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Suzuki LT-Z400 Service Manual

Suzuki LT-Z400
304 pages
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Table of Contents

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Suzuki LT-Z400 Specifications

General IconGeneral
BrandSuzuki
ModelLT-Z400
CategoryOffroad Vehicle
LanguageEnglish

Summary

General Information

Safety and Precautions

Essential safety warnings, cautions, and general precautions for vehicle maintenance and operation.

Vehicle Identification

Information on identifying the vehicle model and serial number locations for reference.

Fluid and Fuel Recommendations

Recommended fuel types, octane ratings, and engine oil specifications for optimal performance.

Maintenance and Break-in Procedures

Procedures for breaking in the engine and understanding vehicle information labels.

Technical Specifications

Key technical specifications for engine, drivetrain, chassis, and electrical systems.

Country and Area Codes

Codes used to identify applicable countries and areas for the vehicle.

Periodic Maintenance

Periodic Maintenance Schedule and Chart

Recommended service intervals and tasks for maintaining the vehicle.

Engine, Fuel, and Cooling System Maintenance

Procedures for maintaining engine, fuel, and cooling systems as per schedule.

Brake System Maintenance

Inspection and maintenance of brake pads, fluid, and hoses for optimal performance.

Chassis, Suspension, and Steering Maintenance

Maintenance tasks for tires, steering, drive chain, suspensions, and chassis fasteners.

Engine Checks and Lubrication

Performing essential lubrication and pressure checks for engine health.

Engine

Engine Removal and Remounting

Complete procedure for removing and reinstalling the engine from the vehicle chassis.

Engine Disassembly and Inspection

Steps for disassembling engine components and inspecting them for wear or damage.

Cylinder Head and Valve Train Service

Detailed procedures for inspecting and servicing cylinder head and valve train components.

Piston, Rings, Cylinder, and Connecting Rod Service

Inspection and service of cylinder, piston, rings, conrod, and related parts.

Crankshaft and Drivetrain Components Service

Service procedures for crankshaft, drivetrain components like clutch, gears, and oil pump.

Engine Reassembly

Step-by-step guide for reassembling the engine after disassembly.

Fuel System

Fuel Tank and Valve Service

Procedures for fuel tank construction, removal, and servicing the fuel valve and strainer.

Carburetor Service

Comprehensive service guide for the carburetor, including disassembly, cleaning, and reassembly.

Cooling and Lubrication System

Cooling System Overview and Maintenance

Explanation of the cooling system and procedures for its maintenance.

Cooling Fan and Switches Service

Testing and servicing the cooling fan, thermo-switch, and coolant temperature switch.

Thermostat and Water Pump Service

Procedures for inspecting and servicing the thermostat and water pump.

Oil Tank, Hoses, and Lubrication System

Service and routing information for the oil tank, hoses, and lubrication system.

Chassis

Exterior Body Panels and Wheels Service

Service procedures for exterior body panels, wheels, and tires.

Front Brake System Service

Procedures for servicing the front brake system, including pads, fluid, caliper, and disc.

Rear Brake System Service

Procedures for servicing the rear brake system, including pads, fluid, caliper, and disc.

Front Suspension and Steering Service

Maintenance and adjustment of the front suspension and steering systems.

Rear Suspension and Axle Service

Service procedures for the rear shock absorber, suspension, and axle assembly.

Control Cables and Routing

Removal, remounting, and adjustment of control cables and their routing.

Electrical System

Electrical System Cautions and Basic Components

General precautions for servicing electrical systems and component locations.

Battery Service and Charging

Battery specifications, initial charging, servicing, and recharging procedures.

Charging, Starter, and Ignition System Troubleshooting

Diagnosing and troubleshooting common issues with charging, starter, and ignition systems.

Ignition System Component Inspection

Testing ignition coil, pickup coil, and signal coil for proper operation.

Indicator Lights, Lamps, and Switches

Checking and replacing indicator lights, lamps, and testing switches.

Servicing Information

Troubleshooting Guides by System

Comprehensive troubleshooting guide covering common issues across all vehicle systems.

Wiring Diagram and Routing

Electrical wiring diagram and guidance on proper routing of harnesses, cables, and hoses.

Special Tools and Service Data

List of special tools, tightening torque specifications, and essential service data.

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