🏷️ Basic Information Identification Make: Suzuki Model: LT-Z400 QuadSport Product Type: Service Repair Manual Product Format: PDF Download Codes Applicable Model Years: 2003-2006 👋 Introduction Market Position Vehicle Class: Sport ATV / Quad Bike Target Audience: Enthusiasts, recreational riders, mechanics Competitive Analysis Competitors: Yamaha Raptor 350/660, Honda TRX400EX, Kawasaki KSF400 KFX Key Features Vehicle Reputation: Known for its sporty handling, reliable engine, and versatility for trail riding and light racing. Manual Value Proposition: Provides essential information for owners to perform routine maintenance and complex repairs, saving time and money. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance, Rebuild, Refurbishment, Restoration Vehicle Systems: Engine, Drivetrain, Chassis, Electrical System, Bodywork Page Count Estimated Pages: Hundreds Manual Type Type: Comprehensive Service and Repair Manual Language Language: English Format Digital Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine overhaul, cylinder head, piston, crankshaft, camshaft, valve train, timing components, lubrication system, cooling system. Fuel System: Carburetor assembly and tuning, fuel tank, fuel lines, fuel pump (if applicable). Ignition System: CDI unit, ignition coil, spark plug, wiring diagrams. Transmission Drivetrain: Clutch operation and adjustment, gearbox disassembly and assembly, chain and sprocket maintenance, drive shaft/axle inspection. Suspension Steering: Front and rear suspension components, shock absorbers, steering linkage, tie rods, wheel bearings. Braking System: Hydraulic brake systems (front and rear), brake calipers, master cylinders, brake pads, brake fluid specifications and bleeding procedures. Electrical System: Wiring diagrams, lighting systems, battery, starter motor, charging system, electrical component testing. Bodywork Frame: Body panel removal and installation, frame inspection, seat, handlebars, footpegs, fenders. Procedures Included Maintenance: Regular servicing, oil changes, filter replacements, chain lubrication and adjustment, tire pressure checks, battery maintenance. Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for all major vehicle components. Rebuild Refurbishment: Detailed instructions for complete engine, transmission, and suspension rebuilds. Technical Depth Diagnostic Level: Advanced diagnostic procedures, including torque specifications, clearances, and electrical testing parameters. Rebuild Detail: Comprehensive overhaul instructions with exploded diagrams and part identification. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes (typically, depending on source scan quality) Print Quality Readability: High (designed for clear viewing and printing) Binding Type Digital Binding: N/A (Digital PDF) Paper Type Digital Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, Single Cylinder Engine Displacement: 398cc (approximately) Bore X Stroke: 85.0 mm x 70.0 mm (typical for this generation) Compression Ratio: 9.3:1 (typical) Cooling System: Liquid-cooled Valve Configuration: SOHC, 4 valves Performance Horsepower: Approximately 30-35 HP (estimated, actual varies with tune and emissions equipment) Torque: Approximately 25-30 lb-ft (estimated) Fuel System Carburetor: Mikuni BSR36 (typical), single carburetor Fuel Type: Unleaded gasoline Oil Specifications Engine Oil Type: API SE, SF, SG, SH, SJ or higher, SAE 10W-40 Engine Oil Capacity: Approx. 1.7 L (1.8 US qt) without filter change; Approx. 1.9 L (2.0 US qt) with filter change. 🔧 Transmission Standard Transmission Type: 5-speed manual with reverse Optional Optional Transmission: N/A Features Clutch Type: Wet, multi-plate Final Drive: O-ring sealed chain Fluid Specifications Transmission Fluid Type: API GL-4 SAE 80W or 90W gear oil Transmission Fluid Capacity: Approx. 0.8 L (0.85 US qt) 📐 Dimensions Exterior Length: Approx. 1850 mm (72.8 in) Width: Approx. 1165 mm (45.9 in) Height: Approx. 1160 mm (45.7 in) Wheelbase: Approx. 1275 mm (50.2 in) Weights Dry Weight: Approx. 190 kg (419 lbs) Tires Front Tire Size: AT22x7-10 Rear Tire Size: AT20x10-9 Wheels Wheel Bolt Pattern: N/A (Hub-centric) 🛡️ Safety Features Ratings Safety Ratings Certification: N/A (ATV classification) Active Features Braking System Type: Hydraulic disc brakes front and rear Parking Brake: Yes (typically lever-actuated on rear caliper or transmission) Passive Features Handlebars: Standard padded handlebars with thumb throttle Footpegs: Wide footpegs with heel guards 💡 Technology Features Infotainment Infotainment System: N/A (Basic vehicle controls, no digital display) Driver Assistance Driver Assistance Features: N/A Connectivity Connectivity Options: N/A 🔧 Maintenance Service Intervals Engine Oil Change Interval: Every 1000 km (620 miles) or 6 months, whichever comes first. Air Filter Cleaning: Every 500 km (310 miles) or annually. Spark Plug Replacement: Every 5000 km (3100 miles) or 2 years. Chain Adjustment: Every 500 km (310 miles) or as needed. Fluid Specifications Brake Fluid Type: DOT 3 or DOT 4. Coolant Type: Suzuki Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors). Known Issues Common Wear Items: Clutch plates, wheel bearings, chain and sprockets, front-end suspension components (bushings, ball joints) due to off-road use. Carburetor Tuning: May require periodic adjustment or cleaning due to fuel quality and usage. Engine Vibrations: Standard for single-cylinder engines; proper maintenance mitigates excessive vibration. 📚 Vehicle History Brand Heritage Manufacturer: Suzuki Motor Corporation Heritage Focus: Strong history in motorcycles, ATVs, and off-road vehicles. Model Evolution Predecessor: Suzuki LT-F400F (4x2 model), LT-Z250 (smaller displacement) Successor: Suzuki LT-Z400 (later revisions and minor updates)...