🏷️ Basic Information Identification Make: Suzuki Model: LT-Z400 QuadSport Model Nickname: QuadSport Product Type: Service Repair Workshop Manual Codes Chassis Code: K821 (for first generation) Engine Code: DV41A (common for this generation) 👋 Introduction Market Position Category: High-performance sport ATV Target Audience: Enthusiasts, recreational riders, competitive riders Competitive Analysis Competitors: Yamaha Warrior 350, Honda TRX300EX, Kawasaki KFX400 (shared platform with KFX400 and Arctic Cat DVX400) Key Features Performance Focus: Agile handling, strong power delivery, user-friendly for sport riding Manual Benefit: Empowers owners and technicians to perform all maintenance and repairs, maximizing performance and longevity. 📋 Manual Details Coverage Areas Applicable Model Years: 2003, 2004, 2005, 2006 Models Covered: LT-Z400, LT-Z400X (all variants) Page Count Estimated Page Count: Comprehensive (exact count not specified, described as 'full & complete') Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, assembly, disassembly, troubleshooting, performance tuning Clutch: Wet multi-plate clutch system, maintenance, adjustment, replacement Transmission: Gearbox operation, maintenance, repair, shift mechanism Cooling System: Radiator, fan, coolant, hoses, thermostat, maintenance and repair Fuel System: Carburetor (Mikuni BSR36), fuel pump, fuel lines, tank, troubleshooting Exhaust System: Muffler, header pipe, heat shields, inspection and repair Ignition System: CDI unit, ignition coil, spark plug, timing checks Electrical System: Battery, charging system, lighting, starter motor, switches, fuses Brakes: Hydraulic front and rear brakes, disc calipers, master cylinders, bleeding, pad replacement Wheels And Tires: Tire pressures, wheel bearing maintenance, wheel balancing Steering: Handlebars, steering stem, tie rods, alignment, troubleshooting Suspension: Front and rear shocks, springs, linkage, adjustments, maintenance Frame And Bodywork: Chassis inspection, body panel removal and installation, seat, fenders Wiring Diagrams: Color-coded, detailed electrical system schematics Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment Troubleshooting: Comprehensive fault finding guides, diagnostic procedures for common issues Repair: Step-by-step repair instructions for all covered systems Rebuilds: Engine and transmission rebuild procedures, including specifications Technical Depth Depth: Professional-grade, covering basic maintenance to complete engine/transmission overhauls and advanced diagnostics. 📊 Manual Specifications File Format Compatibility: All Operating Systems (Windows 95, 98, 2000, Me, Xp, Vista, Windows 7, etc., PC & MAC) Print Quality Image Quality: High Quality Pictures & Diagrams Binding Type Binding: Digital Download (PDF) Paper Type Paper Type: Not Applicable (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, DOHC, 4 valves Displacement: 398 cc (24.3 cu. in.) Bore X Stroke: 90.0 mm x 78.3 mm (3.54 in x 3.08 in) Compression Ratio: 11.3:1 Cooling Method: Liquid-cooled Performance Horsepower Approximate: 32 HP (at crankshaft, depending on specific model year and region) Torque Approximate: 24 lb-ft (at crankshaft, depending on specific model year and region) Fuel System Carburetor Type: Mikuni BSR36 CV (Constant Velocity) Fuel Type: Unleaded gasoline Fuel Tank Capacity: 2.9 US gal (11 L) Fuel Pump: Electric 🔧 Transmission Standard Transmission Type: Constant Mesh, 5-speed manual with Reverse Clutch Type: Wet, multi-plate Features Gear Ratios: Specific ratios detailed within the manual for each gear and reverse. Final Drive: O-ring sealed chain, 520 pitch Transmission Fluid Type: SAE 10W-40 API SE, SG or SH (refer to manual for precise specification and capacity) 📐 Dimensions Exterior Overall Length: 70.9 in (1800 mm) Overall Width: 45.1 in (1145 mm) Overall Height: 43.1 in (1095 mm) Wheelbase: 49.0 in (1245 mm) Ground Clearance: 10.2 in (260 mm) Weights Dry Weight: 370 lbs (168 kg) Curb Weight: Not specified, but generally higher than dry weight due to fluids. 🛡️ Safety Features Ratings Atv Safety Considerations: While not subject to automotive crash ratings, the manual covers safety precautions for operation and maintenance. Active Features Braking System: Dual hydraulic disc front, single hydraulic disc rear Lighting: Halogen headlights, taillight/brake light Passive Features Frame Construction: Steel frame designed for torsional rigidity and rider support 💡 Technology Features Infotainment Infotainment System: Not applicable to this sport ATV; focus is on mechanical and operational technology. Driver Assistance Electronic Aids: None (designed for direct rider control, no electronic stability control or ABS). Connectivity Connectivity Features: Not applicable. Performance Enhancements Tuning Potential: The manual provides the foundational knowledge for understanding engine performance and potential for modifications. 🔧 Maintenance Service Intervals Engine Oil Change: Every 30 hours or 6 months (whichever comes first); more frequently under severe use. Air Filter Cleaning: Every 10 hours of use, or more often in dusty conditions. Spark Plug Inspection: Every 100 hours of use. Chain Adjustment: Every 20 hours of use, or as needed to maintain proper slack. Fluid Specifications Engine Oil Type: SAE 10W-40, API SE, SG, or SH (refer to manual for specific viscosity under different temperature ranges) Coolant Type: High-quality ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio recommended). Brake Fluid Type: DOT 3 or DOT 4 hydraulic brake fluid. Known Issues Carburetor Performance: Can be prone to clogging from debris; proper fuel filtration and cleaning are important....