Suzuki LTZ400 LT-Z400 Quad Sport Service Repair Workshop Manual 2003-2006

■ - — CONTENTS - WARNING/CAUTION/NOTE ».»» ........... „„„..„.„„.„„ ...... „.„„..„„...„ 7- 2 G£l¥£l?4£ PRECAUTIONS »............ „„........ „.„...„..... „„„„„„...„„.... 7- 2 SUZUKI LT-Z400K3 (2003-MODEL) ........ „ ....... „.„„.„ ...... „„„„„„...„ 7- 4 SERIAL NUMBER LOCATION .... „„„ ......... „.„.„...„.„„„...„..„„„„„„. |- 4 FC/Ei 4JV0 OIL RECOMMENDATION ........................................ 7- 4 wa M E/VG/NEO/L ...... „„„ .... „„.„„„.._^ 5 BRAKE FLUID »»»» .... „.„„...„..„„„„„„„..„.„„.„„„..„„„„„„„.„„ 7. 5 EJVGIJVE 0 O 0 I 4 J Y F . . . « . „ ........ „ ...... „...„...„„..„..„.„„„„...„.„„„„ |- 5 BREAK-IN PROCEDURES ..»»» ......... „...„...„..„„„.„...„„„„„„„...„„ 7- § INFORMATION LABELS ...» .............. „ ...... „..„„„ ..... „.„„„„„.„.„„„„. 7- 7 SPECIFICA TIONS ..»-»»» .... „.„„.„...„..„„..„...„.„„„„„„..„.„„„„.„„.. 7. a COUNTRY AND AREA CODES ...... „„„ ...... „.„„„..„ ..... „.„„„„.„„.„„ 7.70 - www.instant-manuals.com -

GENERAL 3 lease read this manual and follow its instructions carefully, To emphasize special information, the symbol tnd the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates Id result in death or inii ION Indicate! nt in I hazard that could result In vehicle clami Indicates special information to make maintenance easier or instructions dearer, Please note, however, that the warnings and cautions contained in this manual cannot possibly cover ail potential hazards relating to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice. GENEI [CAUTIONS Proper service and repair procedures are Important for the the safety and reliability of the vehicle, When two or more persons work together, pay attention to When it Is necessary to run the engine Indoors, make su doors. When working with toxic or flammable materials, make sure th ventilated and that you follow all of the manufacturer's instruct Never use gasoline as a cleaning solvent, To avoid getting burned, do not touch the engine, engine oil, until they have cooled, After servicing the fuel, oil, exhaust or brake systems, chec related to the system for leaks, sty of the service mechanic and safety of each other, hat exhaust gas is forced out™ lat the area you work In is well tlons. , radiator, and exhaust system the lines, and fittings - www.instant-manuals.com -

GENERAL INFORMATION 1-3 CAUTIONJ * If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equivalent, * When removing parts that are to be reused, keep them arranged In an orderly manner so that they may be reinstalled in the proper order, * Be sure to use special tools when instructed. * Make sure that all parts used in reassembly are clean. Lubricate them when specified. * Use the specified lubricants, bonds, or sealants, * When removing the battery, disconnect the 9 battery lead wire first, then the © battery lead wire, * When reconnecting the battery, connect the (+> battery lead wire first, then the 8 battery lead wire, Finally, cover the (+) battery terminal with the terminal cover, * When performing service to electrical parts, disconnect the 6 battery lead wire, unless the service procedure requires the battery power, * When tightening cylinder head and crankcase nuts and bolts, tighten the larger sizes first. Always tighten the nuts and bolts from the inside working out, diagnoally and to the specified torque, * Whenever you remove oil seals, gaskets, packing, O-rlngs, self-locking nuts, locking wash- ers, cotter pins, circlips, snap rings and other specified parts, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces, * Never reuse a circlip and snap ring. When installing a new snap ring, take care not to eipand the end gap larger than required to slip the snap ring over the shaft. After installing a snap ring, always ensure It is completely seated in its groove and securely fitted. * Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil If a thread is smeared with them, * After reassembling, check parts for tightness and proper operation. * To protect the enL,„,..„„nt, do not unlawfully dispose of used motor oil, all other fluids, bat- teries, and tires, * To protect the earth's natural resources, properly dispose of used vehicles and parts, - www.instant-manuals.com -

Difference between photographs and actual vehicles depends on the markets. The frame serial number or V.I.N. (Vehicle Identification Number) (T: is stamped on the left side of the frame pipe. The engine serial number (2) is located on the right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts. M R, vt. ) method or 91 octane or higher rated by • Use only unleaded gasoline of at least 87 pump octane ( F the Research Method. • SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible. • Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. • Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% etna- nol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibi- tors are present in It, • If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. • Failure to follow these guidelines could possibly void applicable warranty coverage. Check with your fue supplier to make sure that the fuel you intend to use meets the requirements listed above. - www.instant-manuals.com -

Use unleaded gasoline that is graded 91 octane or higher by the Research Method, SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or oils that meet API service classifications SF or SG and that have a viscosity rating of SAE 10W-40. If engine oil with a rating of SAE 10W-40 is not available, select an alternative according to the chart. Use a premium quality 4-stroke motor oil to ensure longer service life of your vehicle. Use only oils that meet API service classifications SF or SG and that have a viscosity rating of SAE 10W-40. If engine oil with a rating of SAE 1QW-40 is not available, select an alternative aocordinq to the chart. lassificath 101 fllPl liililiilMlip his vehicle yses a glycol-based brake fluid. Do such as sillcone-based and petroleum-based flui< damage will result to the brake system. Never use any brake fluid taken from old, used, or uns Never reuse brake fluid left over from the last servlc period of time, ; use or mix dil or refilling the sealed contain? or which r ijrifi iriil'fri i^t iceri storsc Since antifreeze also has corrosion- and rust-inhibiting properties, always use engine coolant containing antifreeze, even if the atmospheric temperature does not go below the freezing point, Use an antifreeze designed for aluminum radiator. SUZUKI recommends the use of SUZUKI COOLANT antifreeze, if this is not available, use an equivalent antifreeze for aluminum radiators, Mix only distilled wafer with the antifreeze. Other types of water can corrode and clog the aluminum radiator, For more information, refer to page 5-3 in the Cooling System section. *rcentage of antifreeze in eze is above or below thi will be reduced, Always B. %ff i ll j&tfPft^nS Cffl ft ft* $ ft not qo the coolant shot s range the cooli iceep the antifree the freezing poin protection at above 50% i if the atmospheric - www.instant-manuals.com -

During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to "BREAK-IN" before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. Refer to the following break-in engine speed recommendations. • Keep to these breake-in engine speed limits. After the engine has been operated for 10 hours the engine to full throttle operation, for short periods time, - www.instant-manuals.com -

n Overall length ...........,,,,,,.......,.„„»„.,,.,,,,,,,,1 830 mm (72 Overall width .,,.,,,,,,,,,.....,......,,..,.,,,,,,,......,..,..,,,,,, 1 185 mm (45 Overall height,,.,,,,,,,,,,,,,,.......,.....,,,, 1 180 mm (45 Wheelbase........,,,,,,,,,,,,,,............,,,,,,,,,,,,,......,,,,,, 1 245 mm (49 Front track,,,,,..,..,,,,,,,,,,,,,,.................... 935 mm (36 ear trad- Ground clearance ...........,,,,,,,............, 265 mrn (10 Seat height..,,,,,,,..... ,,,,,,...... 810 mm (31 Dry mass..... ................................................. 189 kg (373 ,0 ,9 ,7 ,0 .8 .8 .4 .9 n) n) n) n) n) n) n) n) Four-stroke, liquid-cooled, DC Number of cylinders Bore 90,u mm (3.540 in; Stroke..........,,,,,,,,.,,..,......,.,..,........................ 62.6 mrn (2.465 in) Piston displacement ................398 cm 3 (24.3 cu.in) Compression ratio 11.3 i 1 Carburetor..........,,,,. ....MIKUNI BSR36 SS, single Air cleaner. ...................................................Polyurethane foam element Sta rte r system.,,.............,,,,,,,......,..,,,,,,,,,,,........... Electric Lubrication system ..,,.,,,.............,,,,,,..........,. Dry sump Idle speed ....,,,,,,,..................,,,,,,.........,..,,,,,,,...... 1 500 ± 100 r/min Clutch,,...,..................,.,,,,............,.,, Wet multi-plate type Transmission ,.5-forward and 1-reverse Gearshift pattern, forward ..,,..............,,,,,,............ 1 down 4 up, foot operated eveise .....,,....,,.,,,......rooi/nanu ope i area Primary reduction ratio....,,,,,,.,,,.,.......,..,.,,,,,,.......2.960 (74/25 2nd,. ............1.866 (30/18 3rd.................................................... 1.238 (26/21) 4th, ........ ,,,,,, ............. ,,,,,, ............... ,,, 1.000 (23/23) Top.,,,,,,,,,,,,,...... ,,,,......,,,,,,,,.,,, 0,348 (22/26) Reverse ,,,....,,,,,..,..,.......,,.,,,............2,153 (28/13) Final reduction ratio 2.857 (40/14) Drive chain.........,,,,,,,............,,,,,,,............,.,,,,......RK 520KZO 98 Links - www.instant-manuals.com -

IENERAL INFORMATION 1-9 Front suspension................................................. Independent, double wishbone, coil spring, oil damped Rear suspension ,,,,.,,,,,..,..,..,,,,.,,,,,,, Swingarm type, coil spring, oil damped Front wheel travel.,,,,,,,,,,,,......,,,,,.,,,,,,,,,,...... 215 mm (8.5 in) Rear wheel travel .............................................. 230 mm (9.1 in) Caster...........,,...,,..,,,,,........,,.,..............,,.,,,,,....... g,5° Trai '..—............... 36 mm (1,42 in) Toe-in.....,,,,,.,..,,,,,,..,...,..,,,,,,,,,,.,,,„...,,,,,,,,,,,,,,,,... 5 mm (0,20 in) Camber ...,..„„,,.,,,,,,,,..,...,,,„...,,,,.,,,,,,,,,,..,.,,, ,,,, -0.9° Steering angle ............................................... 41° Turning radius ..................................................... 3.1 m (10,2 ft) Front brake.......,,,,,,,,,,,,,,,,...., ,,,,,,,,....,..,,.,,,,,,, Disk brake, twin Rear brake ,......,,,, ,,,, ...... ,,,,,,,,,,,,,,,,,„...,.. Disk brake Front tire size ................................ AT22 x 7 R10K* tubeless Rear tire size.... AT2G x 1 0 R 9 ™ tubeless Ignition type.............,.,,,,,............,.,,,.,.. ..,.,..,., Electronic ignition (CDl) Ignition timing „,„„„ ...... 10° B.T.D.C. at 1 500 rpm Sparkplug........ NGK CR7E or DENSO U22ESR-N Battery................................................................. 12 V 28.8 kC (8 Ah)/10 HR Generator.....,,,,,,,,,. Three-phase A.C. generator Main fuse......... .,,..,,,.,... ,,.,,...«.... ,,.,,,,,,,,,, 20 A Headlight,,,,,,,,,,,...,...,,,,,,,,,,,,,,,,......,,..,,.,,.,,,,.,,.,.. 12 V 30/30 W x 2 Brake light/Taillight. 12 V 21/5 W Neutral indicator light 12 V 3 W Reverse indicator light.,,,,,..,,,... .,,,,..,.,......,,,,,, 12 V 3 W Coolant temperature warning light.....,,,,, 12 V 3 W Fuel tank, including reserve,,.,,,,,,,......,,,, io,0 L (2,6/2.2 US/Imp qal) reserve,....,, 2.7 L (0.7/0.6 US/imp gal) Engine oil, oil change 2 000 ml (2,1/1.8 US/Imp qt) filter change ......... „,„,„.„, .... „„,,,,,,„,, 2 100 ml (2.2/1,8 US/Imp qt) overhaul.. 2 200 ml (2.3/1.9 US/Imp qt) Coolant,,,.,,...,,, „.,,„„„,„ 1,2 1(1.3/1,1 US/Imp qt) - www.instant-manuals.com -

E MI m The following codes stand for the applicable countries and areas. ■-33 COUNTRY OR AREA U wr\ California - www.instant-manuals.com -

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Suzuki LTZ400 LT-Z400 Quad Sport Service Repair Workshop Manual 2003-2006

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