format

File Type:

Searchable:

Assumed searchable text content within PDF.

Print Quality

Print Capability:

Printable (single page or entire manual).

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Licensing

Expiry:

No expiry date, lifelong use.

Installations:

Installable on unlimited computers.

Compatibility

Operating Systems:

Compatible with all Windows and MAC computers.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, liquid-cooled, DOHC, 4-valve

Engine Displacement:

398 cc

Bore X Stroke:

90.0 mm x 78.4 mm

Compression Ratio:

11.3:1

Performance

Horsepower Estimated:

Approx. 49 HP (at crankshaft, varies by region/tuning)

Torque Estimated:

Approx. 30 lb-ft (at crankshaft, varies by region/tuning)

Fuel System

Carburetor:

Mikuni BSR36, single

Fuel Type:

Unleaded gasoline

Lubrication System

Oil Capacity:

2.3 L (with filter change)

Recommended Oil:

SAE 10W-40 API SG or higher (refer to manual for specific Suzuki recommendations)

Cooling System

Coolant Type:

Antifreeze coolant (50/50 mix with distilled water)

🔧 Transmission

Standard

Type:

Constant mesh, 5-speed manual

Drive:

Chain drive, manual clutch

Features

Transmission Fluid:

Refer to manual for specific type and capacity (typically SAE 80W-90 GL-5 gear oil for final drive).

📐 Dimensions

Exterior

Length:

Approx. 1845 mm (72.6 in)

Width:

Approx. 1165 mm (45.9 in)

Height:

Approx. 1105 mm (43.5 in)

Wheelbase:

Approx. 1270 mm (50.0 in)

Ground Clearance:

Approx. 260 mm (10.2 in)

Weights

Dry Weight:

Approx. 175 kg (386 lbs)

Curb Weight:

Approx. 183 kg (403 lbs)

Fuel Capacity:

10 L (2.6 US gal)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Adheres to relevant ANSI/SVIA standards for ATVs.

Active Features

Braking System:

Dual hydraulic disc front, single hydraulic disc rear.

Passive Features

Handlebar Design:

Reinforced handlebars with protective padding.

💡 Technology Features

Infotainment

Infotainment System:

Not applicable to this performance ATV model.

Driver Assistance

Driver Assistance Features:

Not applicable to this performance ATV model.

🔧 Maintenance

Service Intervals

Engine Oil Change:

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

Air Filter Cleaning:

Every 200 km (125 miles) or monthly, depending on usage conditions. Replace as needed.

Spark Plug Inspection:

Every 1000 km (600 miles).

Valve Clearance Check:

Every 4000 km (2500 miles) or 24 months.

Chain Lubrication Adjustment:

Every 200 km (125 miles) or after washing/riding in wet conditions.

Fluid Specifications

Engine Oil Viscosity:

SAE 10W-40

Coolant Mixture:

50/50 distilled water and antifreeze

Known Issues

Carburetor Tuning:

Sensitivity to altitude and temperature changes, requiring occasional jetting adjustments.

Cam Chain Tensioner:

Some owners report wear or failure of the automatic cam chain tensioner, leading to rattling noises; manual replacement is often recommended.

Rear Shock ABSorber:

The stock rear shock can be a weak point for aggressive riders, with some opting for aftermarket upgrades.

📚 Vehicle History

Brand Heritage

Suzuki Atv:

Suzuki has a long-standing reputation for producing reliable and performance-oriented ATVs, dating back to early models like the Suzuki QuadRunner.

Model Evolution

Lt Z400 Lineage:

The LT-Z400 QuadSport is a descendant of the highly successful LT-Z250 and shares many components and design principles with its predecessor, the Kawasaki KFX400 (which was co-developed with Suzuki).

Production

Manufacturing Location:

Generally manufactured in Japan or other Suzuki facilities.

🏆 Awards & Recognition

Recognitions

Atv Reviews:

The LT-Z400 series has consistently received positive reviews for its balance of power, handling, and affordability in the sport ATV segment.