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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Document Details

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Document Number / Seller:
24537 / Douglas Reed
File Size:
56.45 MB
File Type:
ZIP
Language:
English
Pages:
302
Printable:
Yes
Category:
ATV
Last updated / verified
Oct 11, 2025

Models Covered & Key Technical Specifications

Suzuki LT-Z400 (2003-2008) (C4085-91017) 2003-2008 Suzuki LT-Z400 Quadsport 400 Service Manual | Reference Bundle.

  • Prescribed Shipping Weight: 169 kg establishes the vehicle's dry mass Information.
  • Standard Print Quality: For optimal operation, 1200 dpi defines the highest resolution.
  • Maximum Assembly Torques: The critical engine mounting bolts require specified values.
  • System Adjustment Range: The throttle cable play must be maintained within 3-5 mm.
  • Calibrated Generation Capacity: The generator output is rated at 20 A.
  • Nominal Form Factor: The overall width corresponds to 1165 mm.

Professional Workshop Service Manual & Technical Specifications

Specialized Procedure Operator's Manual: ATV Suzuki LT-Z400 manual, 03-08 repair guide Knowledge-Base

Calibration-Scope: LT-Z400 // Model-Specs: ATV / Engine Logic // Asset-ID: 302 pages.

Identifier System-Path Context
1 General Information Vehicle Specifications and Labels
2 Periodic Maintenance Service Schedules and Procedures
3 Engine Removal, Installation, and Overhaul
4 Fuel System Carburetor and Fuel Delivery Systems
5 Cooling and Lubrication System Components and Maintenance

Outlining the operational framework across the entire vehicle, this manual details everything from basic maintenance to complete engine disassembly. Quality checks are addressed for air filter and spark plug replacement. The engine section documents complete engine removal and remounting procedures. The troubleshooting chapter addresses potential issues within the fuel system. Cooling system maintenance is addressed in the radiator and hose inspection. Testing requirements are specified for compression and oil pressure checks. This Complete manual documents torque specifications for critical engine components to ensure proper axial load stability.

Quality checks are addressed for

This manual details the procedures for inspecting and replacing key components such as the air cleaner element, spark plug, and fuel hoses, ensuring optimal performance and longevity.

FAQ

What are the **proper** clearance measurements? keyboard_arrow_down

0.10 - 0.20 mm (cold) is the standard tappet clearance measurement for intake valves, as specified on page 2-6.

Specify the **standard** torque specifications. keyboard_arrow_down

115 N·m (8.0 lb-ft) is the specified torque for the crankshaft and cylinder head bolts, detailed on page 3-47 and 3-59 respectively.

What are the **necessary** safety precautions? keyboard_arrow_down

Ensure that the engine is cool and that all fuel lines are disconnected before proceeding with any engine removal, as described on page 3-3 and 3-4.

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