Segment:
High-performance sport ATV
Target Audience:
Enthusiasts, recreational riders, racers, DIY mechanics
Key Competitors:
Yamaha YFZ450, Kawasaki KFX400, Arctic Cat DVX400
Vehicle Focus:
Agility, Power, Handling
Manual Benefit:
Empowers owners to perform comprehensive maintenance and repairs, saving time and money.
Professional Quality:
Factory-level documentation ensures accuracy and completeness.
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
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
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
Format:
PDF (Portable Document Format)
Resolution:
High-resolution, suitable for printing
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Size:
Varies (typically 50-150 MB)
Text Search:
Searchable text content
License Terms:
No Expiry Dates, Unlimited Use
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
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)
Carburetor:
Mikuni BSR36 (CV type)
Fuel Type:
Unleaded gasoline, Octane rating 87 or higher
Ignition Type:
CDI (Capacitor Discharge Ignition)
Spark Plug:
NGK CR9E or equivalent
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
Atv Safety Standards:
Adherence to relevant ATV safety regulations (ANSI/SVIA standards)
Brakes:
Hydraulic disc brakes, front and rear
Parking Brake:
Mechanical parking brake, often integrated into rear brake caliper
Throttle Limiter:
Adjustable thumb throttle for varying rider experience
Kill Switch:
Engine kill switch located on handlebars
Features:
N/A (Sport ATV focused, no infotainment system)
Features:
N/A (Sport ATV focused, no electronic driver assistance features)
Headlights:
Dual halogen headlights for trail visibility
Taillight:
LED taillight and brake light
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.
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
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.
Preventative Maintenance:
Regular cleaning of the air filter, proper chain lubrication and tension, and checking all fasteners are critical for longevity.
Manufacturer:
Suzuki Motor Corporation
Motorsport Legacy:
Suzuki has a strong heritage in motorsports, including motocross and ATV racing.
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.
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.
