🏷️ 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 Features Ratings Atv Safety Considerations: Designed for recreational off-road use. Operator training and protective gear (helmet, eye protection, gloves, boots, long sleeves/pants) are mandatory. Active Features Braking System: Hydraulic disc brakes front and rear. Parking Brake: Mechanical disc brake on rear axle, operated by hand lever. Passive Features Frame Construction: High-tensile steel frame for rigidity and durability. 💡 Technology Features Infotainment Instrumentation: Digital LCD display with speedometer, odometer, trip meter, clock, and indicator lights. Analog tachometer. Driver Assistance Electronic Aids: None (designed as a pure mechanical sport ATV). 🔧 Maintenance Service Intervals Engine Oil Change: Every 1000 km (620 miles) or 6 months, whichever comes first. Also recommended after severe use. Oil Filter Replacement: At every engine oil change. Air Filter Cleaning: Every 200 km (125 miles) or monthly, clean and re-oil. Replacement as needed. Spark Plug Inspection: Every 1000 km (620 miles). Valve Clearance Check: Every 2000 km (1250 miles) or 12 months. Chain Lubrication Adjustment: Every 200 km (125 miles) or...