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Suzuki LT-Z400 (2003 - 2008)

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The original Haynes Repair Manual - Based on a complete stripdown and rebuild of a vehicle

Suzuki LT-Z400 (2003 - 2008)

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What's Covered
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This Suzuki LT-Z400 Manual is 336 pages.

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 / Specifications

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 / 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

INDEX

COLOR WIRING DIAGRAMS

Models covered:
2003 2004 2005 2006 2007 2008 LT-Z400 LTZ400 LTZ 400 Quadsport Quad Sport

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LT-Z400 Quadsport (2003-2008)

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