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Suzuki LT-Z400 2003 User Manual

Suzuki LT-Z400 2003
305 pages
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FOREWORD
This
manual
contains
an
introductory
description on
t
he
SUZUKI
L T-Z400
and
procedures
for
its inspec-
tion, service,
and
overhaul
of
its main
components
.
Other
information
considered
as
generally
known
is
not
included.
Read the GENERAL INFORMATION section
to
familiarize
yourself
with the vehicle
and
its
main
te-
nance. Use this
sec
tion
as
well
as
ot
her
sections
as
a guide
for
proper
inspecti
on
and
service.
This
manual
will help
you
know
the vehicle
better
so
that
you
can
assure
your
customers
of
fast
and
reli-
able
service.
* This
manual
has
been
prepared
on the
basis
of
the latest specifications
at
the time
of
publi
-
cation.
If
modifications
have
been
made
si
nce
then, differences
may
exist
be
t
ween
the
con-
tent
of
this manual and the actual vehicle.
" fl/ustrations
in
this manual are used
to
show
the
basic principles
of
operation and work
procedures.
They
may not represent the
actual vehicle exactly
in
detail .
•
This
manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for
seIVicing SUZUKI vehicles.
If
you
do
not have the proper knowledge and
tools,
ask your authorized SUZUKI motorcy·
cle dealer
to
help you.
A WARNING
Inexperienced
mechanics
or
mechanics
without
the
proper
tools
and equipment
may
not
be able
to
properly perform the
services described in
this
manual.
Improper
repair may result In
injury
to
the
mechanic and may render the vehicle
unsafe
for
the rider.
GROUP
INDEX
GENERAL INFORMATION
PERIODIC
MAINTENANCE
ENGINE
I FUEL SYSTEM
COOLING
AND
LUBRICATION SYSTEM
CHASSIS
ELECTRICAL SYSTEM
I SERVICING INFORMATION

Table of Contents

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Suzuki LT-Z400 2003 Specifications

General IconGeneral
BrandSuzuki
ModelLT-Z400 2003
CategoryOffroad Vehicle
LanguageEnglish

Summary

FOREWORD

GENERAL INFORMATION

WARNING/CAUTION/NOTE

Explains the meaning of signal words like WARNING, CAUTION, and NOTE.

GENERAL PRECAUTIONS

Lists general safety procedures for service and repair.

SERIAL NUMBER LOCATION

Details the location of the frame and engine serial numbers.

FUEL AND OIL RECOMMENDATION

Specifies recommended fuel types and oil grades for the vehicle.

BRAKE FLUID

Specifies the required brake fluid type, DOT 4.

ENGINE COOLANT

Details engine coolant type, mixing, and recommendations.

BREAK-IN PROCEDURES

Outlines the recommended break-in procedures for the engine.

SPECIFICATIONS

Provides detailed specifications for dimensions, engine, and drive train.

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

Lists recommended intervals for all periodic service work.

MAINTENANCE AND TUNE-UP PROCEDURES

Describes the servicing procedures for items in the maintenance chart.

AIR CLEANER

Details the procedure for cleaning the air cleaner element.

VALVE CLEARANCE

Explains how to inspect and adjust valve clearance.

SPARK PLUG

Covers inspection, gap measurement, and replacement of the spark plug.

ENGINE OIL AND OIL FILTER

Details the procedures for changing engine oil and oil filter.

BRAKES

Covers inspection of brake pads and adjustment of rear brake components.

TIRES

Details tire tread condition and pressure checks.

STEERING

Covers inspection and adjustment of the steering system.

DRIVE CHAIN

Explains inspection, adjustment, and lubrication of the drive chain.

CHASSIS BOLTS AND NUTS

Lists chassis bolts and nuts requiring periodic tightening.

GENERAL LUBRICATION

Indicates major lubrication points on the vehicle.

COMPRESSION PRESSURE CHECK

Explains how to check engine compression pressure.

ENGINE

ENGINE REMOVAL AND REMOUNTING

Details the steps for removing and remounting the engine from the frame.

ENGINE COMPONENTS INSPECTION AND SERVICE

Covers inspection and service procedures for various engine components.

CYLINDER HEAD

Details disassembly, inspection, and servicing of the cylinder head.

PISTON AND PISTON RING

Covers measurement and inspection of piston diameter and rings.

CONROD

Details inspection of conrod small end I.D. and deflection.

CRANKSHAFT

Covers inspection of crankshaft runout.

STARTER CLUTCH

Explains the installation and inspection of the starter clutch.

OIL PUMP

Details inspection of oil pump rotors and case.

CLUTCH

Covers inspection of clutch drive and driven plates.

CAM CHAIN TENSION ADJUSTER

Details the installation and adjustment of the cam chain tensioner.

FUEL SYSTEM

FUEL TANK

Shows the construction and assembly of the fuel tank.

FUEL VALVE

Covers removal, inspection, and remounting of the fuel valve.

CARBURETOR

Details the construction, specifications, and removal of the carburetor.

DISASSEMBLY

Outlines the steps for disassembling the carburetor components.

INSPECTION

Lists items to check for damage or clogging in the carburetor.

REASSEMBLY

Covers reassembly steps, including pilot screw and needle jet installation.

COOLING AND LUBRICATION SYSTEM

COOLING SYSTEM

Describes the engine cooling system's operation and components.

ENGINE COOLANT

Provides information on engine coolant mixture, properties, and warnings.

RADIATOR AND HOSES

Covers inspection and removal/remounting of the radiator and hoses.

COOLING FAN

Details inspection and removal of the cooling fan.

THERMOSTAT

Covers removal, inspection, and installation of the thermostat.

WATER PUMP

Shows construction and removal/disassembly of the water pump.

OIL TANK AND HOSES

Details the construction, removal, and remounting of the oil tank and hoses.

LUBRICATION SYSTEM

Lists key components and their related sections for lubrication.

CHASSIS

FRONT AND REAR WHEELS

Shows the construction and removal of front and rear wheels.

TIRES

Covers tire replacement, tread condition, and pressure checks.

FRONT BRAKE

Details the construction and component replacement for the front brake.

BRAKE PAD REPLACEMENT

Explains the procedure for replacing front brake pads.

BRAKE FLUID REPLACEMENT

Details the process for replacing brake fluid and bleeding the system.

BRAKE CALIPER REMOVAL AND DISASSEMBLY

Covers the removal and disassembly of the brake caliper.

BRAKE CALIPER INSPECTION

Details inspection of the brake caliper, piston, and related parts.

FRONT SUSPENSION

Shows the construction of the front suspension components.

STEERING

Details the construction and removal of steering components.

TOE-IN ADJUSTMENT

Explains how to adjust the toe-in for proper alignment.

REAR BRAKE

Shows the construction of the rear brake system components.

REAR SHOCK ABSORBER

Covers construction and removal of the rear shock absorber.

REAR SUSPENSION

Details the construction of rear suspension components.

REAR AXLE

Shows the construction of the rear axle assembly.

REVERSE LOCK RELEASE CABLE

Covers removal and remounting of the reverse lock release cable.

ELECTRICAL SYSTEM

CAUTIONS IN SERVICING

Provides general cautions for servicing electrical components.

BATTERY

Details battery specifications, connecting, and wiring procedures.

LOCATION OF ELECTRICAL COMPONENTS

Shows the locations of key electrical components on the vehicle.

CHARGING SYSTEM

Explains the charging system circuit and troubleshooting steps.

STARTER SYSTEM

Covers troubleshooting and component removal/assembly for the starter system.

IGNITION SYSTEM

Details troubleshooting and inspection procedures for the ignition system.

INDICATOR LIGHT POSITION

Shows the location and wire colors of indicator lights.

LAMPS

Covers headlight and brake/taillight bulb replacement.

SWITCHES

Explains how to measure switch continuity for diagnosis.

BATTERY

Covers battery specifications, initial charging, and servicing.

RECHARGING OPERATION

Details the procedure for recharging the battery.

SERVICING INFORMATION

TROUBLESHOOTING

Provides a troubleshooting guide for common engine and chassis issues.

ENGINE

Lists engine complaints, symptoms, causes, and remedies.

RADIATOR

Details symptoms and remedies for radiator-related overheating or overcooling.

CARBURETOR

Lists carburetor complaints, symptoms, causes, and remedies.

CHASSIS

Lists chassis-related complaints, symptoms, causes, and remedies.

BRAKES

Details brake complaints, symptoms, causes, and remedies.

ELECTRICAL

Lists electrical complaints, symptoms, causes, and remedies.

WIRING HARNESS, CABLE AND HOSE ROUTING

Shows proper routing for wiring harnesses, cables, and hoses.

TIGHTENING TORQUE

Provides a list of engine and chassis tightening torque specifications.

SERVICE DATA

Lists standard and limit values for various engine measurements.

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