Suzuki LT-Z400 Service Manual (2009 Model) - Sport ATV

Suzuki LT-Z400 Service Manual (2009 Model) - Comprehensive Guide to Inspection and Overhaul

This professional-grade service manual is the definitive technical resource for the 2009 Suzuki LT-Z400. Specifically developed for the K9 model year, this document provides the exact factory specifications and diagnostic procedures used by certified technicians. With the 2009 transition to Fuel Injection (FI), having the correct technical data for the ECM and sensor calibration is vital for any serious owner or mechanic aiming to maintain the high-performance standards of this Sport ATV.

Complete Model Coverage

The following model designations are fully covered within this technical documentation:

• LT-Z400K9 (2009)
• LT-Z400 (2009)
• Quadsport Z400 (2009)

This manual is applicable for global regions including the U.S.A. (E-33), Canada (E-28), and the European Union (E-19).

Precise Vehicle Identification

To ensure you are using the correct data for your specific machine, the manual details the following identification markers:

• Frame Serial Number (V.I.N.): Located on the left side of the front frame pipe (e.g., Canada models starting from JSAAK4AA92 100001–).
• Engine Serial Number: Stamped on the right side of the crankcase for easy verification.

In-Depth Technical Content & Systems

• Advanced Fuel Injection (FI): Comprehensive breakdown of the 2009 fuel system, including the Engine Control Module (ECM), fuel pump, and the complete array of sensors (IAP, TP, ECT, and IAT).
• Engine Mechanics (398 cm³ DOHC): Full teardown and rebuild instructions for the 4-stroke, liquid-cooled engine. Featuring detailed specs such as the 11.3:1 compression ratio and dry sump lubrication system requirements.
• Periodic Maintenance & Tune-Up: Clear service intervals (1-month, 3-month, and 6-month) and critical adjustments, including valve clearance specs (IN: 0.10–0.20 mm; EX: 0.20–0.30 mm) and spark plug gaps (0.7–0.8 mm for NGK CR7E).
• Chassis & Suspension Geometry: Detailed service for the independent double-wishbone front and swingarm-type rear suspension. Includes specific torque values like the 66 N·m (47.5 lb-ft) required for wheel set nuts and rear axle components.
• Integrated Diagnostics: Utilize the built-in "Dealer Mode" and Suzuki Diagnosis System (SDS) instructions to read Diagnostic Trouble Codes (DTC) and perform efficient electronic troubleshooting.

Essential Specifications for Owners

• Transmission: 5-speed constant mesh with integrated reverse gear (1-down, 4-up shifting).
• Drive System: RK 520SMOZ10S chain with 96 links.
• Fluid Capacities: Comprehensive data on oil changes (2,100 ml with filter change) and the 9.5-liter fuel tank.
• Electrical Equipment: Full wiring diagrams, battery charging rates, and starter motor service procedures.

Professional Workshop Features

• Systematic Troubleshooting: Dedicated sections for diagnosing engine stalls, poor mid-range performance, and electrical gremlins.
• Exploded View Diagrams: High-quality illustrations showing exactly how components like the throttle body, cooling system, and clutch assembly fit together.
• Precision Torque Tables: A master list of tightening torques for every critical bolt to prevent hardware failure and ensure rider safety.
• Special Tool Requirements: Identification of specific Suzuki tools needed for specialized tasks, such as the multi-circuit tester or bearing removers.

Equip your workshop with the same level of detail used at the factory level to ensure your Quadsport Z400 remains trail-ready and reliable for years to come.