The QuadSport Z400, also known by its chassis code LT-Z400, is a sport ATV renowned for its agility, power, and rider comfort in demanding off-road conditions. Produced between 2008 and 2012, this model builds upon a proven platform, reflecting a heritage of engineering reliable and performance-oriented vehicles. Designed for enthusiasts, trail riders, and recreational riders alike, the QuadSport Z400 is celebrated for its exceptional handling, robust power delivery, and competitive value, making it a standout in its segment. This comprehensive workshop service manual provides detailed guidance for the repair and maintenance of your QuadSport Z400. Covering the years 2008 through 2012, this 492-page English language manual offers in-depth procedures for all major systems, including the engine, fuel system, transmission, drivetrain, suspension, brakes, and electrical system. It equips owners and technicians with the knowledge necessary for everything from routine service checks and oil changes to complex engine overhauls and electrical diagnostics, ensuring optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: Suzuki Model: QuadSport Z400 Model Nickname: LT-Z400 Vehicle Type: ATV (All-Terrain Vehicle) Generation Generation Code: K8-L2 Codes Chassis Code: LT-Z400 👋 Introduction Market Position Segment: Sport ATV Target Audience: Enthusiasts seeking high performance, trail riders, recreational riders Competitive Analysis Key Competitors: Yamaha Warrior/Raptor, Honda TRX, Kawasaki KFX Key Features Atv Philosophy: Designed for agility, power, and rider comfort in off-road conditions. Manual Value Proposition: Enables owners to perform comprehensive maintenance and repairs, saving on labor costs and maximizing vehicle lifespan. 📋 Manual Details Coverage Areas Years Covered: 2008, 2009, 2010, 2011, 2012 Page Count Total Pages: 492 Manual Type Type: Workshop Service Manual Purpose: Repair and Maintenance Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, timing, lubrication, cooling Fuel System: Carburetor tuning, fuel pump, fuel filter replacement, fuel tank maintenance Transmission: Clutch service, gear inspection, shift mechanism repair, oil changes Drivetrain: Chain drive, sprockets, axle maintenance, differential service Suspension: Front and rear suspension components, shock absorber adjustment and replacement, steering linkage Brakes: Hydraulic system, brake pad replacement, caliper service, rotor inspection, bleeding procedure Electrical System: Battery, charging system (stator, regulator/rectifier), ignition system, starter motor, lighting, wiring diagrams Cooling System: Radiator, fan, coolant flushing, thermostat replacement Frame And Bodywork: Chassis inspection, panel removal and installation, seat, handlebar, footpeg maintenance Procedures Included Maintenance: Regular service checks, oil changes, filter replacements, lubrication points Troubleshooting: Diagnostic charts for common problems, symptom-based solutions Repair: Detailed step-by-step instructions for component overhaul and replacement Disassembly And Assembly: Complete procedures for engine, transmission, and chassis components Torque Specifications: Precise torque values for all critical fasteners Wiring Diagrams: Comprehensive electrical system schematics Technical Depth Depth: Comprehensive, covering from basic user maintenance to full engine rebuilds and complex electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchable: Yes Print Quality Quality: High-resolution for clear diagrams and text Binding Type Type: Digital Download (PDF) Paper Type Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code: F397 Engine Type: 4-stroke, Single-cylinder, DOHC, 4-valve Displacement: 376 cc Bore X Stroke: 88.0 mm x 70.1 mm Cooling System: Liquid-cooled Performance Horsepower Estimated: ~30 HP Torque Estimated: ~24 lb-ft Fuel System Fuel Delivery: Mikuni BSR36 carburetor Fuel Type: Unleaded gasoline Fuel Tank Capacity: 2.6 US gal (9.8 L) Lubrication Oil Type: SAE 10W-40 API SG or higher Oil Capacity With Filter: 1.8 US qt (1.7 L) 🔧 Transmission Standard Transmission Type: 5-speed manual with reverse Features Clutch Type: Wet multi-plate Drive: 2WD Final Drive: O-ring sealed chain, Drive sprocket, Rear axle, Pinion sprocket Fluid Specifications Transmission Oil Type: SAE 80W API GL-4 Fluid Capacity Transmission Oil Capacity: 0.8 US qt (0.75 L) 📐 Dimensions Exterior Overall Length: 70.9 in (1800 mm) Overall Width: 41.9 in (1065 mm) Overall Height: 43.9 in (1115 mm) Wheelbase: 49.4 in (1255 mm) Ground Clearance: 10.2 in (260 mm) Weights Dry Weight: 375 lbs (170 kg) Curb Weight: 393 lbs (178 kg) 🛡️ Safety Features Ratings Crash Test Info: N/A (ATV, typically not crash-tested by agencies like NHTSA) Active Features Braking System: Front: Dual hydraulic disc; Rear: Single hydraulic disc Passive Features Lighting: Halogen headlights, LED taillight/brake light Operator Protection: Handlebar controls, footwells, throttle limiter (adjustable) 💡 Technology Features Infotainment System: N/A (Focus on performance, not infotainment) Driver Assistance Features: N/A (Designed for manual control and rider input) Connectivity Features: N/A Engine Management System: CDI (Capacitor Discharge Ignition) 🔧 Maintenance Service Intervals Engine Oil Change: Every 1000 km (600 miles) or 6 months, whichever comes first. Inspect more frequently under severe use. Air Filter Cleaning: Every 1000 km (600 miles) or more often in dusty conditions. Spark Plug Replacement: Every 4000 km (2500 miles) or as needed. Check gap at 1000 km. Chain Lubrication And Tension: Every 500 km (300 miles). Fluid Specifications Engine Oil Recommendation: Suzuki Genuine 4-stroke Motorcycle Oil (10W-40) or equivalent meeting API...