Suzuki LTZ400 QUAD SPORT Full Service & Repair Manual 2003-2006

Prix habituel: $16.99
Prix soldé: $16.99
Prix habituel
Prix unitaire: par

The LT-Z400 QuadSport is a high-performance sport ATV renowned for its agility, power, and handling. Introduced by the company, this model has a strong motorsports legacy and was developed to...

26 people are viewing this right now

Taper: Atv

Distributeur:

UGS: 57023

Mots clés: 2003 2004 2005 2006 Atv LTZ400 QUAD SPORT Misc Motorcycles Suzuki

Variantes de produits

Description

The LT-Z400 QuadSport is a high-performance sport ATV renowned for its agility, power, and handling. Introduced by the company, this model has a strong motorsports legacy and was developed to compete in the growing sport ATV market. Designed for enthusiasts, recreational riders, and racers, the LT-Z400 is a testament to the company's engineering quality, offering a robust 398cc liquid-cooled engine with a 5-speed manual transmission and reverse. Its agile chassis, featuring independent front suspension and a swingarm rear, combined with powerful hydraulic disc brakes, ensures a thrilling and controlled riding experience. This comprehensive service and repair manual provides detailed instructions for maintaining and repairing the LT-Z400 QuadSport for the model years 2003 through 2006. It covers all essential systems, including the powertrain, chassis, electrical system, fuel system, and cooling system, with in-depth procedures for disassembly, assembly, maintenance, and troubleshooting. This documentation offers accuracy and completeness, empowering owners and technicians with the knowledge to perform everything from basic service checks and oil changes to complete engine rebuilds and electrical diagnostics, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

LT-Z400 QuadSport

Product Type:

Service & Repair Manual

Format:

PDF Download

👋 Introduction

Market Position

Segment:

High-performance sport ATV

Target Audience:

Enthusiasts, recreational riders, racers, DIY mechanics

Competitive Analysis

Key Competitors:

Yamaha YFZ450, Kawasaki KFX400, Arctic Cat DVX400

Key Features

Vehicle Focus:

Agility, Power, Handling

Manual Benefit:

Empowers owners to perform comprehensive maintenance and repairs, saving time and money.

Manual Value

Professional Quality:

Factory-level documentation ensures accuracy and completeness.

📋 Manual Details

Coverage Areas

Model Years:

2003, 2004, 2005, 2006

Vehicle Type:

ATV (All-Terrain Vehicle)

Page Count

Estimated Pages:

300-400

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Delivery:

Instant Digital Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Transmission, Clutch, Driveshaft, Differential

Chassis:

Frame, Suspension (Front & Rear), Steering, Brakes (Hydraulic), Wheels & Tires

Electrical:

Ignition System, Lighting, Battery, Starter Motor, Charging System, CDI Unit, Wiring Diagrams

Fuel System:

Carburetor (CVK39), Fuel Tank, Fuel Lines, Fuel Pump (if applicable)

Cooling System:

Radiator, Cooling Fan, Coolant Hoses

Exhaust System:

Exhaust Manifold, Muffler, Heat Shields

Body And Trim:

Body Panels, Fenders, Seat, Handlebars, Controls

Procedures Included

Maintenance:

Scheduled Service Checks, Oil Changes, Filter Replacements, Chain Adjustment, Valve Clearance Adjustment

Troubleshooting:

Diagnostic Flowcharts for Common Issues (e.g., starting problems, poor performance, electrical faults)

Repair:

Engine Rebuild, Transmission Overhaul, Brake System Servicing, Suspension Component Replacement, Electrical Component Repair

Disassembly And Assembly:

Step-by-step instructions for major component removal and installation

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds)

Diagnostics:

Detailed diagnostic procedures, specifications, and troubleshooting guides

Torque Specifications:

All critical torque values for fasteners

Wiring Diagrams:

Complete, high-quality electrical wiring schematics

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Print Quality

Resolution:

High-resolution, suitable for printing

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

File Size

Size:

Varies (typically 50-150 MB)

Searchability

Text Search:

Searchable text content

Licensing

License Terms:

No Expiry Dates, Unlimited Use

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke, DOHC, 4-Valve

Displacement:

398cc (398 cubic centimeters)

Bore X Stroke:

90.0 mm x 78.0 mm

Cooling System:

Liquid-Cooled

Compression Ratio:

11.3:1

Performance

Horsepower Estimate:

Approx. 33-38 HP (at crankshaft, varies by region and tuning)

Torque Estimate:

Approx. 28-30 lb-ft (at crankshaft, varies by region and tuning)

Fuel System

Carburetor:

Mikuni BSR36 (CV type)

Fuel Type:

Unleaded gasoline, Octane rating 87 or higher

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition)

Spark Plug:

NGK CR9E or equivalent

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) with filter change

🔧 Transmission

Standard

Transmission Type:

5-speed manual with Reverse

Optional

Transmission Options:

N/A (Standard configuration)

Features

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain

Fluid Specifications

Transmission Oil Type:

SAE 80W API GL-4

Transmission Oil Capacity:

0.6 L (0.6 US qt)

📐 Dimensions

Exterior

Overall Length:

1840 mm (72.4 in)

Overall Width:

1165 mm (45.9 in)

Overall Height:

1040 mm (40.9 in)

Wheelbase:

1270 mm (50.0 in)

Ground Clearance:

265 mm (10.4 in)

Weights

Dry Weight:

192 kg (423 lbs)

Wet Weight:

205 kg (452 lbs)

Tires

Front Tire Size:

AT21x7R-10

Rear Tire Size:

AT20x10R-9

Wheels

Wheel Bolt Pattern:

4/110 (for both front and rear, typically)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Adherence to relevant ATV safety regulations (ANSI/SVIA standards)

Active Features

Brakes:

Hydraulic disc brakes, front and rear

Parking Brake:

Mechanical parking brake, often integrated into rear brake caliper

Passive Features

Throttle Limiter:

Adjustable thumb throttle for varying rider experience

Kill Switch:

Engine kill switch located on handlebars

💡 Technology Features

Infotainment

Features:

N/A (Sport ATV focused, no infotainment system)

Driver Assistance

Features:

N/A (Sport ATV focused, no electronic driver assistance features)

Lighting

Headlights:

Dual halogen headlights for trail visibility

Taillight:

LED taillight and brake light

🔧 Maintenance

Service Intervals

Initial Service:

First service typically around 10-20 operating hours or 1 month.

Engine Oil Change:

Every 100 operating hours or 6 months, whichever comes first.

Air Filter Cleaning:

Every 20 operating hours or monthly; replace as needed.

Spark Plug Check:

Every 100 operating hours or 6 months.

Chain Tension Check:

Every 20 operating hours or monthly.

Valve Clearance Check:

Every 200 operating hours or 12 months.

Fluid Specifications

Coolant Type:

Suzuki Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors), pre-mixed 50/50 with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Known Issues

Common Wear Items:

Brake pads, brake rotors, wheel bearings, steering stem bearings, chain and sprockets, tie rod ends.

Potential Failures:

Carburetor issues (clogging, adjustment drift), electrical connector corrosion, occasional stator or rectifier failures.

Recommendations

Preventative Maintenance:

Regular cleaning of the air filter, proper chain lubrication and tension, and checking all fasteners are critical for longevity.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation

Motorsport Legacy:

Suzuki has a strong heritage in motorsports, including motocross and ATV racing.

Model Evolution

Development Origin:

The LT-Z400 was developed as Suzuki's answer to the growing sport ATV market, sharing a platform with Kawasaki's KFX400 and Arctic Cat's DVX400.

Production

Manufacturing Location:

Primarily manufactured in Japan and potentially other global facilities by Suzuki.

Initial Release:

The LT-Z400 platform debuted in 2002 (as a 2003 model year). This manual covers the initial generation.

🏆 Awards & Recognition

Recognitions

Market Reputation:

The LT-Z400 was widely regarded as a capable and reliable sport ATV in its class, popular with both trail riders and racers.

Industry Impact:

Contributed significantly to the growth and popularity of the 400cc sport ATV segment.