2003-2008 Suzuki LT-Z400 Quadsport 400 Service Manual
Suzuki LT-Z400 troubleshooting and repair reference guide covering 2003-2008 models. Includes detailed procedures and part numbers for maintenance, engine, and chassis systems.
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Sample pages from the 2003-2008 Suzuki LT-Z400 Quadsport 400 Service Manual manual
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Suzuki Models Covered & Key Technical Specifications
Models: Suzuki LT-Z400
Sub-models / Variants: K3 (2003 model)
Build Years: 2003–2008
Serial Numbers: C4085-91017
Technical Data:
- Engine displacement: 398 cc
- Engine type: Four-stroke, liquid-cooled, DOHC, single-cylinder
- Bore and stroke: 90.0 mm x 62.6 mm
- Compression ratio: 11.3:1
- Carburetor: MIKUNI BSR36 SS
- Transmission: 5-forward and 1-reverse
- Dry mass: 169 kg
- Ignition type: Electronic CDI
- Spark plug: NGK CR7E or DENSO U22ESR-N
- Engine oil capacity (oil and filter change): 2.1 liters
- Coolant capacity: 1.2 liters
- Idle speed: 1500 +/- 100 r/min
- Tire size (front): AT22 x 7 R10
- Tire size (rear): AT20 x 10 R9
Suzuki Manual Features & Content Preview
2003–2008 Suzuki LT-Z400 Service Manual
- Covers 2003–2008 Suzuki LT-Z400 Quadsport all-terrain vehicles, detailing engine, chassis, electrical, and drivetrain service specifications
- Original OEM publication C4085-91017, documenting the LT-Z400K3 series and subsequent annual carryover models
- Includes 32 detailed torque-value tables for major assembly bolts, 5 comprehensive electrical wiring and circuit diagrams, and 8 exploded-view engine component schematics
- Delivered as a direct download the moment payment clears
- Indexed PDF search covers every chapter and appendix
- Stored against your account so you can retrieve it after a hard-drive loss
- This 302-page reference is the factory manual for the Quadsport 400, providing the specific assembly and inspection data required for the DOHC single-cylinder engine rebuild
Engine and Maintenance Overview
The 2003–2008 Suzuki LT-Z400 service manual provides exhaustive documentation for the maintenance and repair of the Quadsport 400 powertrain and chassis. Chapters categorize tasks from engine removal to complete internal inspection, covering the liquid-cooled DOHC engine, cylinder head, piston assembly, and transmission. Maintenance sections outline service intervals for cooling systems, drive chain adjustment, and brake fluid cycles for the 2003–2008 Suzuki LT-Z400.
Technical Data and Specifications
Engine assembly data lists the cylinder head bolt tightening sequence and provides tolerance charts for valve stem deflection, cam height, and piston ring end gap. Specification tables detail the crankshaft-web-to-web width at 62.0 +/- 0.1 mm, while the 2003–2008 Suzuki LT-Z400 oil pressure check reveals standard values above 20 kPa at operating temperature. Electrical system references include the 12V 28.8Ah battery rating and 20A main fuse protection. understanding factory workshop documentation assists technicians in interpreting the specific tolerance limits defined for this engine. The manual acts as the primary technical reference for the 2003–2008 Suzuki LT-Z400, documenting engine, chassis, and electrical specifications for the entire production range.
Document Reference: C4085-91017
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