2003 Suzuki LTZ400 K3 Service Manual
LTZ400 service documentation with complete engine, transmission, cooling, fuel, and chassis procedures. Includes valve clearance adjustment, carburetor tuning, suspension maintenance, and brake system specifications.
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Models Covered & Key Technical Specifications
Suzuki LTZ400 K3 — 2003 Precision Engineering Vault | LTZ400 Series Repository.
- Reference Native Resolution: 398 cm³ (24.3 cu.in) is set to the engine piston displacement Architecture.
- Approved Clamp Forces: The compression ratio is standardized to 7.5:1 for combustion chamber pressure Baseline.
- Designated Fluid Levels: Fuel tank capacity reaches 10.0 L (2.6 US/2.2 imp gal) Parameters.
- Certified Wattage Specs: Engine oil capacity corresponds to 2.0 L (2.1 US/1.8 imp qt) Threshold.
- Factory Cold Start Limits: Engine coolant volume is established at 1.2 L (1.3/1.1 US/imp qt) Mapping.
- Fundamental Scan Resolution: For electrical system reliability, 12 V 26.8 kC (8 Ah/10 HR) yields the battery storage capacity Configuration.
Professional Workshop Service Manual & Technical Specifications
Multi-System undefined Workshop Manual: 2003 Suzuki LTZ400 K3 Quadsport Blueprint-Vault
Serial-Range: Suzuki LTZ400 K3 (2003 models) // Series-Validation: Complete ATV Service and Operations Logic // Serial-Range: Comprehensive mechanical systems documentation with factory-level specifications.
| Scope | Depth | Reference Materials |
|---|---|---|
| Periodic Maintenance Systems | Complete interval schedules and procedures | Maintenance charts with 2-year service timelines |
| Engine and Transmission Architecture | Full disassembly protocols and component specifications | Exploded diagrams with journal clearances documented |
| Brake and Suspension Technology | Comprehensive bleeding and adjustment procedures | Complete torque specifications for all fasteners |
Technical content addresses the periodic maintenance schedule, engine specification data, and component service requirements. The document encompasses steering system documentation for alignment procedures, fuel system inspection guidelines for carburetor cleaning and adjustment, and alignment specifications for toe-in measurements. Reference data is included for brake fluid capacity and cooling system circuit inspection methods. This manual covers the cylinder head assembly, crankshaft and camshaft servicing, clutch operation principles, and transmission gear arrangement. Inspection guidelines are provided for piston ring clearance, valve spring tension measurement, and bearing wear assessment.
Systematic Methodology
Methodically requiring careful attention to measurement standards, the manual documents compression pressure specifications for the liquid-cooled engine. Exhaust system component data is presented with fastener torque references for muffler and pipe mounting. The document includes wiring diagrams for the electrical charging system, cooling fan thermostat circuit, and ignition timing specifications. Factory specifications reference engine idle speed, spark plug gap clearance, and throttle cable adjustment ranges. Complete information covers fuel tank capacity, engine oil viscosity ratings, and antifreeze mixture percentages for the aluminum radiator cooling system.
Comprehensive Topology
Inspection procedures are documented for drive chain slack measurement and rear wheel suspension geometry. The document presents technical specifications for front and rear brake disc thickness, brake fluid DOT 4 classification, and brake caliper piston seal material requirements. Reference materials include illustrations of tappet shim selection tables for valve clearance adjustment and tables showing piston ring gap specifications. The manual provides detailed procedures for wheel hub bearing removal and installation using specialized tools, along with dust seal application points and steering shaft bushing replacement protocols.
Operational Sequences
Alignment specifications are included for steering geometry, including caster angle and turning radius data. Reference data is included for carburetor specifications including main jet sizing, float height measurements, and needle jet positioning. The document includes detailed component listings for suspension springs, shock absorber mounting points, and tie rod end adjustment procedures. Technical specifications document the transmission gear ratio selection for forward and reverse gearing, along with primary reduction ratio and final drive reduction specifications.
Core Parameters
Reference data is included for battery capacity (26.8 Ah), main fuse amperage (20A), and charging circuit specifications. The manual documents torque specifications for the engine sprocket bolt assembly and cylinder head bolt tightening sequences with specified initial and final torque values. Wheel set nut specifications and brake caliper mounting bolt torque values are included throughout the document. The cooling system documentation includes engine coolant capacity volumes, radiator hose routing diagrams, and water pump bearing installation depths with specialized tool requirements.
Precise Standard
The document provides torque specifications for the crankshaft assembly to ensure proper shaft support and alignment during engine rebuilding procedures.
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