Category:
Mid-size Utility ATV
Target Audience:
Owners, farmers, ranchers, hunters, and recreational riders seeking a dependable mid-size work and trail ATV
Competitors:
Honda FourTrax 350/400, Kawasaki Prairie 360/400, Yamaha Big Bear 400, Polaris Sportsman 400/500
Advantage:
Reliable single-cylinder engine with shaft drive, independent front suspension on 4WD models, and lower cost of ownership than many rivals
Distinctive Features:
Reliable single-cylinder engine, independent front suspension (IFS) on 4WD models (LT-A400F), versatile for work and recreation, user-friendly operation
Manual Advantage:
Contains all information found in original factory service manuals, enabling professional-level diagnostics and repairs
Benefits:
Cost-effective repairs and maintenance, extended vehicle lifespan, improved performance through proper upkeep, DIY capability
Applicable Years:
2002, 2003, 2004, 2005, 2006, 2007
Applicable Models:
LT-A400, LT-A400F (including all sub-trims and variations)
Type:
Factory Service Manual (FSM)
Content Scope:
Repair, Service, and Technical Manual
Delivery Method:
Instant digital download
Binding:
Digital (printable for 3-ring binder)
Primary Systems:
Engine, Drivetrain, Fuel System, Cooling System, Lubrication System, Chassis, Electrical System, Suspension, Brakes, Steering
Electrical Details:
Complete electrical system diagnosis, wiring diagrams, component testing, troubleshooting of lighting, ignition, charging system, and starter
Engine Section:
Cylinder head, valves and timing, pistons and cylinders, clutch, lubrication circuit, cooling system service
Fuel and Carburetion:
Carburetor disassembly, jetting, fuel tap, throttle and choke cable service, fuel tank and lines
Drivetrain Section:
CVT clutch assemblies, transmission gearcase, propeller shaft, front differential and 4WD engagement (LT-A400F)
Chassis Section:
Frame, front and rear suspension, wheels and tires, steering, front and rear brakes
Body and Fixtures:
Fenders, racks, seat, footrests, and cargo rack attachment service
Repair Maintenance:
Routine Maintenance, Scheduled Servicing, Component Repair, Troubleshooting, Diagnostics, Overhauls, Adjustments, Replacements, Electrical System Diagnosis
Engine Overhaul:
Engine disassembly, cleaning, inspection, component replacement (pistons, rings, valves, bearings), reassembly, and break-in procedures
Drivetrain Repair:
CVT clutch inspection and replacement, gearcase maintenance, propeller shaft inspection, differential servicing (LT-A400F)
Periodic Service:
Oil and filter changes, valve clearance adjustment, carburetor tuning, brake and cable inspection, drive belt replacement, coolant service
Diagnostics:
Symptom-based troubleshooting flowcharts, electrical testing procedures, specification-based inspections and tolerances
Depth:
Comprehensive: From basic troubleshooting to complete engine and transmission rebuilds, including detailed electrical schematics and component-specific procedures
Diagrams Illustrations:
Detailed exploded views, step-by-step illustrations, and clear wiring schematics for all major systems and components
Specifications:
Full torque specifications, clearances, limits, and special tool callouts throughout each service procedure
Part Numbers:
Factory part numbers referenced where applicable for ordering replacement components
Fastener Data:
Torque values and thread specifications for all critical fasteners
Fluids:
Approved oil, coolant, and brake fluid specifications with capacities
Special Tools:
Suzuki special tool part numbers identified where a procedure requires them, with practical alternatives noted
Model Year Differences:
Includes specific supplements for 2003-2007 models, highlighting any updates or changes to procedures or specifications
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
Engine Type:
4-stroke, SOHC, 1-cylinder, liquid-cooled
Displacement:
376 cc (23.0 cu. in.)
Bore X Stroke:
85.0 mm x 66.0 mm (3.35 in. x 2.60 in.)
Horsepower:
Approx. 20-22 HP (estimated based on typical class performance)
Torque:
Approx. 20-22 lb-ft (estimated based on typical class performance)
Carburetor:
Mikuni BSR32 (for most models)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Cooling System:
Liquid-cooled with fan-assisted radiator
Lubrication System:
Wet sump
Recommended Oil:
Suzuki 4-stroke motorcycle oil SAE 10W-40 API SG or higher (refer to manual for specific requirements)
Length:
Approx. 76.6 in. (1945 mm)
Width:
Approx. 42.1 in. (1070 mm)
Height:
Approx. 45.7 in. (1160 mm)
Wheelbase:
Approx. 48.4 in. (1230 mm)
Front Rack Capacity:
Approx. 44 lbs (20 kg)
Rear Rack Capacity:
Approx. 88 lbs (40 kg)
Dry Weight:
Approx. 500-520 lbs (227-236 kg) depending on 2WD/4WD
Curb Weight:
Approx. 530-550 lbs (240-250 kg) depending on 2WD/4WD
Towing Capacity:
Approx. 1,000 lbs (454 kg)
Front Tire Size:
AT 25x8-12
Rear Tire Size:
AT 25x10-12
Recommended Tire Pressure:
Refer to manual (typically 3-5 psi)
Safety Standards:
Manufactured to meet ANSI/SVIA 1-2001 and 2003 standards
Crash Test Ratings:
N/A - ATVs are not crash tested like passenger vehicles; ANSI/SVIA compliance applies
Braking System:
Front: Dual hydraulic disc brakes; Rear: Single hydraulic disc brake
Handling:
Low center of gravity and wide stance for stable operation on varied terrain
Lighting:
Dual 30W headlights, 1 x 8W taillight/stoplight
Ergonomics:
Comfortable seating position, easy-to-reach controls, handlebar design for stability
Oil Change:
Every 1,000 km or 6 months (refer to manual for precise intervals and conditions)
Air Filter Cleaning:
Every 1,000 km or 6 months, or more frequently in dusty conditions
Spark Plug Check:
Every 2,000 km or 12 months
Valve Clearance Check:
Every 4,000 km or 24 months
Engine Oil Capacity:
Approx. 2.1 L (2.2 US qt) with filter change
Coolant Type:
Mixture of antifreeze and pure water (refer to manual for specific mix ratio and type)
Brake Fluid Type:
DOT 4 brake fluid
Known Issues and Wear Items
Common Wear Items:
CVT belt wear, starter motor brushes, wheel bearings, brake pads, suspension bushings. The manual helps in diagnosing and replacing these.
Diagnostic Sections:
Includes detailed troubleshooting flowcharts for common problems like starting issues, poor running, electrical faults, and transmission problems.
