The Suzuki LT-Z400 QuadSport, also known as the QuadSport, is a versatile All-Terrain Vehicle (ATV) produced for the 2003, 2004, 2005, and 2006 model years. As a key player in the sport ATV segment, it was engineered for enthusiasts and recreational riders seeking agile handling and a powerful engine. Its first-generation design, featuring a 398 cc liquid-cooled engine, 5-speed manual transmission with reverse, and hydraulic disc brakes, established it as a strong competitor in its class, praised for its aggressive styling and performance on trails and in recreational racing. This comprehensive service repair manual covers all essential aspects of the Suzuki LT-Z400 QuadSport from 2003 to 2006. It provides detailed procedures for engine overhaul, fuel system maintenance, cooling and ignition system service, transmission and drivetrain repair, suspension adjustments, brake system servicing, and electrical system diagnostics. The manual also includes scheduled maintenance guidelines, troubleshooting charts for common issues, and in-depth wiring diagrams. This resource is designed to assist owners, technicians, and mechanics in maintaining, diagnosing, and repairing the QuadSport, ensuring its optimal performance and longevity. 🏷️ Basic Information Identification Make: Suzuki Model: LT-Z400 QuadSport Model Nickname: QuadSport Vehicle Type: ATV (All-Terrain Vehicle) Chassis Code: LT-Z400 Generation Generation Identifier: First Generation 👋 Introduction Market Position Segment: Sport ATV, Recreational Off-Road Target Audience: Enthusiasts, recreational riders, racers Competitive Analysis Key Competitors: Yamaha Warrior/Banshee, Honda TRX series, Kawasaki KFX series Key Features Performance Focus: Aggressive styling, agile handling, powerful engine for its class 📋 Manual Details Coverage Areas Applicable Years: 2003, 2004, 2005, 2006 Page Count Estimated Page Count: 300+ Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, diagnostics Fuel System: Carburetor adjustment and cleaning, fuel pump, fuel lines, fuel tank Cooling System: Radiator, fan, thermostat, coolant replacement Ignition System: Spark plugs, ignition coil, CDI unit, timing Transmission: Clutch operation, gear shifting, internal components, fluid change Drivetrain: Chain adjustment and replacement, sprocket wear, drive axle Suspension: Front and rear suspension, shock absorbers, A-arms, linkages, adjustment Brakes: Hydraulic brake system, brake pads, rotors, calipers, bleeding procedure Electrical System: Wiring diagrams, battery, starter motor, lighting, charging system Frame And Bodywork: Chassis inspection, plastics, seat, handlebars, footpegs Wheels And Tires: Tire pressure, wheel bearing maintenance, rim inspection Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, inspections Troubleshooting: Diagnostic charts, common problems and solutions, fault finding Repair: Step-by-step repair procedures for all major components Overhaul: Complete engine and transmission overhaul instructions Wiring Diagrams: Detailed electrical system schematics Technical Depth Depth: Comprehensive: Covers basic maintenance to complete engine rebuilds and diagnostics 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF Printability: Printable pages for workshop use Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, DOHC, 4-valve Displacement: 398 cc (24.3 cu in) Bore X Stroke: 90.0 mm x 78.0 mm Compression Ratio: 11.3:1 Cooling Method: Liquid-cooled Performance Horsepower Est: 30-34 hp (at crank) Torque Est: 22-25 lb-ft (at crank) Fuel System Carburetor: Mikuni BSR36, CV (Constant Velocity) Fuel Type: Unleaded gasoline, 87-91 octane Ignition System Ignition: Electronic ignition (CDI) 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) without filter change, 1.9 L (2.0 US qt) with filter change 🔧 Transmission Standard Type: 5-speed manual with reverse Clutch Type: Wet multi-plate Features Gear Ratios: Detailed in manual (e.g., 1st: 3.182, 2nd: 2.000, 3rd: 1.579, 4th: 1.273, 5th: 1.050) Fluid Specifications Transmission Oil Type: SAE 80W API GL-4 Gear Oil Transmission Oil Capacity: 0.7 L (0.74 US qt) 📐 Dimensions Exterior Overall Length: 1820 mm (71.7 in) Overall Width: 1170 mm (46.1 in) Overall Height: 1105 mm (43.5 in) Wheelbase: 1270 mm (50.0 in) Ground Clearance: 260 mm (10.2 in) Weights Dry Weight Est: 170 kg (375 lbs) Curb Weight Est: 181 kg (399 lbs) Suspension Travel Front Suspension Travel: 230 mm (9.1 in) Rear Suspension Travel: 252 mm (9.9 in) Wheels Tires Front Tire Size: AT21x7-10 Rear Tire Size: AT20x10-9 Bolt Pattern: 4x110 mm 🛡️ Safety Features Ratings Atv Safety Standards: Adherence to ANSI/SVIA standards for recreational ATVs Active Features Braking System: Hydraulic disc brakes front and rear Throttle Limiter: Adjustable thumb throttle for control Passive Features Chassis Design: Steel frame, integrated grab bar, footwells with heel guards Lighting: Dual halogen headlights, LED tail/brake light 💡 Technology Features Infotainment Display: Digital multi-function meter (speedometer, odometer, trip meter, clock, neutral indicator, high-beam indicator, oil pressure indicator) Driver Assistance Throttle Control: Ergonomic thumb throttle for precise acceleration control. Connectivity Charging System: Stator and battery charging system 🔧 Maintenance Service Intervals Engine Oil Change: Every 1000 km (600 miles) or 6 months, whichever comes first. Also after every 20 hours of operation. Oil Filter Replacement: At every engine oil...