The Suzuki LT-Z400 QuadSport is a highly regarded sport/recreational ATV, known for its reliable and potent 398 cc engine, agile handling, and user-friendly nature. Produced for the 2009 and 2010 model years, this 4-stroke, single-cylinder machine offers an engaging riding experience for enthusiast riders and recreational off-roaders. Its design prioritizes performance and maneuverability, making it a popular choice in a competitive segment. The LT-Z400 is built upon Suzuki's extensive ATV heritage, reflecting a commitment to engineering quality and rider enjoyment. This comprehensive Factory Service Repair Manual provides detailed information for the maintenance, repair, and troubleshooting of the 2009 and 2010 Suzuki LT-Z400 QuadSport. It covers all essential systems, including engine mechanicals, fuel, ignition, transmission, cooling, brakes, suspension, steering, and the electrical system. The manual includes regular maintenance schedules, step-by-step repair procedures with torque specifications, diagnostic guides, and complete wiring diagrams. This resource is designed to assist owners, mechanics, and technicians in effectively maintaining and repairing the vehicle, ensuring its optimal performance and longevity. 🏷️ Basic Information Identification Make: Suzuki Model: LT-Z400 QuadSport Year: 2009, 2010 Product Name: Suzuki LT-Z400 QuadSport 2009 2010 Factory Service Repair Manual Download PDF Codes Chassis Code: K7, K8 (common designations for these model years) 👋 Introduction Market Position Quad Segment: Sport/Recreational ATV Target Audience: Enthusiast riders, recreational off-roaders, trail riders. Competitive Analysis Key Competitors: Yamaha Raptor 350/660, Honda TRX400EX/TRX450R, Kawasaki KFX400/KFX450R. Key Features Vehicle Reputation: Known for its reliable and punchy engine, agile handling, and user-friendly nature, making it a popular choice for both novice and experienced riders. 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual / Repair Manual Language: English Format: PDF Download Models Covered: Suzuki LT-Z400 QuadSport 2009, Suzuki LT-Z400 QuadSport 2010 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, inspection, tuning, timing, valves, piston, crankshaft, connecting rod, cylinder head, cylinder block, lubrication system. Fuel System: Carburetor service (cleaning, adjustment, rebuilding), fuel pump, fuel filter, fuel tank. Ignition System: Ignition coil, CDI unit, spark plug, timing. Transmission Drivetrain: Clutch inspection and replacement, gearbox disassembly and assembly, final drive, chain drive, drive shaft maintenance. Cooling System: Radiator, fan, hoses, thermostat, coolant flush and replacement. Brake System: Hydraulic brake system, caliper overhaul, master cylinder, brake lines, brake pads, brake fluid flush, parking brake. Suspension Steering: Front and rear suspension components, shocks, springs, linkages, steering system, tie rods, ball joints, wheel alignment. Electrical System: Wiring diagrams, battery, charging system (stator, rectifier/regulator), starter motor, lighting, switches, fuses, relays. Frame Bodywork: Frame inspection, body panel removal and installation, seat, handlebars, footpegs, fenders. Procedures Included Maintenance Schedule: Regular service intervals for oil changes, filter replacements, chain lubrication, spark plug checks, brake inspections, and valve clearance checks. Troubleshooting Guides: Diagnostic procedures for common issues, symptom-based troubleshooting charts, error code explanations (if applicable). Repair Procedures: Step-by-step instructions for component removal, installation, disassembly, and reassembly with torque specifications. Rebuild Procedures: Detailed instructions for overhauling major components like the engine and transmission. Wiring Diagrams: Complete electrical schematics for fault finding and component identification. Technical Depth Depth Level: Comprehensive (from basic maintenance to complete engine/transmission rebuilds and diagnostics) 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Text-searchable (allowing quick keyword lookups) Printability: Printable (allows users to print specific sections or the entire manual) Resolution: High-resolution for clear diagrams and images Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Single-cylinder, DOHC, 4-valve Displacement: 398 cc (24.3 cu. in.) Bore X Stroke: 90.0 mm x 73.8 mm (3.54 in. x 2.91 in.) Compression Ratio: 11.3:1 Performance Horse Power: Approximately 35-40 HP (varies by tune and specific market regulations) Torque: Approximately 25-28 lb-ft (varies by tune and specific market regulations) Fuel System Fuel Delivery: Mikuni BSR36 carburetor Fuel Type: Unleaded gasoline Fuel Tank Capacity: 2.6 US gal (10 L) Lubrication System Oil Type: Suzuki Performance 4-stroke Engine Oil (10W-40 recommended, check manual for specific API/JASO rating) Oil Capacity: Approx. 1.7 L (1.8 US qt) without filter change, 1.9 L (2.0 US qt) with filter change. Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: 5-speed manual with Reverse Clutch Type: Wet multi-plate Features Drive System: Chain drive, 2WD Fluid Type Transmission Oil Type: Suzuki Gear Oil (check manual for specific viscosity grade, e.g., 80W-90 GL-5 recommended) Fluid Capacity Transmission Oil Capacity: Approx. 0.6 L (0.63 US qt) 📐 Dimensions Exterior Overall Length: 70.9 inches (1800 mm) Overall Width: 46.1 inches (1170 mm) Overall Height: 44.1 inches (1120 mm) Wheelbase: 49.2 inches (1250 mm) Ground Clearance: 4.4 inches (112 mm) Weights Dry Weight: Approximately 397 lbs (180 kg) Curb Weight: Approximately 423 lbs (192 kg) (with all fluids) Cargo Front Rack Capacity: N/A (typically not specified for this model, focus is on rider and maneuverability) Rear Rack Capacity: N/A (typically not specified for this model) 🛡️ Safety...