Suzuki LT-Z400 Repair Manual 2003-2008

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Item # M270-2  ISBN: 9781599692951




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This repair and service manual covers the Suzuki LT-Z400 all terrain vehicle (ATV), 2003-2008.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Service methods | Storage

CHAPTER TWO: TROUBLESHOOTING
Water damage | Starting the engine | Engine does not start | Poor idle speed performance | Poor, medium and high speed performance | Electrical testing | Starting system | Charging system | Ignition system | Lighting system | Fuel system | Engine overheating | Engine noises | Cylinder leakdown test | Clutch | Transmission | Suspension | Frame | Brakes

CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP
Maintenance schedule | Pre-Ride inspection | Air box drain plug | Air filter | Engine oil | Oil pressure check | Spark plug | Spark arrestor cleaning | Fuel line inspection | Fuel tank vent hose | Carburetor | Ignition timing | Valve clearance inspection | Compression check | Control cables | Cooling system | Tires and wheels | Battery | Drive chain and sprockets | Brake system | Shock absorbers | Front suspension | Swing arm bearing inspection | Rear suspension inspection | Skid plate inspection | Specifications

CHAPTER FOUR: ENGINE TOP END
Break-In period | Exhaust system | Cylinder head cover | Camshafts and cam chain tensioner | Cylinder head | Valves | Cylinder | Piston and piston rings | Specifications

CHAPTER FIVE: ENGINE LOWER END
Engine | Crankcase | Crankcase seals | Crankcase bearings | Engine balancer | Oil pump | Oil strainer | Oil pressure check valve | Oil tank | Crankshaft | Cam chain and rear guide | Balancer driven gear | Primary and balancer drive gears | Specifications

CHAPTER SIX: CLUTCH and EXTERNAL SHIFT MECHANISM
Right crankcase cover | Clutch | Clutch release camshaft | Shift lever | Shift mechanism | Clutch cable replacement | Clutch lever replacement | Reverse shift cable replacement | Specifications

CHAPTER SEVEN: TRANSMISSION and INTERNAL SHIFT MECHANISM
Transmission operation | Transmission service | Input shaft | Output shaft | Reverse gear and axle | Transmission inspection | Shift drum and forks | Specifications

CHAPTER EIGHT: FUEL SYSTEM
Carburetor | Throttle position sensor (2005-on models) | Carburetor operation | Fuel valve | Throttle cable replacement | Choke cable replacement | Fuel tank | Specifications

CHAPTER NINE: ELECTRICAL SYSTEM
Electrical component replacement | Alternator cover | Lower idle gear | Stator assembly | Rotor and starter clutch | Starter | Starting system switches | Ignition system | Charging system | Radiator fan system | Coolant temperature warning circuit | Headlight | Taillight | Meter lights | Switches | Specifications

CHAPTER TEN: COOLING SYSTEM
Safety precautions | Fan and fan switch | Radiator | Thermostat | Water pump | Specifications

CHAPTER ELEVEN: FRONT SUSPENSION and STEERING
Front wheel | Front hub | Tie rods | Steering knuckle | Control arms | Ball joint replacement | Shock absorbers | Handlebar | Steering shaft | Tires and wheels | Specifications

CHAPTER TWELVE: REAR SUSPENSION
Rear wheel | Rear wheel hubs | Rear axle | Rear axle housing | Sprockets | Drive chain | Shock absorber | Shock linkage | Swing arm | Specifications

CHAPTER THIRTEEN: BRAKE SYSTEM
Brake service | Front brake pads | Front brake caliper | Front master cylinder | Rear brake pads | Rear brake caliper | Rear master cylinder | Rear brake pedal | Brake system draining | Brake system bleeding | Brake disc | Parking brake | clutch lever | Specifications

CHAPTER FOURTEEN: BODY
Retaining clips | Seat | Upper fuel tank cover | Side covers | Headlight cover | Front fender | Rear fender | Footpegs and footguard

COLOR WIRING DIAGRAM

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Suzuki LT-Z400 Repair Manual 2003-2008