Suzuki LT-Z400 Manuals

Manuals and User Guides for Suzuki LT-Z400. We have 3 Suzuki LT-Z400 manuals available for free PDF download: Service Manual, Owner's Manual

Suzuki LT-Z400 Service Manual (492 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 32 MB

Section 1 Engine

63
- Table of Contents
  63
- Engine General Information and
  
  69
  - FI System Wiring Diagram
    71
  - Terminal Alignment of ECM Coupler
    72
- Component Location
  
  73
  - FI System Parts Location
    73
- Diagnostic Information and Procedures
  
  74
- Specifications
  
  134
  - Service Data
    134
- Special Tools and Equipment
  
  135
  - Special Tool
    135
- Emission Control Devices
  
  136
- Precautions
  
  136
  - Precautions for Emission Control Devices
    136
- Schematic and Routing Diagram
  
  136
  - Oil Return Tank Hose Routing Diagram
    136
- Repair Instructions
  
  136
- 1C-1 Engine Electrical Devices
  
  138
- Precautions
  
  138
  - Precautions for Engine Electrical Device
    138
- Component Location
  
  138
  - Engine Electrical Components Location
    138
- Diagnostic Information and Procedures
  
  138
  - Engine Symptom Diagnosis
    138
- Repair Instructions
  
  139
  - ECM Removal and Installation
    139
  - CKP Sensor Inspection
    139
  - CKP Sensor Removal and Installation
    139
  - IAT Sensor Inspection
    139
  - IAT Sensor Removal and Installation
    139
- Specifications
  
  144
  - Recommended Service Material
    145
  - Special Tool
    146
- Engine Mechanical
  
  146
- Diagnostic Information and Procedures
  
  146
  - Engine Mechanical Symptom Diagnosis
    146
  - Compression Pressure Check
    146
- Repair Instructions
  
  147
  - Engine Components Removable with the Engine in Place
    147
  - Air Cleaner Element Removal and Installation
    149
  - Air Cleaner Element Cleaning
    149
  - Air Cleaner Box Removal and Installation
    149
  - Throttle Cable Removal and Installation
    150
  - Throttle Cable Inspection
    150
  - Throttle Cable Play Inspection and Adjustment
    150
  - Starter Cable Removal and Installation
    151
  - Throttle Body Components
    152
  - Throttle Body Construction
    153
  - Throttle Body Inspection
    154
  - Throttle Body Removal and Installation
    154
  - Throttle Body Disassembly and Assembly
    155
  - Throttle Body Inspection and Cleaning
    158
  - Engine Assembly Removal
    158
  - Engine Assembly Installation
    161
  - Engine Top Side Disassembly
    162
  - Engine Top Side Assembly
    165
  - Valve Clearance Inspection and Adjustment
    171
  - Camshaft Inspection
    171
  - Cam Chain Tension Adjuster Inspection
    173
  - Cam Chain Guide Removal and Installation
    173
  - Cam Chain Guide Inspection
    173
  - Cam Chain Tensioner Inspection
    174
  - Cylinder Head Disassembly and Assembly
    174
  - Cylinder Head Related Parts Inspection
    178
  - Valve Guide Replacement
    181
  - Valve Seat Repair
    182
  - Cylinder Inspection
    183
  - Piston Ring Removal and Installation
    184
  - Piston and Piston Ring Inspection
    185
  - Engine Bottom Side Disassembly
    186
  - Engine Bottom Side Assembly
    193
  - Oil Sump Filter Inspection
    201
  - Oil Pump Inspection
    201
  - Gearshift Shaft Inspection
    201
  - Conrod and Crankshaft Inspection
    201
  - Balancer Shaft Inspection
    202
  - Crankshaft Bearing / Balancer Shaft Bearing Inspection
    202
  - Crankshaft Bearing / Balancer Shaft Bearing Removal and Installation
    203
  - Crankshaft Oil Seal Inspection
    204
  - Crankshaft Oil Seal Removal and Installation
    204
  - Clutch Release Camshaft Removal and Installation
    204
- Specifications
  
  205
  - Service Data
    205
  - Tightening Torque Specifications
    206
- Special Tools and Equipment
  
  207
  - Recommended Service Material
    207
  - Special Tool
    207
- Engine Lubrication System
  
  211
- Precautions
  
  211
  - Precautions for Engine Oil
    211
- Schematic and Routing Diagram
  
  211
  - Engine Oil Hose and Pipe Routing Diagram
    211
  - Engine Lubrication System Chart Diagram
    212
- Diagnostic Information and Procedures
  
  213
  - Engine Lubrication Symptom Diagnosis
    213
  - Oil Pressure Check
    213
- Repair Instructions
  
  214
  - Engine Oil and Filter Replacement
    214
  - Engine Oil Level Inspection
    214
  - Oil Sump Filter Removal and Installation
    214
  - Oil Sump Filter Inspection and Cleaning
    214
  - Oil Pump Components
    215
  - Oil Pump Removal and Installation
    215
  - Oil Pump Inspection
    216
  - Engine Oil Hose and Pipe Construction
    217
  - Oil Tank Inspection
    218
  - Engine Oil Pipe Removal and Installation
    218
  - Oil Tank Removal and Installation
    219
  - Oil Pipe Removal and Installation
    220
  - Oil Pipe Inspection
    221
- Specifications
  
  221
  - Service Data
    221
  - Tightening Torque Specifications
    221
- Special Tools and Equipment
  
  222
  - Recommended Service Material
    222
  - Special Tool
    222
- Engine Cooling System
  
  223
- Precautions
  
  223
  - Precautions for Engine Cooling System
    223
  - Precautions for Engine Coolant
    223
- General Description
  
  224
  - Engine Coolant Description
    224
- Schematic and Routing Diagram
  
  224
  - Cooling Circuit Diagram
    224
  - Water Hose Routing Diagram
    225
- Diagnostic Information and Procedures
  
  226
  - Engine Cooling Symptom Diagnosis
    226
- Repair Instructions
  
  226
  - Cooling Circuit Inspection
    226
  - Radiator Cap Inspection
    227
  - Radiator Inspection and Cleaning
    227
  - Radiator Removal and Installation
    227
  - Cooling Fan Motor Removal and Installation
    229
  - Water Hose Inspection
    230
  - Radiator Cover Removal and Installation
    230
  - Water Hose Removal and Installation
    230
  - Radiator Reservoir Tank Inspection
    231
  - Radiator Reservoir Tank Removal and Installation
    231
  - Cooling Fan Inspection
    231
  - Cooling Fan Relay Inspection
    232
  - ECT Sensor Removal and Installation
    232
  - ECT Sensor Inspection
    232
  - Engine Coolant Temperature Indicator Inspection
    232
  - Thermostat Removal and Installation
    232
  - Thermostat Inspection
    233
  - Water Pump Components
    234
  - Water Pump Removal and Installation
    235
  - Water Pump Disassembly and Assembly
    236
  - Water Pump Related Parts Inspection
    238
- Specifications
  
  239
  - Service Data
    239
  - Tightening Torque Specifications
    239
- Special Tools and Equipment
  
  240
  - Recommended Service Material
    240
  - Special Tool
    240
- Fuel System
  
  241
- Precautions
  
  241
  - Precautions for Fuel System
    241
- General Description
  
  242
  - Fuel System Description
    242
- Schematic and Routing Diagram
  
  243
  - Fuel Hose Routing Diagram
    243
- Diagnostic Information and Procedures
  
  244
  - Fuel System Diagnosis
    244
- Repair Instructions
  
  245
- Specifications
  
  254
  - Service Data
    254
  - Tightening Torque Specifications
    254
- Special Tools and Equipment
  
  254
  - Special Tool
    254
- Ignition System
  
  255
- Schematic and Routing Diagram
  
  255
  - Ignition System Diagram
    255
  - Ignition System Components Location
    255
- Diagnostic Information and Procedures
  
  256
  - Ignition System Symptom Diagnosis
    256
  - No Spark or Poor Spark
    257
- Repair Instructions
  
  258
- Specifications
  
  262
  - Service Data
    262
  - Tightening Torque Specifications
    262
- Special Tools and Equipment
  
  262
  - Special Tool
    262
- Starting System
  
  263
- Schematic and Routing Diagram
  
  263
  - Starting System Diagram
    263
- Component Location
  
  263
  - Starting System Components Location
    263
- Diagnostic Information and Procedures
  
  263
- Repair Instructions
  
  265
- Specifications
  
  275
  - Service Data
    275
  - Tightening Torque Specifications
    275
- Special Tools and Equipment
  
  276
  - Recommended Service Material
    276
  - Special Tool
    276
- Charging System
  
  277
- Schematic and Routing Diagram
  
  277
  - Charging System Diagram
    277
- Component Location
  
  277
  - Charging System Components Location
    277
- Diagnostic Information and Procedures
  
  277
  - Charging System Symptom Diagnosis
    277
  - Battery Runs down Quickly
    278
Section 2 Suspension

297
- Precautions
  
  298
  - Precautions for Suspension
    298
- Diagnostic Information and Procedures
  
  299
  - Suspension and Wheel Symptom Diagnosis
    299
- Suspension General Diagnosis
  
  299
- Repair Instructions
  
  300
- Front Suspension
  
  300
- Specifications
  
  315
  - Service Data
    315
  - Tightening Torque Specifications
    315
- Special Tools and Equipment
  
  315
  - Recommended Service Material
    315
  - Special Tool
    316
- Rear Suspension
  
  317
- Repair Instructions
  
  317
- Specifications
  
  332
  - Service Data
    332
  - Special Tools and Equipment
    333
    
    Recommended Service Material
    333
    
    Special Tool
    333
- Wheels and Tires
  
  334
- Repair Instructions
  
  334
- Precautions
  
  334
  - Precautions for Wheel and Tire
    334
- Specifications
  
  338
  - Service Data
    338
  - Tightening Torque Specifications
    338
Section 3 Driveline / Axle

339
- Precautions
  
  340
  - Precautions for Driveline / Axle
    340
- Diagnostic Information and Procedures
  
  341
  - Drive Chain and Sprocket Symptom Diagnosis
    341
- Drive Chain / Drive Train / Drive Shaft
  
  341
- Repair Instructions
  
  342
- Specifications
  
  356
  - Service Data
    356
  - Tightening Torque Specifications
    356
- Special Tools and Equipment
  
  357
  - Recommended Service Material
    357
  - Special Tool
    357
Section 4 Brake

359
- Precautions
  
  361
  - Precautions for Brake System
    361
  - Brake Fluid Information
    361
- Brake Control System and Diagnosis
  
  362
- Schematic and Routing Diagram
  
  362
- Diagnostic Information and Procedures
  
  366
  - Brake Symptom Diagnosis
    366
- Repair Instructions
  
  366
- Special Tools and Equipment
  
  382
  - Recommended Service Material
    382
  - Special Tool
    382
- Front Brakes
  
  383
- Repair Instructions
  
  383
  - Front Brake Components
    383
  - Front Brake Pad Inspection
    384
  - Front Brake Pad Replacement
    384
  - Front Brake Caliper Removal and Installation
    385
  - Front Brake Caliper Disassembly and Assembly
    386
  - Front Brake Caliper Parts Inspection
    388
  - Front Brake Disc Removal and Installation
    390
  - Front Brake Disc Inspection
    390
  - Front Brake Disc Cover Inspection
    391
  - Service Data
    391
- Special Tools and Equipment
  
  392
  - Recommended Service Material
    392
  - Special Tool
    392
- Rear Brakes
  
  393
- Repair Instructions
  
  393
- Specifications
  
  402
  - Service Data
    402
  - Tightening Torque Specifications
    403
- Special Tools and Equipment
  
  403
  - Recommended Service Material
    403
  - Special Tool
    403
- Repair Instructions
  
  404
- Parking Brake
  
  404
- Specifications
  
  407
  - Recommended Service Material
    407
- Special Tools and Equipment
  
  407
Section 5 Transmission / Transaxle

409
- Precautions
  
  410
  - Precautions for Transmission / Transaxle
    410
- Diagnostic Information and Procedures
  
  411
  - Manual Transmission Symptom Diagnosis
    411
- Repair Instructions
  
  411
- Manual Transmission
  
  411
- Specifications
  
  429
  - Service Data
    429
  - Tightening Torque Specifications
    429
- Special Tools and Equipment
  
  430
  - Recommended Service Material
    430
  - Special Tool
    430
- Clutch
  
  431
- Diagnostic Information and Procedures
  
  431
  - Clutch System Symptom Diagnosis
    431
- Repair Instructions
  
  431
  - Clutch Lever Position Switch Inspection
    431
  - Clutch Cable Inspection and Adjustment
    432
  - Clutch Cable Removal and Installation
    432
  - Clutch Lever Components
    433
  - Clutch Lever Removal and Installation
    433
  - Clutch Release Camshaft Removal and Installation
    435
  - Clutch Components
    436
  - Clutch Removal
    437
  - Clutch Installation
    439
  - Clutch Parts Inspection
    441
- Precautions
  
  431
  - Precautions for Clutch System
    431
- Specifications
  
  443
  - Service Data
    443
  - Tightening Torque Specifications
    443
- Special Tools and Equipment
  
  444
  - Recommended Service Material
    444
  - Special Tool
    444
Section 6 Steering

445
- Precautions
  
  446
  - Precautions for Steering
    446
- Diagnostic Information and Procedures
  
  447
  - Steering Symptom Diagnosis
    447
- Steering General Diagnosis
  
  447
- Steering / Handlebar
  
  448
- Repair Instructions
  
  448
  - Steering / Handlebars Components
    448
  - Handlebar Construction
    449
  - Handlebars Removal and Installation
    450
  - Handlebars Inspection
    452
  - Steering Shaft / Tie-Rod Removal and Installation
    452
  - Steering Parts Inspection
    457
  - Toe-Out Adjustment
    458
- Specifications
  
  458
  - Service Data
    458
  - Tightening Torque Specifications
    459
- Special Tools and Equipment
  
  459
  - Recommended Service Material
    459
  - Special Tool
    459
Section 9 Body and Accessories

461
- Precautions
  
  462
  - Precautions for Electrical System
    462
- Component Location
  
  462
  - Electrical Components Location
    462
- Schematic and Routing Diagram
  
  463
  - Wiring Diagram
    463
  - Wiring Harness Routing Diagram
    465
- Wiring Systems
  
  463
- Specifications
  
  468
  - Service Data
    468
  - Tightening Torque Specifications
    468
- Lighting Systems
  
  469
- Repair Instructions
  
  469
  - Headlight Components
    469
  - Headlight Removal and Installation
    470
  - Headlight Bulb Replacement
    470
  - Headlight Beam Adjustment
    471
  - Rear Combination Light Components
    471
  - Rear Combination Light Removal and Installation
    472
  - Rear Combination Light Bulb Replacement
    472
  - Dimmer Switch Inspection
    473
- Specifications
  
  473
  - Service Data
    473
- Special Tools and Equipment
  
  473
  - Special Tool
    473
- Combination Meter / Fuel Meter / Horn
  
  474
- Repair Instructions
  
  474
- Special Tools and Equipment
  
  477
  - Special Tool
    477
- Specifications
  
  477
  - Service Data
    477
- Exterior Parts
  
  478
- Repair Instructions
  
  478
- Specifications
  
  485
  - Tightening Torque Specifications
    485
- Special Tools and Equipment
  
  485
  - Recommended Service Material
    485
- Body Structure
  
  486
- Repair Instructions
  
  486
- Specifications
  
  489
  - Tightening Torque Specifications
    489
- Special Tools and Equipment
  
  489
  - Recommended Service Material
    489

Suzuki LT-Z400 Service Manual (304 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 22 MB

General Information 1

3
- Table of Contents
  3
- General Information
  4
  - General Precautions
    4
  - Warning/Caution/Note
    4
  - Fuel and Oil Recommendation
    6
    
    Fuel
    6
    
    Engine Oil
    7
    
    Brake Fluid
    7
    
    Engine Coolant
    7
  - Serial Number Location
    6
  - Suzuki Lt-Z400K3 (2003-Model)
    6
  - BREAK-Ln PROCEDURES
    8
  - Information Labels
    9
  - Specifications
    10
  - Country and Area Codes
    12
Periodic Maintenance

15
- Periodic Maintenance Schedule
  16
  - Periodic Maintenance Chart
    16
- Maintenance and Tune-Up Procedures
  17
  - Air Cleaner
    17
  - Exhaust Pipe Nuts and Muffler Bolts
    18
  - Engine
    18
  - Valve Clearance
    19
  - Spark Plug
    24
  - Fuel Hose
    25
  - Throttle Cable Play
    25
  - Engine Idle Speed
    25
  - Engine Oil and Oil Filter
    26
  - Engine Oil Hoses
    27
  - Engine Coolant
    28
  - Radiator Hoses
    29
  - Spark Arrester
    29
  - Clutch
    30
  - Brakes
    30
  - Brake Fluid
    32
  - Brake Hoses
    34
  - Tires
    34
  - Steering
    35
  - Drive Chain
    36
  - Drive Chain Slack
    37
  - Suspensions
    38
  - Chassis Bolts and Nuts
    39
  - General Lubrication
    42
- Compression Pressure Check
  43
  - Compression Test Procedure
    43
- Oil Pressure Check
  44
  - Oil Pressure Test Procedure
    44
Engine

45
- Engine Components Removable with Engine in Place
  46
  - Engine Left Side
    46
  - Engine Right Side
    46
  - Engine Center
    46
- Engine Removal and Remounting
  47
  - Engine Removal
    47
  - Engine Remounting
    51
- Engine Disassembly
  53
- Engine Components Inspection and Service
  63
  - Cylinder Head
    63
  - Camshaft/Automatic Decompression Assembly
    72
  - Camshaft Runout
    73
  - Cam Chain Tension Adjuster and Tensioner
    74
  - Cylinder
    74
  - Piston and Piston Ring
    75
    
    Piston Diameter
    75
    
    Piston Ring Thickness
    75
  - Conrod
    77
  - Crankshaft
    77
  - Crankshaft Runout
    77
  - Balancer Shaft and Balancer Driven Gear
    78
  - Starter Clutch
    79
  - Starter Torque Limiter
    80
  - Oil Pump
    80
  - Clutch
    81
  - Gearshift Fork and Gear
    82
  - Transmission
    83
  - Crankcase
    86
  - Clutch Cover
    90
- Engine Reassembly
  91
  - Crankshaft
    91
  - Gearshift Cam, Fork and Reverse Lock Shaft
    92
  - Crankcase
    93
  - Starter Clutch and Generator Rotor
    94
  - Primary Drive Gear and Balancer Gear
    95
  - Gearshift Cam Driven Gear
    96
  - Oil Pump
    97
  - Cam Chain
    97
  - Oil Pipe
    97
  - Clutch
    98
  - Neutral Switch
    100
  - Generator Rotor Cover
    100
  - Piston Ring
    101
  - Piston and Cylinder
    102
  - Cylinder Head
    103
  - Camshaft/Automatic Decompression Assembly
    104
  - Cylinder Head Cover
    106
  - Cam Chain Tension Adjuster
    107
Fuel System

108
- Fuel Tank
  109
  - Construction
    109
  - Fuel Line Inspection
    110
  - Removal
    110
  - Remounting
    110
- Fuel Valve
  111
  - Removal and Inspection
    111
  - Fuel Strainer
    111
  - Remounting
    111
- Carburetor
  112
  - Construction
    112
  - Specifications
    113
  - I.D. No. Location
    113
  - Removal
    114
  - Disassembly
    115
  - Cleaning
    119
  - Inspection
    119
  - Reassembly
    120
  - Remounting
    121
Cooling and Lubrication System

122
- Cooling System
  123
  - Description
    123
- Engine Coolant
  124
- Radiator and Hoses
  125
  - Cooling Circuit Inspection
    125
  - Radiator Cap Inspection
    125
  - Radiator Inspection
    125
  - Radiator Hose Inspection
    126
  - Radiator Removal
    126
  - Radiator Remounting
    127
  - Radiator Reservoir Tank
    127
- Cooling Fan
  128
  - Inspection
    128
  - Removal
    128
  - Remounting
    129
- Cooling Fan Thermo-Switch
  130
  - Removal
    130
  - Inspection
    131
  - Installation
    131
- Engine Coolant Temperature Switch
  132
  - Removal
    132
  - Inspection
    132
  - Installation
    132
- Thermostat
  133
  - Removal
    133
  - Inspection
    133
  - Installation
    133
- Water Pump
  134
  - Construction
    134
  - Removal and Disassembly
    135
  - Inspection
    137
  - Reassembly and Installation
    138
- Oil Tank and Hoses
  142
  - Construction
    142
  - Removal
    143
  - Remounting
    144
- Lubrication System
  145
  - Oil Pressure
    145
  - Oil Filter
    145
  - Oil Sump Filter
    145
  - Oil Pump
    145
  - Engine Lubrication System Chart
    146
Chassis

147
- Exterior Parts
  149
  - Construction
    149
  - Removal
    151
  - Remounting
    155
- Front and Rear Wheels
  156
  - Construction
    156
  - Removal
    157
  - Inspection and Disassembly
    158
  - Reassembly and Remounting
    159
- Tires
  162
  - Tire Replacement
    162
- Front Brake
  164
  - Construction
    164
  - Brake Pad Replacement
    165
  - Brake Fluid Replacement
    166
  - Brake Caliper Removal and Disassembly
    166
  - Brake Caliper Inspection
    168
  - Brake Caliper Reassembly and Remounting
    169
  - Brake Disc Removal and Disassembly
    171
  - Brake Disc Inspection
    171
  - Brake Disc Reassembly and Remounting
    171
  - Master Cylinder Removal and Disassembly
    172
  - Master Cylinder Inspection
    173
  - Master Cylinder Reassembly and Remounting
    173
- Front Suspension
  175
  - Construction
    175
  - Removal
    176
  - Inspection and Disassembly
    177
  - Reassembly and Remounting
    180
  - Suspension Setting
    183
- Steering
  184
  - Construction
    184
  - Removal
    185
  - Inspection and Disassembly
    188
  - Reassembly and Remounting
    190
  - Toe-In Adjustment
    194
- Front Wheel, Front Brake, Front Suspension and Steering Reassembling Information
  195
- Rear Brake
  196
  - Construction
    196
  - Brake Pad Replacement
    197
  - Brake Fluid Replacement
    198
  - Brake Caliper Removal and Disassembly
    199
  - Brake Caliper Inspection
    201
  - Brake Caliper Reassembly and Remounting
    202
  - Brake Disc Removal and Remounting
    205
  - Brake Disc Inspection
    205
  - Master Cylinder Removal and Disassembly
    206
  - Master Cylinder Inspection
    207
  - Master Cylinder Reassembly and Remounting
    208
- Rear Shock Absorber
  209
  - Construction
    209
  - Removal
    209
  - Inspection
    211
  - Rear Shock Absorber Disposal
    211
  - Remounting
    212
  - Suspension Setting
    212
- Rear Suspension
  214
  - Construction
    214
  - Removal
    215
  - Inspection and Disassembly
    217
  - Reassembly
    221
  - Remounting
    224
- Rear Axle
  226
  - Construction
    226
  - Removal
    227
  - Inspection and Disassembly
    228
  - Reassembly and Remounting
    230
- Rear Wheel, Rear Brake, Rear Suspension, Rear Swingarm and Rear Axle Shaft Reassembling Information
  236
- Reverse Lock Release Cable
  238
  - Removal
    238
  - Remounting
    239
Electrical System

241
- Cautions in Servicing
  242
  - Connectors
    242
  - Couplers
    242
  - Clamps
    242
  - Fuses
    242
  - Semi-Conductor Equipped Parts
    242
  - Battery
    243
  - Connecting the Battery
    243
  - Wiring Procedure
    243
  - Using the Multi Circuit Tester
    243
- Location of Electrical Components
  244
- Charging System
  246
  - Troubleshooting
    246
  - Inspection
    248
- Starter System
  251
  - Troubleshooting
    251
  - Starter Motor Removal and Disassembly
    252
  - Starter Motor Inspection
    253
  - Starter Motor Reassembly and Remounting
    254
  - Starter Relay Inspection
    255
- Ignition System
  257
  - Troubleshooting
    257
  - Inspection
    259
- Indicator Light Position
  262
  - Inspection
    262
- Lamps
  263
  - Headlight
    263
  - Brake Light/Taillight
    264
- Switches
  265
- Battery
  266
  - Specifications
    266
  - Initial Charging
    266
  - Servicing
    268
  - Recharging Operation
    268
Servicing Information

269
- Troubleshooting
  270
  - Engine
    270
  - Radiator
    273
  - Carburetor
    273
  - Chassis
    274
  - Brakes
    275
  - Electrical
    276
  - Battery
    277
- Wiring Diagram
  278
- Wiring Harness, Cable and Hose Routing
  279
  - Wiring Harness Routing
    279
  - Cable Routing
    281
  - Fuel Hose Routing
    283
  - Engine Oil Hose and Pipe Routing
    284
  - Cooling System Hose Routing
    286
  - Front Brake Hose Routing
    287
  - Rear Brake Hose Routing
    288
- Seat Rail and Chain Roller Installation
  289
- Special Tools
  290
- Tightening Torque
  293
  - Engine
    293
  - Chassis
    294
  - Tightening Torque Chart
    295
- Service Data
  296
  - Tire Pressure
    302

Suzuki LT-Z400 Owner's Manual (111 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 1 MB

Table of Contents

8
- Fuel and Engine Oil Recommendation
  10
Controls, Equipment and Adjustments

14
- Location of Parts
  15
- Ignition Switch
  18
- Key
  18
- Indicator Lights
  19
- Gearshift Lever
  20
- Reverse Selection Knob
  20
- Left Handlebar
  21
- Choke Lever
  22
- Right Handlebar
  22
- Fuel Valve
  23
- Rear Brake Pedal
  23
- Throttle Limiter
  23
- Fuel Tank Cap
  24
- Flag Bracket
  26
- Seat Lock
  26
- Front Suspension
  27
- Rear Suspension
  28
Riding Your Atv

30
- What You Should Know before Riding
  31
- Inspection before Riding
  32
- What to Wear
  34
- Break-In
  35
- Starting the Engine
  36
- Starting off and Shifting
  37
- Braking
  42
- Parking
  42
- Turning
  43
- Operation on Hills
  44
- Skidding or Sliding
  44
- Riding over Obstacles
  48
- Riding through Water
  48
- Riding in Cold Weather
  49
- Riding in Reverse
  52
- Accessory Use and Vehicle Loading
  54
Inspection and Maintenance

56
- Maintenance Schedule
  57
- Battery
  59
- Tool
  59
- Spark Plug
  60
- Idle Speed Adjustment
  61
- Choke Cable Adjustment
  62
- Fuel Hose
  62
- Throttle Cable Adjustment
  62
- Engine Oil
  63
- Air Cleaner
  67
- Air Cleaner Drain Tube
  70
- Clutch Adjustment
  71
- Drive Chain
  71
- Engine Coolant
  74
- Tires
  75
- Brakes
  77
- Parking Brake Adjustment
  80
- Front and Rear Wheel Removal
  81
- Spark Arrester
  82
- Light Bulb Replacement
  83
- Fuse
  84
- General Lubrication
  85
- Troubleshooting
  86
- Preparation for Winter Riding
  90
- Transporting
  92
Cleaning Procedure

96
- Preparation for Cleaning
  97
- Washing Your Atv
  98
- Inspection after Cleaning
  99
- Storage Procedure
  99
- Maintenance During Storage
  100
- Procedure for Returning to Service
  100
- Consumer Information
  102
- Specifications
  107

Suzuki Categories

Motorcycle Automobile Motorcycle Accessories Outboard Motor Offroad Vehicle

More Suzuki Manuals

Suzuki LT-Z400 Manuals

Suzuki LT-Z400 Service Manual (492 pages)

Table of Contents

Section 1 Engine

Engine General Information and

Component Location

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Emission Control Devices

Precautions

Schematic and Routing Diagram

Repair Instructions

1C-1 Engine Electrical Devices

Precautions

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Engine Mechanical

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Lubrication System

Precautions

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Cooling System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Fuel System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Ignition System

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Starting System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Charging System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Section 2 Suspension

Precautions

Diagnostic Information and Procedures

Suspension General Diagnosis

Repair Instructions

Front Suspension

Specifications

Special Tools and Equipment

Rear Suspension

Repair Instructions

Specifications

Wheels and Tires

Repair Instructions

Precautions

Specifications

Section 3 Driveline / Axle