🏷️ Basic Information Identification Make: Suzuki Model: LT-Z400 QuadSport Product Type: Service & Repair Manual Format: PDF Download 👋 Introduction Market Position Segment: High-performance sport ATV Target Audience: Enthusiasts, recreational riders, racers, DIY mechanics Competitive Analysis Key Competitors: Yamaha YFZ450, Kawasaki KFX400, Arctic Cat DVX400 Key Features Vehicle Focus: Agility, Power, Handling Manual Benefit: Empowers owners to perform comprehensive maintenance and repairs, saving time and money. Manual Value Professional Quality: Factory-level documentation ensures accuracy and completeness. 📋 Manual Details Coverage Areas Model Years: 2003, 2004, 2005, 2006 Vehicle Type: ATV (All-Terrain Vehicle) Page Count Estimated Pages: 300-400 Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Delivery: Instant Digital Download 📖 Manual Coverage Systems Covered 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 Procedures Included 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 Technical Depth 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 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Print Quality Resolution: High-resolution, suitable for printing Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) File Size Size: Varies (typically 50-150 MB) Searchability Text Search: Searchable text content Licensing License Terms: No Expiry Dates, Unlimited Use ⚙️ Engine Specifications Primary Engine 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 Performance 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) Fuel System Carburetor: Mikuni BSR36 (CV type) Fuel Type: Unleaded gasoline, Octane rating 87 or higher Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Spark Plug: NGK CR9E or equivalent 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) with filter change 🔧 Transmission Standard Transmission Type: 5-speed manual with Reverse Optional Transmission Options: N/A (Standard configuration) Features Clutch Type: Wet, multi-plate Final Drive: O-ring sealed chain Fluid Specifications Transmission Oil Type: SAE 80W API GL-4 Transmission Oil Capacity: 0.6 L (0.6 US qt) 📐 Dimensions Exterior Overall Length: 1840 mm (72.4 in) Overall Width: 1165 mm (45.9 in) Overall Height: 1040 mm (40.9 in) Wheelbase: 1270 mm (50.0 in) Ground Clearance: 265 mm (10.4 in) Weights Dry Weight: 192 kg (423 lbs) Wet Weight: 205 kg (452 lbs) Tires Front Tire Size: AT21x7R-10 Rear Tire Size: AT20x10R-9 Wheels Wheel Bolt Pattern: 4/110 (for both front and rear, typically) 🛡️ Safety Features Ratings Atv Safety Standards: Adherence to relevant ATV safety regulations (ANSI/SVIA standards) Active Features Brakes: Hydraulic disc brakes, front and rear Parking Brake: Mechanical parking brake, often integrated into rear brake caliper Passive Features Throttle Limiter: Adjustable thumb throttle for varying rider experience Kill Switch: Engine kill switch located on handlebars 💡 Technology Features Infotainment Features: N/A (Sport ATV focused, no infotainment system) Driver Assistance Features: N/A (Sport ATV focused, no electronic driver assistance features) Lighting Headlights: Dual halogen headlights for trail visibility Taillight: LED taillight and brake light 🔧 Maintenance Service Intervals 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. Fluid Specifications 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 Known Issues 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. Recommendations Preventative Maintenance: Regular cleaning of the air filter, proper chain lubrication and tension, and checking all fasteners are critical for longevity. 📚 Vehicle History Brand Heritage Manufacturer: Suzuki Motor Corporation Motorsport Legacy:...