Suzuki LT-Z400 2003 Manuals

Manuals and User Guides for Suzuki LT-Z400 2003. We have 1 Suzuki LT-Z400 2003 manual available for free PDF download: Service Manual

Suzuki LT-Z400 2003 Service Manual

Suzuki LT-Z400 2003 Service Manual (305 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 35.55 MB

Table of Contents

General Informa Tion

5
- Table of Contents
  5
- General Precautions
  6
- Suzuki Lt-Z400
  8
- Serial Number Location
  8
- Fuel and Oil Recommendation
  8
- Fuel
  9
- Engine Oil
  9
- Brake Fluid
  9
- Engine Coolant
  9
- Break-In Procedures
  10
- Information Labels
  11
- Specifications
  12
- Country and Area Codes
  14
Periodic Maintenance

15
- Periodic Maintenance Chart
  16
- Periodic Maintenance Schedule
  16
- Air Cleaner
  17
- Maintenance and Tune-Up Procedures
  17
- Exhaust Pipe Nuts and Muffler Bolts
  18
- Valve Clearance
  19
- Spark Plug
  24
- Engine Idle Speed
  25
- Fuel Hose
  25
- Throttle Cable Play
  25
- Engine Oil and Oil Filter
  26
- Engine Oil Hoses
  27
- Engine Coolant
  28
- Radiator Hoses
  29
- Spark Arrester
  29
- Brakes
  30
- Clutch
  30
- Brake Fluid
  32
- Brake Hoses
  34
- Tires
  34
- Steering
  35
- Drive Chain
  36
- Suspensions
  38
- Chassis Bolts and Nuts
  39
- General Lubrication
  42
- Compression Pressure Check
  43
- Compression Test Procedure
  43
- Oil Pressure Check
  44
- Oil Pressure Test Procedure
  44
Engine

45
- Engine Center
  46
- Engine Components Removable with Engine in Place
  46
- Engine Left Side
  46
- Engine Right Side
  46
- Engine Removal
  47
- Engine Removal and Remounting
  47
- Engine Remounting
  51
- Engine Disassembly
  53
- Cylinder Head
  63
- Engine Components Inspection and Service
  63
- Camshaftiautoma Chain Tension Adjuster and Tensioner
  74
- Cylinder
  74
- Piston and Piston Ring
  75
- Conrod
  77
- Crankshaft
  77
- Balancer Shaft and Balancer Driven Gear
  78
- Starter Clutch
  79
- Oil Pump
  80
- Starter Torque Limiter
  80
- Clutch
  81
- Gearshift Fork and Gear
  82
- Transmission
  83
- Crankcase
  86
- Clutch Cover
  90
- Crankshaft
  91
- Engine Reassembly
  91
- Gearshift Cam, Fork and Reverse Lock Shaft
  92
- Crankcase
  93
- Starter Clutch and Generator Rotor
  94
- Primary Drive Gear and Balancer Gear
  95
- Gearshift Cam Driven Gear
  96
- Cam Chain
  97
- Oil Pipe
  97
- Oil Pump
  97
- Clutch
  98
- Generator Rotor Cover
  100
- Neutral Switch
  100
- Piston Ring
  101
- Piston and Cylinder
  102
- Cylinder Head
  103
- Camshaftiautoma Tic Decompression Assembl y
  104
- Cylinder Head Cover
  106
- Cam Chain Tension Adjuster
  107
Fuel System

109
- Construction
  110
- Fuel Tank
  110
- Fuel Line Inspection
  111
- Remounting
  111
- Removal
  111
- Fuel Strainer
  112
- Fuel Valve
  112
- Remounting
  112
- Removal and Inspection
  112
- Carburetor
  113
- Construction
  113
- Location
  114
- SPECIFICA Tlons
  114
- Removal
  115
- Disassembly
  116
- Cleaning
  120
- Inspection
  120
- Reassembly
  121
- Remounting
  122
Cooling and Lubrica Tion System

123
- Cooling System Description
  124
- Engine Coolant
  125
- Cooling Circuit Inspection
  126
- Radiator and Hoses
  126
- Radiator Cap Inspection
  126
- Radiator Inspection
  126
- Radiator Hose Inspection
  127
- Radiator Removal
  127
- Radiator Remounting
  128
- Radiator Reservoir Tank
  128
- Cooling Fan
  129
- Inspection
  129
- Removal
  129
- Remounting
  130
- Cooling Fan Thermo-Switch
  131
- Removal
  131
- Inspection
  132
- Installation
  132
- Engine Coolant Temperature Switch
  133
- Inspection
  133
- Installation
  133
- Removal
  133
- Inspection
  134
- Installation
  134
- Removal
  134
- Thermostat
  134
- Construction
  135
- Water Pump
  135
- Removal and Disassembly
  136
- Inspection
  138
- Reassembly and Installation
  139
- Construction
  143
- Oil Tank and Hoses
  143
- Removal
  144
- Remounting
  145
- Lubrication System
  146
- Oil Filter
  146
- Oil Pressure
  146
- Oil Pump
  146
- Oil Sump Filter
  146
- Engine Lubrication System Chart
  147
Chassis

148
- Construction
  150
- Exterior Parts
  150
- Removal
  152
- Remounting
  156
- Construction
  157
- Front Ano Rear Wheels
  157
- Removal
  158
- Inspection Ano Oisassembl y
  159
- Reassembly and Remounting
  160
- Tire Replacement
  163
- Tires
  163
- Construction
  165
- Front Brake
  165
- Brake Pad Replacement
  166
- BRAKE CALIPER REMOVAL and Disassembly
  167
- Brake Fluio Replacement
  167
- Brake Caliper Inspection
  169
- Brake Caliper Reassembly and Remounting
  170
- Brake Disc Inspection
  172
- Brake Disc Reassembly and Remounting
  172
- Brake Disc Removal and Disassembly
  172
- MASTER CYLINDER REMOVAL and Disassembly
  173
- Master Cylinder Inspection
  174
- Master Cylinder Reassembly and Remounting
  174
- Construction
  176
- Front Suspension
  176
- Removal
  177
- Inspection and Disassembly
  178
- Reassembly and Remounting
  181
- Suspension Setting
  184
- Construction
  185
- Steering
  185
- Removal
  186
- Inspection and Disassembly
  189
- Reassembly and Remounting
  191
- Toe-In Adjustment
  195
- Front Wheel, Front Brake, Front Suspension and Steering Reassembling Information
  196
- Construction
  197
- Rear Brake
  197
- Brake Pad Replacement
  198
- Brake Fluid Replacement
  199
- Brake Caliper Removal and Disassembly
  200
- Brake Caliper Inspection
  202
- Brake Caliper Reassembly and Remounting
  203
- Brake Disc Inspection
  206
- Brake Disc Removal and Remounting
  206
- Master Cylinder Removal and Disassembly
  207
- Master Cylinder Inspection
  208
- Master Cylinder Reassembly and Remounting
  209
- Construction
  210
- Rear Shock Absorber
  210
- Removal
  210
- Inspection
  212
- Rear Shock Absorber Disposal
  212
- Remounting
  213
- Suspension Setting
  213
- Construction
  215
- Rear Suspension
  215
- Removal
  216
- Inspection and Disassembly
  218
- Remounting
  225
- Construction
  227
- Rear Axle
  227
- Removal
  228
- Inspection and Disassembl
  229
- Reassembly and Remounting
  231
- Removal
  239
- Reverse Lock Release Cable
  239
- Remounting
  240
Electrical System

243
- Cautions in Servicing
  244
- Clamps
  244
- Connectors
  244
- Couplers
  244
- Fuses
  244
- Semi-Conductor Equipped Parts
  244
- Connecting the Battery
  245
- Using the Multi Circuit Tester
  245
- Location of Electrical Components
  246
- Charging System
  248
- Troubleshooting
  248
- Inspection
  250
- Starter System
  253
- Troubleshooting
  253
- STARTER MOTOR REMOVAL and Disassembly
  254
- Starter Motor Inspection
  255
- Starter Motor Reassembly and Remounting
  256
- Starter Relay Inspection
  257
- Ignition System
  259
- Troubleshooting
  259
- Inspection
  261
- Indicator Light Position
  264
- Inspection
  264
- Lamps Headlight
  265
- BRAKE Llghtrrailllght
  266
- Switches
  267
- Ba Ttery
  268
- Initial Charging
  268
- Specifications
  268
- Recharging Operation
  270
- Servicing
  270
Servicing Informa Tion

271
- Engine
  272
- Troubleshooting
  272
- Carburetor
  275
- Radiator
  275
- Chassis
  276
- Brakes
  277
- Electrical
  278
- Battery
  279
- Wiring Harness Routing
  281
- Wiring Harness, Cable and Hose Routing
  281
- Cable Routing
  283
- Fuel Hose Routing
  285
- Seat Rail and Chain Roller Installation
  291
- Special Tools
  292
- Engine
  295
- Tightening Torque
  295
- Chassis
  296
- Tightening Torque Chart
  297
- Service Data
  298

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