Basic Information Identification Make: Suzuki Model: LT-Z400 QuadSport Product Type: ATV Repair Manual Generation Generation Designation: First Generation (Kodiak/Quadsport Platform) Introduction Market Position Market Position: The Suzuki LT-Z400 QuadSport was a highly popular and influential sport ATV in its segment, known for its performance, handling, and reliability. This manual targets owners and technicians working on these performance-oriented machines. Competitive Analysis Competitive Analysis: Competed directly with models like the Yamaha YFZ450 and Kawasaki KFX400 (which shared the same basic platform). The manual's comprehensive nature provides a significant advantage for DIY maintenance and repair against competitors. Key Features Key Features: Digital accessibility for on-trail repairs, lifetime replacement policy for lost/damaged files, and broad coverage across six model years and all versions of the LT-Z400. Manual Details Coverage Areas Vehicle Years: 2003, 2004, 2005, 2006, 2007, 2008 Vehicle Variants Covered: All versions of the Suzuki LT-Z400 QuadSport ATV Page Count Estimated Page Count: Variable (typical for comprehensive repair manuals in this era, estimate 300-500 pages) Manual Type Manual Type: Comprehensive Service/Repair Manual (includes owner's manual aspects and parts catalog information) Language Language: English Format Format: Digital Downloadable PDF Manual Coverage Systems Covered Engine System: Yes (General Information, Engine Removal/Installation, Engine Specifications, Intake & Exhaust, Fuel System, Lubrication & Cooling) Drivetrain System: Yes (Transmission, Drive Chain & Sprockets) Suspension System: Yes (Shocks - likely includes front and rear suspension, adjustments, and maintenance) Steering System Steering System: Yes (Steering System components, maintenance, and troubleshooting) Electrical System Electrical System: Yes (Electrical System, including wiring diagrams, component testing, and troubleshooting) Bodywork Chassis Bodywork Chassis: Yes (Body Work, likely covering plastic panels, frame, and mounting components) Procedures Included Maintenance Procedures: Yes (Routine Maintenance, including fluid changes, filter replacements, lubrication, and adjustments) Repair Procedures: Yes (Engine Overhaul, component replacement, transmission service, etc.) Troubleshooting Procedures: Yes (Advanced Troubleshooting, diagnosing common and complex issues) Technical Depth Technical Depth: Comprehensive (from basic maintenance and adjustments to complete engine rebuilds and advanced electrical diagnostics) Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for printing individual pages as needed. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Engine Specifications Primary Engine Engine Type: 4-stroke, DOHC, 4-valve, Liquid-Cooled, Single-Cylinder Engine Displacement: 398 cc (24.3 cu. in.) Bore X Stroke: 90.0 mm x 77.0 mm (3.54 in. x 3.03 in.) Compression Ratio: 11.3:1 Carburetion: Mikuni BSR36, single Performance Estimated Horsepower: Approximately 33-38 HP (varies slightly by year and specific tuning) Estimated Torque: Approximately 25-28 lb-ft Fuel System Fuel Type: Unleaded Gasoline Fuel Tank Capacity: 2.9 US gallons (11 liters) Lubrication Cooling Cooling System: Liquid-cooled Engine Oil Type Spec: SAE 10W-40 API SG or higher (check manual for exact specifications) Transmission Standard Transmission Type: 5-speed manual with Reverse Clutch Type: Wet multi-plate Final Drive: O-ring sealed chain, 520 pitch Features Transmission Features: Internal gear type, single stage reduction Dimensions Exterior Overall Length: 70.5 in (1790 mm) Overall Width: 45.1 in (1145 mm) Overall Height: 42.3 in (1075 mm) Wheelbase: 49.2 in (1250 mm) Weights Dry Weight: Approximately 370-380 lbs (168-172 kg) Curb Weight: Not officially specified, but typically around 400-410 lbs with fluids. Ground Clearance: 10.2 in (259 mm) Safety Features Ratings Safety Ratings: N/A for ATVs in the traditional automotive sense; focus on design safety and handling characteristics. Active Features Braking System: Hydraulic disc brakes front and rear. Front: Dual disc. Rear: Single disc. Parking Brake: Mechanical drum or disc type, typically operated via lever. Passive Features Chassis Design: Steel frame, designed for stability and rider control. Tire Specifications: Front: AT21x7-10. Rear: AT20x10-9 (typical sizes, manual will confirm specific requirements). Technology Features Infotainment Infotainment System: N/A (Basic ATV design, no complex infotainment) Driver Assistance Driver Assistance: N/A (Focus on mechanical systems and rider input) Connectivity Connectivity: N/A Maintenance Service Intervals Oil Change Interval: Every 1,000 miles or 6 months (refer to manual for precise interval and conditions) Air Filter Cleaning: Every 300 miles or as needed in dusty conditions (refer to manual) Spark Plug Replacement: Refer to manual for recommended mileage, typically every 3,000-5,000 miles. Valve Clearance Check: Refer to manual for specific mileage, often around 2,000-3,000 miles. Fluid Specifications Coolant Type: Permanent type antifreeze (ethylene glycol based), 50/50 mix with distilled water. (Confirm specific Suzuki coolant recommendation in manual) Brake Fluid Type: DOT 3 or DOT 4 Hydraulic Brake Fluid (refer to manual for exact specification). Known Issues Common Issues: Carburetor jetting for altitude/modifications, oil leaks from crankshaft seals, stator failure, occasional starter clutch issues, and chain/sprocket wear are common for this model. The manual will provide diagnostic procedures. Vehicle History Brand Heritage Brand Heritage: Suzuki has a long-standing reputation in powersports, with a history of producing reliable and performance-oriented motorcycles and ATVs. Model Evolution Model Evolution: The LT-Z400 was a significant model for Suzuki, establishing them firmly in the sport ATV market. It...