Vehicle Class:
Sport ATV / Quad Bike
Target Audience:
Enthusiasts, recreational riders, mechanics
Competitors:
Yamaha Raptor 350/660, Honda TRX400EX, Kawasaki KSF400 KFX
Vehicle Reputation:
Known for its sporty handling, reliable engine, and versatility for trail riding and light racing.
Manual Value Proposition:
Provides essential information for owners to perform routine maintenance and complex repairs, saving time and money.
Primary Coverage:
Service, Repair, Maintenance, Rebuild, Refurbishment, Restoration
Vehicle Systems:
Engine, Drivetrain, Chassis, Electrical System, Bodywork
Estimated Pages:
Hundreds
Type:
Comprehensive Service and Repair Manual
Digital Format:
PDF (Portable Document Format)
Engine Mechanical:
Full engine overhaul, cylinder head, piston, crankshaft, camshaft, valve train, timing components, lubrication system, cooling system.
Fuel System:
Carburetor assembly and tuning, fuel tank, fuel lines, fuel pump (if applicable).
Ignition System:
CDI unit, ignition coil, spark plug, wiring diagrams.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox disassembly and assembly, chain and sprocket maintenance, drive shaft/axle inspection.
Suspension Steering:
Front and rear suspension components, shock absorbers, steering linkage, tie rods, wheel bearings.
Braking System:
Hydraulic brake systems (front and rear), brake calipers, master cylinders, brake pads, brake fluid specifications and bleeding procedures.
Electrical System:
Wiring diagrams, lighting systems, battery, starter motor, charging system, electrical component testing.
Bodywork Frame:
Body panel removal and installation, frame inspection, seat, handlebars, footpegs, fenders.
Maintenance:
Regular servicing, oil changes, filter replacements, chain lubrication and adjustment, tire pressure checks, battery maintenance.
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for all major vehicle components.
Rebuild Refurbishment:
Detailed instructions for complete engine, transmission, and suspension rebuilds.
Diagnostic Level:
Advanced diagnostic procedures, including torque specifications, clearances, and electrical testing parameters.
Rebuild Detail:
Comprehensive overhaul instructions with exploded diagrams and part identification.
Engine Type:
Four-stroke, Single Cylinder
Engine Displacement:
398cc (approximately)
Bore X Stroke:
85.0 mm x 70.0 mm (typical for this generation)
Compression Ratio:
9.3:1 (typical)
Cooling System:
Liquid-cooled
Valve Configuration:
SOHC, 4 valves
Horsepower:
Approximately 30-35 HP (estimated, actual varies with tune and emissions equipment)
Torque:
Approximately 25-30 lb-ft (estimated)
Carburetor:
Mikuni BSR36 (typical), single carburetor
Fuel Type:
Unleaded gasoline
Engine Oil Type:
API SE, SF, SG, SH, SJ or higher, SAE 10W-40
Engine Oil Capacity:
Approx. 1.7 L (1.8 US qt) without filter change; Approx. 1.9 L (2.0 US qt) with filter change.
Safety Ratings Certification:
N/A (ATV classification)
Braking System Type:
Hydraulic disc brakes front and rear
Parking Brake:
Yes (typically lever-actuated on rear caliper or transmission)
Handlebars:
Standard padded handlebars with thumb throttle
Footpegs:
Wide footpegs with heel guards
Engine Oil Change Interval:
Every 1000 km (620 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 500 km (310 miles) or annually.
Spark Plug Replacement:
Every 5000 km (3100 miles) or 2 years.
Chain Adjustment:
Every 500 km (310 miles) or as needed.
Brake Fluid Type:
DOT 3 or DOT 4.
Coolant Type:
Suzuki Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors).
Common Wear Items:
Clutch plates, wheel bearings, chain and sprockets, front-end suspension components (bushings, ball joints) due to off-road use.
Carburetor Tuning:
May require periodic adjustment or cleaning due to fuel quality and usage.
Engine Vibrations:
Standard for single-cylinder engines; proper maintenance mitigates excessive vibration.
Manufacturer:
Suzuki Motor Corporation
Heritage Focus:
Strong history in motorcycles, ATVs, and off-road vehicles.
Predecessor:
Suzuki LT-F400F (4x2 model), LT-Z250 (smaller displacement)
Successor:
Suzuki LT-Z400 (later revisions and minor updates) and models like the LTR450.
Manufacturing Origin:
Typically manufactured in Japan or USA.
