Suzuki LT-A400 2002-2007 Workshop Service Manual for Repair
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🏷️ Basic Information Identification Make: Suzuki Model: LT-A400 Model Designation: Eiger 400 Generation Generation Identifier: First Generation (LT-A400) Codes Chassis Code Range: LT-A400 👋 Introduction Market Position Segment: Utility ATV (All-Terrain Vehicle) Target Audience: Recreational riders, farmers, hunters, general utility users. Competitive Analysis Key Competitors: Honda FourTrax, Yamaha Kodiak, Kawasaki Bayou/Brute Force, Polaris Sportsman. Key Features Vehicle Strengths: Reliability, ease of maintenance, robust build, capable off-road performance for its class. Manual Value Proposition: Provides comprehensive, step-by-step repair and maintenance guidance, enabling DIY servicing and extending vehicle lifespan. 📋 Manual Details Coverage Areas Applicable Years: 2002, 2003, 2004, 2005, 2006, 2007 Page Count Total Pages: 424 Manual Type Type: Workshop Service Manual Purpose: Repair and Maintenance Language Primary Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnosis, troubleshooting, adjustments, specifications. Fuel System: Carburetor(s), fuel pump, fuel lines, fuel tank inspection and repair. Ignition System: CDI unit, ignition coil, spark plug, timing inspection and adjustment. Transmission: Automatic transmission (CVT), clutch, drive belt, gears, maintenance, and repair. Drivetrain: Shaft drive, differential, constant velocity (CV) joints, front and rear drive shafts. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, alignment. Brakes: Hydraulic brake system, front and rear calipers, brake discs, brake lines, master cylinder, bleeding procedures. Electrical System: Lighting, starting system, charging system (stator, regulator/rectifier), battery, wiring diagrams, fuses, relays. Cooling System: Air-cooled engine, cylinder head cooling fins, fan (if applicable). Exhaust System: Muffler, exhaust pipe, heat shields, inspection and replacement. Frame And Bodywork: Frame inspection, chassis components, body panels, seat, fenders, handlebars, controls. Wheels And Tires: Tire inspection, replacement, wheel bearing maintenance, tire pressure specifications. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication, spark plug replacement, valve clearance checks. Troubleshooting: Diagnosis of common problems, electrical system troubleshooting, engine performance issues. Disassembly: Detailed step-by-step procedures for component removal. Assembly: Detailed step-by-step procedures for component reinstallation. Repair: Instructions for fixing worn or damaged components. Adjustment: Carburetor adjustments, brake adjustments, clutch adjustments, ignition timing adjustments. Special Tools: Identification and usage of required special service tools. Technical Depth Depth Level: Comprehensive (Bumper-to-Bumper) Detail Level: Step-by-step procedures with pictorial diagrams, exploded views, and photos. Diagnostic Coverage: Inclusion of diagnostic information and procedures. Specification Coverage: Service data, tightening torques, wear limits, and factory specifications. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Yes, all pages are printable. Readability: High quality, zoomable, clear text and images. Binding Type Binding: Digital Download (No physical binding) Paper Type Paper Type: N/A (Digital PDF) Compatibility Operating Systems: Windows, Mac, Linux OS Required Software: Adobe Reader or compatible PDF viewer. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, single-cylinder Displacement: 376 cc (23.0 cubic inches) Bore X Stroke: 81.0 mm x 72.0 mm Cooling System: Air-cooled Compression Ratio: 9.2:1 Performance Horsepower: Approx. 22-25 HP (Estimate based on class and era) Torque: Not explicitly specified in product info, but adequate for utility tasks. Fuel System Fuel Delivery: Mikuni BSR33 carburetor Fuel Type: Unleaded gasoline, minimum 87 octane Fuel Tank Capacity: Approx. 16 Liters (4.2 US gal) 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) Drive Modes: 2WD/4WD selectable with Hi/Lo range and Reverse Features Drive Belt Maintenance: Manual covers inspection, replacement, and tensioning of the drive belt. 📐 Dimensions Exterior Overall Length: Approx. 2070 mm (81.5 in) Overall Width: Approx. 1110 mm (43.7 in) Overall Height: Approx. 1170 mm (46.1 in) Weights Curb Weight: Approx. 255 kg (562 lbs) Payload Capacity: Not explicitly stated, but typically around 150-200 kg for utility ATVs. Towing Capacity: Approx. 300 kg (661 lbs) Front Rack Capacity: Approx. 45 kg (99 lbs) Rear Rack Capacity: Approx. 85 kg (187 lbs) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (ATVs typically do not undergo standardized automotive crash testing) Active Features Braking System: Hydraulic disc brakes front and rear. Selectable 4Wd: Enhances traction and stability in varied terrain. Passive Features Operator Safety: Manual includes warnings, cautions, and recommendations for safe operation. Component Integrity: Emphasis on using correct tools and procedures to maintain vehicle safety. 💡 Technology Features Infotainment Infotainment System: N/A (Basic utility ATV, no integrated infotainment system). Driver Assistance Assistance Features: None (Standard mechanical controls). Connectivity Connectivity Options: None (Standard mechanical vehicle). 🔧 Maintenance Service Intervals Engine Oil Change: Refer to manual for specific mileage/hour intervals (typically every 100-200 hours or 6-12 months). Air Filter Cleaning: Frequent inspection and cleaning recommended, especially in dusty conditions. Spark Plug Replacement: Refer to manual for mileage/hour interval, typically every 100-200 hours. Fluid Specifications Engine Oil Type: Suzuki recommends specific SAE viscosity grades (e.g., SAE 10W-40 or 20W-50) and API classification (e.g., SG or higher) for air-cooled engines. Refer to manual for precise specification. Engine Oil Capacity: Refer to manual for exact capacity, typically around 1.5-2.0 liters with filter change. Brake Fluid Type: DOT 3 or DOT 4 hydraulic...
Manual covers inspection, replacement, and tensioning of the drive belt.
📐 Dimensions
Exterior
Overall Length:
Approx. 2070 mm (81.5 in)
Overall Width:
Approx. 1110 mm (43.7 in)
Overall Height:
Approx. 1170 mm (46.1 in)
Weights
Curb Weight:
Approx. 255 kg (562 lbs)
Payload Capacity:
Not explicitly stated, but typically around 150-200 kg for utility ATVs.
Towing Capacity:
Approx. 300 kg (661 lbs)
Front Rack Capacity:
Approx. 45 kg (99 lbs)
Rear Rack Capacity:
Approx. 85 kg (187 lbs)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (ATVs typically do not undergo standardized automotive crash testing)
Active Features
Braking System:
Hydraulic disc brakes front and rear.
Selectable 4Wd:
Enhances traction and stability in varied terrain.
Passive Features
Operator Safety:
Manual includes warnings, cautions, and recommendations for safe operation.
Component Integrity:
Emphasis on using correct tools and procedures to maintain vehicle safety.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic utility ATV, no integrated infotainment system).
Driver Assistance
Assistance Features:
None (Standard mechanical controls).
Connectivity
Connectivity Options:
None (Standard mechanical vehicle).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Refer to manual for specific mileage/hour intervals (typically every 100-200 hours or 6-12 months).
Air Filter Cleaning:
Frequent inspection and cleaning recommended, especially in dusty conditions.
Spark Plug Replacement:
Refer to manual for mileage/hour interval, typically every 100-200 hours.
Fluid Specifications
Engine Oil Type:
Suzuki recommends specific SAE viscosity grades (e.g., SAE 10W-40 or 20W-50) and API classification (e.g., SG or higher) for air-cooled engines. Refer to manual for precise specification.
Engine Oil Capacity:
Refer to manual for exact capacity, typically around 1.5-2.0 liters with filter change.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Gear Oil Type:
Manual will specify appropriate gear oil for final drive/differential, likely a GL-4 or GL-5 gear oil.