The LT-Z400 QuadSport is a high-performance sport ATV renowned for its agility, power, and handling. Introduced by the company, this model has a strong motorsports legacy and was developed to compete in the growing sport ATV market. Designed for enthusiasts, recreational riders, and racers, the LT-Z400 is a testament to the company's engineering quality, offering a robust 398cc liquid-cooled engine with a 5-speed manual transmission and reverse. Its agile chassis, featuring independent front suspension and a swingarm rear, combined with powerful hydraulic disc brakes, ensures a thrilling and controlled riding experience. This comprehensive service and repair manual provides detailed instructions for maintaining and repairing the LT-Z400 QuadSport for the model years 2003 through 2006. It covers all essential systems, including the powertrain, chassis, electrical system, fuel system, and cooling system, with in-depth procedures for disassembly, assembly, maintenance, and troubleshooting. This documentation offers accuracy and completeness, empowering owners and technicians with the knowledge to perform everything from basic service checks and oil changes to complete engine rebuilds and electrical diagnostics, ensuring optimal performance and longevity. 🏷️ 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:...