Wed, 10 Oct 2018 07:15:00 GMT SUZUKI LTZ 400 SERVICE MANUAL Pdf Download. - FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI LT-Z400 and procedures for its inspec. Repair manual2003 suzuki ltz 400 repair manual freefree suzuki ltz 400 repair manual. Download Suzuki Ltz 400, suzuki 400 ltz quad sport 2018 SUZUKI LTZ 400 LTZ400 2018 Service Repair Manual Pdf Download contains maintenance schedule and Aug 02, 2018 Clymer Manuals Suzuki LT-Z400 2018 repair manual is written specifically for the do-it.

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. This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. TABLE OF CONTENTS Precautions. 00-i Precautions.00-1 General Information. 0-i General Information.0A-1 Maintenance and Lubrication.

0B-1 Service Data.0C-1 Engine. 1-i Precautions. 1-1 Engine General Information and Diagnosis. 1A-1 Emission Control Devices.1B-1 Engine Electrical Devices.1C-1 Engine Mechanical.1D-1 Engine Lubrication System. Table of Contents 00- i Section 00 Precautions CONTENTS Precautions.00-1 General Precautions. 00-1 Precautions for Electrical Circuit Service.

00-2 Precautions.00-1 Warning / Caution / Note.00-1. CAUTION special meanings.

Pay special attention to the messages highlighted by these signal words. If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or WARNING their equivalent. Indicates a potential hazard that could result. When removing parts that are to be reused, in death or injury. Precautions: 00-2. Use a torque wrench to tighten fasteners. Before refitting the sealed coupler, make sure its seal to the specified torque.

Wipe off grease rubber is positioned properly. The seal rubber may and oil if a thread is smeared with them. Possibly come off the position during disconnecting work and if the coupler is refitted with the seal rubber. 00-3 Precautions:. When connecting meter probe from the terminal side Fuse of the coupler (where connection from harness side. When a fuse is blows, always investigate the cause to not being possible), use extra care not to force and correct it and then replace the fuse.

Precautions: 00-4. When disconnecting and connecting the coupler,. Before measuring voltage at each terminal, check to make sure to turn OFF the ignition switch, or make sure that battery voltage is 11 V or higher. Electronic parts may get damaged. Terminal voltage check with a low battery voltage will lead to erroneous diagnosis.

00-5 Precautions: When checking system circuits including an electronic 4) Using continuity inspect or voltage check procedure control unit such as ECM, etc., it is important to perform as described below, inspect the wire harness careful check, starting with items which are easier to terminals for open circuit and poor connection. Precautions: 00-6 Voltage check Short circuit check (Wire harness to ground) If voltage is supplied to the circuit being checked, voltage 1) Disconnect the negative (–) cable from the battery. Check can be used as circuit check.

2) Disconnect the connectors/couplers at both ends of 1) With all connectors/couplers connected and voltage the circuit to be checked.: 8 (Multi-circuit tester set) I7-02 “D”: To other parts Using the multi-circuit testers. Use the Suzuki multi-circuit tester set. Use well-charged batteries in the tester. Be sure to set the tester to the correct testing range. Special tool (A): 8 (Multi-circuit tester set). Engine Idle Speed Inspection and Adjustment.0B-10 Symbols.

0A-1 Throttle Body Inspection.0B-10 Abbreviations.0A-2 Throttle Cable Play Inspection and SAE-to-Former SUZUKI Term.0A-2 Adjustment.0B-10 Vehicle Side View.0A-3 Fuel Line Replacement.0B-11 Vehicle Identification Number.0A-3 Fuel Line Inspection.0B-11. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1: 1) Apply SUZUKI SUPER GREASE “A” or equivalent.

0 Apply SUZUKI MOLY PASTE or equivalent. 0 Apply WATER RESISTANCE GREASE or equivalent. J1930 terms and abbreviations which may be used in CPU: Central Processing Unit this manual in compliance with SAE recommendations, as well as their former SUZUKI names. DC: Direct Current Ex.

SAE term (Abbreviation): Former SUZUKI term DMC: Dealer Mode Coupler. Voltage Regulator (VR): Voltage Regulator Vehicle Side View I9-07 B94 NOTE Difference between illustration and actual vehicle may exist depending on the markets. SUZUKI LT-Z400 (2009-model) Right side “B” I9-01 Fuel and Oil Recommendation B96 Fuel (for USA and Canada).

Use distilled water only. Water other than distilled water JASO.

Can corrode and clog the aluminum radiator. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select and Anti-freeze / Engine coolant alternative according to the chart.

0A-5 General Information: Country and Area Codes B99 The following codes stand for the applicable country(-ies) and area(-s). Code Country or area Effective frame No. LT-Z400K9 (E-19) E.U. LT-Z400K9 (E-28) Canada JSAAK4AA92 100001– LT-Z400K9 (E-33) U.S.A. Wire Color Symbols B90 Symbol Wire color Symbol.

General Information: 0A-6 Warning, Caution and Information Labels Location B91 17 E F 11 F 8 F 6 F 4 F 9 E 7 E 1 E,13 E 3 E 10 E 5 E 19 B E, 20 C F 15 F 14 E 12 E F, 16. 0A-7 General Information: Component Location Electrical Components Location B91 I9-02 1. Ignition coil 9. Cooling fan fuse 2. Ignition fuse 6. Cooling fan relay 10.

Cooling fan 3. Starter relay/Main fuse 7. TO sensor 11. IAT sensor 4.

Fuel injector 8. General Information: 0A-8 I9-02 12. Mode select switch coupler 16. Regulator/Rectifier 20. GP switch 13.

Fuel level gauge (Thermistor) 17. Fuel pump 21.

CKP sensor 14. IAP sensor 18. ECT sensor 22.

Generator 15. TP sensor 19. Starter motor. 0A-9 General Information: Specifications Specifications B91 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Overall length 1 830 mm (72.0 in) Overall width 1 190mm (46.9 in) Overall height 1 145 mm (45.1 in) Wheelbase 1 245 mm (49.0 in) Front track.

General Information: 0A-10 Chassis Item Specification Front suspension Independent, double wishbone, coil spring, oil damped Rear suspension Swingarm type, coil spring, oil damped Front wheel travel 215 mm (8.5 in) Rear wheel travel 230 mm (9.1 in) Caster 6.3° Trail 28.6 mm (1.13 in) Toe-out 6 mm (0.24 in). 0A-11 General Information: Special Tools and Equipment Special Tool B91 7 8 1 2 2 Snap ring pliers Snap ring pliers Vernier calipers (1/15 Vernier calipers (1/20 Micrometer (1/100 mm, 150 mm) mm, 200 mm) mm, 25 – 50 mm) 4 5 8.

General Information: 0A-12 1 0 1 0 1 Universal clamp Crankshaft installer Oil seal remover Bearing installer set Compression gauge wrench attachment attachment 2 1 1 3 1 Compression gauge Oil pressure gauge set Oil pressure gauge Oil pressure gauge Meter (for high hose attachment. 0A-13 General Information: 1 0 1 0 1 Drive chain cutting Bearing remover Bearing remover Bearing installer set Bearing installer set and joining tool 1 0 4 1 1 Spark plug wrench set Torx wrench Rotor remover slide Rotor remover Rotor remover shaft 0.

Maintenance and Lubrication: 0B-1 Maintenance and Lubrication General Information Precautions Precautions for Maintenance B91 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience. 0B-2 Maintenance and Lubrication: Scheduled Maintenance Periodic Maintenance Schedule Chart B91 NOTE I = Inspect and clean, adjust, replace or lubricate as necessary. L = Lubricate.

Interval Item Initial 1 month Every 3 months Every 6 months Air cleaner element. Maintenance and Lubrication: 0B-3 Lubrication Points B92 Lubricate exposed parts Initially at 1 month and every 3 months thereafter Proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated as follows. 0B-4 Maintenance and Lubrication: Repair Instructions Air Cleaner Element Cleaning 7) Remove the drain plug (1) of the air cleaner box to B91 allow any water to drain out. Air cleaner element cleaning Every 3 months Inspect and clean the air cleaner element in the following procedures: 1) Remove the air cleaner element.

Maintenance and Lubrication: 0B-5 Valve Clearance Inspection and Adjustment 6) Remove the valve timing inspection plug (5) and B93 generator cover cap (6). Inspect valve clearance Initially at 1 month and every 6 months thereafter Inspection Tappet clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism is serviced, and c) when the camshafts are removed for servicing. 0B-6 Maintenance and Lubrication: 8) Insert the thickness gauge between the tappet and 3) Check the figures printed on the shim.

These figures the cam. If the clearance is out of specification, indicate the thickness of the shim, as illustrated. Adjust it to the specified range. Maintenance and Lubrication: 0B-7 (INTAKE SIDE) I9-03. 0B-8 Maintenance and Lubrication: (EXHAUST SIDE) I9-02. Maintenance and Lubrication: 0B-9 6) Install the intake or exhaust camshafts. Refer to “Engine Top Side Assembly in Section 1D (Page 1D- 20)”.

7) Rotate the engine so that the tappet is depressed fully. This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement, then check the clearance again to confirm that it is within the specified range. 0B-10 Maintenance and Lubrication: Spark Arrester Cleaning 3) Set the engine idle speed between 1 500 and 1 700 B96 r/min by turning the idle air screw (1). Spark arrester cleaning Engine idle speed Every 6 months 1 600 ± 100 r/min Clean the spark arrester in the following procedures: 1) Remove the spark arrester (1).

Maintenance and Lubrication: 0B-11 3) Tighten the lock-nut (1) while holding the adjuster Engine Oil and Filter Replacement (2). B92 Replace engine oil 4) Install the boot correctly. Initially at 1 month and every 6 months thereafter Replace oil filter Initially at 1 month and every 6 months thereafter Oil should be changed while the engine is warm. 0B-12 Maintenance and Lubrication: Oil filter replacement CAUTION When reassembling the oil filter, make sure that the oil filter is installed as properly. If the filter is installed improperly, serious engine damage may result.

1) Drain engine oil as described in the engine oil replacement procedure. Maintenance and Lubrication: 0B-13 6) Install the oil filter cap (1) and tighten the bolts Clutch Inspection and Adjustment securely. B94 Inspect clutch lever play NOTE Initially at 1 month and every 6 months thereafter Face the triangle mark “A” on the cap Inspect and adjuster the clutch lever play “a”. 0B-14 Maintenance and Lubrication: 4) Flush the radiator with fresh water if necessary. 5) Tighten the drain plug (2) to the specified torque.

CAUTION Replace the gasket with a new one. Tightening torque Engine coolant drain plug (a): 6 Nm (0.6 kgf-m, 4.5 lb-ft) I9-01 Engine coolant change. Maintenance and Lubrication: 0B-15 9) After warming up and cooling down the engine 3) After finishing the radiator hose inspection, reinstall several times, add the engine coolant up to the full the left side cover. Level of the reservoir tank. Radiator Hoses Replacement CAUTION Replace radiator hoses.

0B-16 Maintenance and Lubrication: Drive chain length inspection 3) Loosen or tighten the chain adjuster nut (2) until there is 30 – 40 mm (1.2 – 1.6 in) “a” of slack at the 1) Place the vehicle on level ground. Middle of the chain between the engine and rear 2) Loosen the rear axle housing bolts (1). Do not use any oil sold commercially as affected. “drive chain oil”.

Such oil can damage the O-rings. Front. The standard drive chain is a RK520 SMOZ10S.

SUZUKI recommends to use this standard drive chain as a replacement. “A” I9-01 Rear I9-01. 0B-18 Maintenance and Lubrication: Brake pedal height inspection and adjustment 1) Loosen the parking brake adjuster lock-nut (1) while holding the adjuster (2) with a wrench. 1) Inspect the brake pedal height “a” between the pedal top face and footrest. 2) Loosen the adjuster (2).

Maintenance and Lubrication: 0B-19 Brake fluid level check Front and rear brake hose inspection Inspect brake fluid level Inspect brake hose Every 3 months Every 6 months 1) Place the vehicle on a level ground and place the Inspect the brake hoses and hose joints for crack, handlebars straight. 0B-20 Maintenance and Lubrication: Special tool Front and Rear Wheel Set Nuts Inspection: 5 (Tire depth gauge) B99 Tighten front and rear wheel set nuts Tire tread depth “a” (Service limit) Each time the vehicle is ridden Front: 4.0 mm (0.16 in) Rear: 4.0 mm (0.16 in) Tighten the front and rear wheel set nuts to the specified torque. Maintenance and Lubrication: 0B-21 Check that the rear axle nut is tightened to it specified 5) Apply thread lock to the rear axle nut bolt (3). Torque.: Thread lock cement 0 If the specified torque is lower than specification, tighten (THREAD LOCK CEMENT SUPER 1322 or the rear axle nut and lock-nut as follows. 0B-22 Maintenance and Lubrication: Suspensions Inspection Steering System Inspection B91 B92 Inspect suspensions Inspect steering system Every 6 months Initially at 1 month and every 3 months thereafter Inspect the suspensions in the following procedures: Steering should be adjusted properly for smooth turning of handlebars and safe running. Maintenance and Lubrication: 0B-23 Chassis Bolts and Nuts Inspection B93 Tighten chassis bolts and nuts Initially at 1 month and 3 months thereafter Check that all chassis bolts and nuts are tightened to their specified torque.

I9-01 Wishbone arm pivot nut (Upper & Lower) 65 N⋅m (6.5 kgf-m, 47.0 lb-ft) I9-01 Handlebar clamp bolt 26N⋅m (2.6 kgf-m, 19.0 lb-ft). 0B-24 Maintenance and Lubrication: I9-02 I9-02 Tie-rod end nut 29 N⋅m (2.9 kgf-m, 21.0 lb-ft) Front brake pipe nut (Upper) 16 N⋅m (1.6 kgf-m, 11.5 lb-ft) Tie-rod end lock-nut 29 N⋅m (2.9 kgf-m, 21.0 lb-ft) Footrest mounting bolt 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) Knuckle end nut 29 N⋅m (2.9 kgf-m, 21.0 lb-ft) I9-02 I9-02.

. LT-F400/F OWNER’S MANUAL This owner’s manual contains important safety information. Please read it carefully. Never allow anyone under 16 years old to ride this ATV.

99011-27H61-03A April, 2008 www.quad-forum.sk. California Proposition 65 Warning WARNING Engine exhaust, some of its constituents, and certain product com- ponents contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. This manual should be considered a permanent part of the ve- hicle and should remain with the vehicle when resold or other- wise transferred to a new owner or operator.

WARNINGs and CAUTIONs IMPORTANT are arranged like this:  WARNING /CAUTION /NOTE  WARNING-or-CAUTION Please read this manual and fol- low its instructions carefully. To This first part will identify a emphasize special information, POTENTIAL HAZARD.  the symbol and the words WARNING, CAUTION and NOTE This second part will describe. In the USA, anyone who pur- available at the time of publica- chases a new Suzuki ATV, and tion. Due to improvements or everyone in the purchaser's other changes, there may be immediate family who is old. Read this manual and all emission compliance. Your labels carefully and follow the authorized Suzuki dealer has operating procedures experienced technicians that described.

Are trained to provide your. Never operate an ATV without machine with the best possible proper instruction. Always avoid operating an ATV.

Never operate on excessively rough, slippery or loose terrain on paved surfaces, including sidewalks, paths, parking lots, until you have learned and drive ways, and streets. Practiced the skills necessary to control the ATV on such ter-. Always follow proper proce-. Always check for obstacles before operating in a new dures for going down hills and braking hills area.

Never attempt to operate described this manual. Over large obstacles, such as large rocks or fallen trees.

Check the terrain carefully before you start down any hill. Never exceed the stated load capacity for an ATV. Cargo should be properly distributed securely attached.

Reduce speed follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. MORE INFORMATION ABOUT ATV SAFETY, owners in the USA can call the Consumer Product Safety Commission at 1- 800-638-2772, or the ATV Distrib. TABLE OF CONTENTS FUEL AND OIL RECOMMENDATIONS CONTROLS, EQUIPMENT AND ADJUSTMENTS RIDING YOUR ATV ACCESSORY USE AND VEHICLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING PREPARATION FOR WINTER RIDING TRANSPORTING CLEANING PROCEDURE AND STORAGE PROCEDURE CONSUMER INFORMATION SPECIFICATIONS INDEX www.quad-forum.sk. www.quad-forum.sk. FUEL AND OIL RECOMMENDATIONS FUEL.1-2 ENGINE OIL.1-3 FRONT DIFFERENTIAL GEAR OIL (LT-F400F) AND FINAL GEAR OIL.1-4 www.quad-forum.sk. Oxygenated fuels which meet the such fuels are not the responsibil- minimum octane requirement and ity of Suzuki and may not be cov- the requirements described below ered under the New Vehicle may be used in your ATV without.

Be sure that any oxygenated engine oil. Suzuki recommends fuel you use has octane rat- the use of SUZUKI PERFOR- ings of at least 87 pump MANCE 4 MOTOR OIL or equiva- octane ((R+M)/2 method). Lent engine oil.

Use oil with an API. JASO T903 Energy Conserving The JASO T903 standard is an Suzuki does not recommend the index to select engine oils for 4- use of “ENERGY CONSERVING” stroke motorcycle oils. Some engine oils which have engines. Motorcycle and ATV an API classification of SH. CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS.2-2 KEY.2-5 IGNITION SWITCH.2-6 SPEEDOMETER AND INDICATOR LIGHTS.2-7 RANGE LEVER.2-8 SELECTION LEVER (LT-F400F). 2-9 GEARSHIFT LEVER.2-10 LEFT HANDLEBAR.

2-10 RIGHT HANDLEBAR.2-13 THROTTLE LIMITER. CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS 1 Rear brake lever 2 Left handlebar switches 3 Choke lever 4 Speedometer and indicator lights 5 Selection lever (LT-F400F) 6 Front brake fluid reservoir 7 Front brake lever 8 Range lever 9 Fuel tank cap 0 Fuel gauge A Ignition switch B Throttle lever.

2018 Suzuki Ltz 400 Service Manual Free Download

C Fuel valve D Box E Seat lock F Recoil starter G Gearshift lever H Footrests www.quad-forum.sk. I Rear brake pedal www.quad-forum.sk.  WARNING Indicates a potential hazard that could result in injury or death. Two keys come with this vehicle. Keep the spare key in a safe place. An identifying number is stamped on the keys.

Use this number when making a replace- ment key. IGNITION SWITCH CAUTION Leaving the ignition switch in  the “ ” position for a long time can damage the ATV’s bat- tery. The battery will run down if the lights are no for a long time when the engine is not run- The ignition switch has three posi- ning. SPEEDOMETER AND Oil temperature Indicator “” INDICATOR LIGHTS A red light will come on if the engine oil gets too hot. The light will come on during starting to check bulb operation. The light should be off during normal oper- ation. Operating the range lever when the ATV is moving can be haz- ardous.

If you shift into reverse gear when the LT-F400/F is moving, it could stop suddenly, throw- ing you from the ATV. If you Select a range position according. SELECTION LEVER (LT-F400F) The selection lever is used for changing the manner in which 4WD: Engine power is supplied to engine power is supplied to the the front and rear wheels, and the wheels. Select 2WD or 4WD right front wheel and left front according to surface conditions.

Parking Brake Lock 2 Use this lock to set and lock the parking brake. Use the parking brake to help prevent the LT-F400/ F from moving when it is parked, being started, or at idle.

To lock This vehicle has a 5-speed trans. Dimmer Switch 3 CAUTION Use the dimmer switch to select the high or low headlight beam Sticking some tape or placing when the ignition switch is in the objects in front of the headlight “(LIGHTS)” position. When you can damage the headlight. Move the dimmer switch to the “”. Electric Starter Button “” 5 Use this button to turn the starter motor. Before starting the engine, turn the ignition switch to the “ON” position and shift the transmission into neutral. Push the electric starter button to start the engine.

NOTE: The engine can be started in any gear, if it is hard to shift into neutral, by squeezing the rear. CHOKE LEVER “” RIGHT HANDLEBAR The carburetor of this vehicle has Front Brake Lever 1 a choke system to provide easy Apply the front brake by squeez- starting when the engine is cold. Ing the front brake lever towards The choke system works by mov- the grip. THROTTLE LIMITER REAR BRAKE PEDAL Pressing the rear brake pedal will Use the throttle limiter to restrict apply the rear brake. Maximum engine power by limit- ing throttle lever travel. Adjust this NOTE: The rear brake may also limiter according to the rider’s skill be applied by squeezing the rear and experience.

FUEL VALVE Reserve fuel supply: 2.9 L (0.8 US gal) This vehicle is equipped with an automatic type, diaphragm style fuel valve. There are three posi- tions: “ON,” “RES” and “PRI.” “PRI” (PRIME) Position In this position, fuel can flow from the fuel valve to the carbureter. RECOIL STARTER FUEL TANK CAP This vehicle has a recoil starter To open the fuel tank cap, remove which can start the vehicle’s the end of the vent tube from the engine if the electric starter does vehicle body. Turn the fuel tank not work. FUEL GAUGE “”  WARNING Overfilling the fuel tank can be hazardous. If you overfill the fuel tank, fuel may overflow when it expands.

Fuel expands due to engine heat or heating by the sun. Fuel that overflows can catch fire. The fuel gauge shows the approx- imate amount of gasoline remain- Stop adding fuel when the fuel. SEAT LOCK FLAG BRACKET A bracket is provided so you can mount a flag on your LT-F400/F. To remove the seat, move the seat lock lever upward. Raise the rear end of the seat and slide it backward.

To lock the seat, slide the seat hook into the seat hook retainer and push down firmly. Small and light articles such as the tool kit, owner’s manual, rain gear or a wind breaker can be placed in the box. NOTE:. The box can get very hot since the heated engine is under the box. Do not keep any flamma- ble items, low heat-resistant items, foods or drink in the box. www.quad-forum.sk.

RIDING YOUR ATV WHAT YOU SHOULD KNOW BEFORE RIDING.3-2 INSPECTION BEFORE RIDING.3-4 WHAT TO WEAR.3-6 BREAK-IN.3-7 STARTING THE ENGINE.3-8 STARTING OFF AND SHIFTING.3-10 BRAKING.3-15 TURNING.3-16 SKIDDING OR SLIDING. Beginning and inexperienced operators should complete the certified training course offered by Suzuki. You should regularly practice the skills learned in the course and the operating techniques described in this owner’s man- ual. For more information.

Before you begin riding, you  WARNING should find a good place to prac- tice the skills you need to ride Operation of this ATV by chil- safely. Find a flat, open area with dren under age 16 can be haz- enough space to practice new ardous. INSPECTION BEFORE RIDING  WARNING  WARNING Operating this with improper tires, with Failure to inspect the ATV improper or uneven tire pres- before operating it can be haz- sure can be hazardous. Failure to perform proper maintenance can also If you use improper tires or be hazardous. Tank cap closed securely ATV, be sure to check the follow- Lighting Proper operation of all lights – Headlight, Brake/Taillight ing items.

Be sure your LT-F400/F is in good condition for the per- Engine stop Proper operation switch sonal safety of the rider and pro- tection of the vehicle. WHAT TO WEAR A helmet is the most important piece of gear you should wear. A  WARNING helmet can help prevent a serious head injury. Choose a helmet that Operating this ATV without fits snugly. Ask your dealer for wearing an approved motorcy- help in selecting a good quality cle helmet, eye protection. BREAK-IN Allow the Engine Oil to Circulate Before Riding The first month is the most impor- Allow enough idling time after tant in the life of your vehicle.

Warm or cold engine starting Proper operation during this before revving the engine or plac- break-in period will help assure ing the transmission in gear. NOTE: If the ATV is used under electric starter recoil extremely cold conditions, ask starter. To use the electric starter, your authorized Suzuki dealer to simply push the electric starter start the engine smoothly under button. When you use the recoil the extremely cold conditions. When the Engine is Warm:  WARNING Operation of the carburetor choke system should not be necessary. Leaving the fuel valve in the Open the throttle slightly and “PRI” position when the engine push the electric starter button or is off can be hazardous.

Use the recoil starter as described above to start the engine. STARTING OFF AND SHIFTING  WARNING  WARNING Operating this ATV on paved surfaces, including sidewalks, Carrying a passenger on this paths, parking lots, driveways, ATV can be hazardous. And streets can be hazardous.

Carrying a passenger can ATV tires are designed for off- greatly reduce your ability to road use.  WARNING  WARNING Operating this ATV on public Operating this ATV at exces- streets, roads or highways can sive speeds can be hazardous. Be hazardous. Riding at excessive speeds You can collide with another increases your chances of los- vehicle if you ride on public ing control of the ATV, which roads.  WARNING  WARNING Removing your hands from the Failure to use extra care when handlebars or feet from the operating excessively footrests during operation can rough, slippery, or loose terrain be hazardous.

Can be hazardous. If you remove even one hand or Failure to use extra care can foot from the ATV, you can cause loss of traction or vehi.

 WARNING  WARNING Failure to use extra care when The ATV can start moving as operating this ATV on unfamil- soon as you release the park- iar terrain can be hazardous. You can come upon hidden Unexpected movement rocks, bumps, or holes, without cause you to lose control of the. table below shows  WARNING approximate speed range each gear with the Range Lever Shifting incorrectly can be haz- set to High Range. Shifting up schedule Downshifting at too high of a Gear position km/h miles/h speed can cause sudden slow- →. BRAKING  WARNING To stop the LT-F400/F, first release the throttle lever. Next, apply the Operating the parking brake front and rear brakes evenly and lock when the ATV is moving at the same time. As vehicle can be hazardous.

TURNING To turn the LT-F400/F, use the fol- lowing technique:  WARNING. Move your body weight for- ward and to the inside of the Turning the ATV improperly turn.

Can be hazardous. Turn the handlebars while looking in the direction of the If you turn the ATV improperly, turn.

SKIDDING OR SLIDING You may experience skidding or sliding when you are not braking.  WARNING You may be able to overcome it by using the techniques listed below. Skidding or sliding improperly can be hazardous. If your front wheel skids: Gain front wheel traction by You may lose control of your reducing the throttle opening.

OPERATION ON HILLS Climbing a Hill  WARNING  WARNING Climbing hills improperly can Operating this ATV on exces- be hazardous. Sively steep hills can be haz- ardous. Climbing hills improperly can cause loss of control or cause The ATV can overturn more the ATV to overturn. Be extra careful when braking this section. To climb a hill with the LT-F400/F, follow the directions below.

Speed up and maintain a steady speed before reaching the bottom of the hill. Shift down to increase approach speed, if necessary. Use one of the following proce- dures to turn the vehicle around. If you are able to, drag the rear end of the LT-F400/F around until the vehicle points downhill. Stay on the uphill side of the vehicle while dragging it around. Braking on hills can be hazard- Going down a hill improperly ous.

Can be hazardous. As the LT-F400/F is four-wheel Going down a hill improperly drive, using either the front can cause loss of control or brake alone or the rear brake cause the ATV to overturn. Crossing hills or turning on any obstacles before you start hills improperly can be hazard- down the hill. Point the LT-F400/F straight downhill. Crossing hills or turning on 3.

Transfer body weight to the rear by sliding back on the hills improperly can cause loss seat. RIDING OVER OBSTACLES Remember that some obstacles are too high for your ATV or for  WARNING your abilities. If you are not sure that you can safely cross over an Improperly operating this ATV obstacle, back up and ride around over obstacles can be hazard- the obstacle. This could lead to an After repeated operation of the accident. ATV in these condition, bring it to your Suzuki dealer to have. Never operate this ATV in fast flowing water or in water brakes inspected deeper than described in this cleaned. If the brakes are frozen, bring the the brakes do not regain full stop- ATV to a warmer area to thaw out ping power, have your local the brakes.

Suzuki dealer check them before you continue riding your ATV. Www.quad-forum.sk 3-25. Dressing for Cold Weather  WARNING Riding  WARNING Operating the ATV without a properly functioning brake sys- Operating your ATV in cold tem can be hazardous. Weather without proper cloth- ing can be hazardous.

Wet or frozen brakes will increase stopping distance. We strongly recommend that if Riding your ATV on Snow and you do any cold-weather riding, you familiarize yourself with the  WARNING symptoms, treatment, and pre- vention of hypothermia.

Informa- Riding on snow-covered terrain tion is available at libraries and without care can be hazardous. Your eyes may be sensitive to  WARNING sunlight when you ride over snow or ice on a bright, sunny day.

Failure to use extra care when Snow or ice reflects more light operating on slippery surfaces into your eyes than dirt or grass such as hard-packed snow and does. RIDING IN REVERSE  WARNING  WARNING Sudden application of the throttle or making abrupt turns Improperly riding this ATV in in reverse gear can be hazard- reverse can be hazardous.

You could hit an obstacle or Throttle surges or abrupt turns person behind you, resulting in could cause you to lose control injury. www.quad-forum.sk. ACCESSORY USE AND VEHICLE LOADING ATV WINCH LEAD WIRES. 4-4 www.quad-forum.sk. Operating this with There are many types of accesso- improper modifications can be ries for sale. However, Suzuki can hazardous. Not have direct control over the quality or suitability of non-Suzuki Improper installation of acces- accessories.

Suzuki can not test sories or modification of the each accessory that is available. Suzuki dealers offer a variety of genuine Suzuki accessories for your ATV. Please contact your Suzuki dealer for details. Accessory Use and Vehicle Load- ing Guidelines. The combined weight of the rider, gear, trailer tongue weight and any accessories or cargo must never exceed the vehicle’s load capacity of 172. Suzuki genuine acces- sory ATV winch, rated line pull: 1360 kg (3000 lbs). The part num- ber of the Suzuki ATV winch for this vehicle is 99000-990YW-016.

Consult your Suzuki dealer for details about attaching the acces- sory ATV winch. INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE.5-2 NOTICE. 5-3 TOOL.5-5 BATTERY.5-5 SPARK PLUG. 5-7 IDLE SPEED ADJUSTMENT.5-9 THROTTLE CABLE ADJUSTMENT.5-9 CHOKE CABLE ADJUSTMENT.

5-10 FUEL HOSE. 5-10 ENGINE OIL. 5-11 AIR CLEANER.

INSPECTION AND MAINTENANCE  WARNING Indicates a potential hazard that could result in injury or death. MAINTENANCE SCHEDULE Perform maintenance according to odometer reading or time interval, whichever comes first. Interval Initial 200 Every 1000 Every 2000 miles Initial 100 Every 600 Every 1200 Item. If you perform improper main- tenance or do not maintain your ATV, you may have an accident.

Keep your ATV in good condi- tion. Ask your Suzuki dealer or a qualified mechanic to do the maintenance items marked with an asterisk (.). When replacing parts on your frequent full throttle, or in vehicle, use only genuine dusty, wet, sandy, or muddy Suzuki replacement parts or areas. These conditions can their equivalent. Cause the ATV to wear more quickly. TOOL BATTERY A tool kit is provided with your The battery is located under the ATV. It is located under the seat.

This battery is a sealed type battery and requires no mainte- nance. Have your dealer check the battery’s state of charge peri- odically.  WARNING CAUTION Hydrogen gas produced by bat- Reversing the battery lead teries can be hazardous. Wires can harm your ATV. Batteries produce flammable Reversing the battery lead hydrogen which wires can damage the charging explode if exposed to flames or system and the battery.

A white or dark insulator indicates that the engine may need adjustment, or another plug type may be needed. Consult your Suzuki dealer if your plug insulator is not a light brown color. CAUTION Failure to use the proper spark plug can be hazardous. Dirt can damage engine parts NOTE: If the above-named plugs that move. Are not available, consult your Suzuki dealer. Cover the spark plug hole while the spark plug is out of To install a spark plug, turn it in as the hole.

THROTTLE CABLE To adjust the idle speed properly, ADJUSTMENT you need a tachometer. If you do not have one, ask your Suzuki dealer to perform this adjustment. To adjust the throttle cable play: 1.

Remove the boot. Loosen the lock nut 1. CHOKE CABLE ADJUSTMENT FUEL HOSE Replace the fuel hose every 4 years, even if it appears to be in To adjust the choke cable play: good condition. Damage from 1.

Remove the boot. Aging may not always be visible. Loosen the lock nut 1. ENGINE OIL The oil level inspection should be performed under the following Long engine life depends much conditions: on the selection of a quality oil.

Park the vehicle on level and the periodic changing of the ground. Daily oil level checks and peri-. ENGINE OIL AND FILTER  WARNING CHANGE Change the engine oil and oil filter New and used oil can be haz- at the scheduled times. Engine should always be warm when the oil is changed so the oil Children and pets may be will drain easily.

Available from Suzuki dealer Oil filter wrench (Part No. Turn the oil filter 4 counter- clockwise with a Suzuki “cap type” oil filter wrench or a “strap type” filter wrench of the proper size. Remove the screw and fasten- ers. Wipe off the mounting surface 5 on the engine where the Be sure to use a genuine new filter will be seated with a SUZUKI oil filter or an equiva- clean rag. Lent filter designed for your ATV. Screw the new filter by hand.

Engine damage may occur if the mounting you use oil that does not meet surface. Suzuki’s specifications. Be sure to use the oil specified in the FUEL AND OIL RECOM- MENDATIONS section. 11.Start the engine (while the. AIR CLEANER CAUTION The air cleaner element must be kept clean to provide good engine Failure to inspect the air power and gas mileage. If you use cleaner element frequently if your vehicle under normal, low- the vehicle is used in dusty, stress conditions, you should ser- wet, or muddy conditions can vice the air cleaner at the intervals. Removing the Element 1.

Remove the seat. Pull out the foam element from the element frame.

Remove the fastener. Unhook the hooks and take off the air cleaner case cover 1. Remove the screw 2, then remove the element assembly www.quad-forum.sk 5-17. Washing the Element CAUTION Wash the element as follows: A torn air filter can damage your ATV. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after clean- ing it.

AIR CLEANER DRAIN TUBE  WARNING Oil and solvent can be hazard- ous. Children and pets can be harmed from contact with oil and solvent. Be sure to keep oil and solvent away from children and pets. Periodically check the drain tube shown by the arrow to see if any Dispose of used oil and solvent gasoline or oil has accumulated. GEAR OIL CHANGE Inspect and change the gear oil according to the MAINTENANCE SCHEDULE. When changing the gear oil, use SAE90 hypoid gear oil which is rated GL-5 under the API classification system. If you operate the LT-F400F where the ambient temperature is normally below 0°C (32°F), use SAE 80 Front differential gear oil (LT-F400F).

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TIRES  WARNING The LT-F400/F is equipped with low pressure tubeless tires of the New and used oil can be haz- size and type listed below: ardous. Front Rear Children and pets may be Size AT25 × 8-12 AT25 × 10-12. Tire Tread Condition Tire Pressure A low pressure gauge is provided in the tool kit, so you can measure the air pressure in your LT-F400/ F’s tires. Check the air pressure in all tires before each use of the 4.0 mm vehicle.

When operating your these sections when replacing LT-F400/F in areas where trans- tires. Portation or service facilities are not readily available, it is strongly It is very important to use the. BRAKES  WARNING The ATV is equipped with front disk and rear drum brakes.

Operating the ATV in harsh conditions can be hazardous if  WARNING you do not inspect brake wear often. Failure to properly inspect and maintain your ATV’s brake sys- Operating in mud, water, sand tems can be hazardous.

If there is fre- thoroughly after handling. Quent loss of fluid, take your Solution can be poisonous to vehicle to a SUZUKI dealer for animals. Keep out of the reach of chil- dren and animals. Riding with unevenly worn brake pads will increase your chances of having an accident. If you need to replace brake pads, have your Suzuki dealer do this work. Inspect and main- tain the brake pads as recom- mended.  WARNING  WARNING Riding this ATV after brake sys- Replacing only one of the two tem repair or brake pad brake pads can be hazardous.

Replacement without pumping the brake lever can be hazard- Replacing only one brake pad ous. REAR BRAKE Brake Pedal Adjust the brake pedal as follows: Adjust the rear brake by adjusting the brake pedal first and then adjust the brake lever.  WARNING Misadjusting the rear brake pedal and lever can be hazard- ous. 20 – 30 mm The rear brake lever and brake (0.8 –. Brake lever (Parking Brake) 5. After adjusting the play, check that the rear wheels roll freely The rear brake lever play as mea- sured at the lever holder should with the brake disengaged, the be 3 – 5 mm (0.1 – 0.2 in) when transmission in neutral and the the lever is lightly pulled in toward rear wheels off the ground. If the extension line is beyond the range (Fig.B), have the brake shoes replaced by your Suzuki dealer to insure safe operation.

Www.quad-forum.sk 5-30. Loosen the wheel nuts 1 on use one, ask your authorized the wheel to be removed. Suzuki dealer to check the 3.

Lift up the front or rear end of nuts. The vehicle by placing a jack or block under the final gear case. SPARK ARRESTER The muffler has a spark arrester which must periodically cleaned to maintain good effi- ciency. At the intervals shown in the maintenance chart, clean the spark arrester as follows.  WARNING A hot muffler can harm you. Use a brush to remove carbon deposits from spark. 12V 21/5W Taillight Check the drive shaft rubber CAUTION boots for damage and grease leak.

Ask you Suzuki dealer if Failure to use a light bulb with replacement is necessary. The correct wattage rating can damage your ATV. The electrical system can over- load, or the bulb may burn out sooner.

HEADLIGHT To replace the headlight bulb, use the following procedure: 3. Disconnect the socket 3. Remove the rubber cap 1.

Unhook the bulb holder spring 4 and pull out the bulb 5. To replace the headlight bulb, reverse the above sequence. BRAKE/TAILLIGHT FUSE Replace the brake/taillight bulb as follow: The main fuse is located under the seat. One 30A spare fuse is located inside the fuse box cover.

Turn the socket counterclock- wise and pull it off. The fuses are located under the seat. 10A TAIL fuse protects the tail- light and speedometer light. 10A IGNITION fuse protects the indicator light, brake light LT-F400/F has an output terminal and CDI unit. For attaching 12V electrical acces-. 10A FAN fuse protects the sories. Total electrical accessory cooling fan motor.

Be sure that all lubrication is performed during periodic maintenance on the vehi- cle. Shorten intervals when you use your ATV in severe condi- tions. Your authorized Suzuki dealer should do general lubrica- tion as shown in the MAINTE- NANCE CHART.

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We strongly advise you to use a genuine Suzuki trailer or an equivalent ATV trailer. You may use your LT-F400/F to tow a light trailer but always VEHICLE/TRAILER LOADING observe the requirements and To load your vehicle and trailer recommendation in this section. The weight of your loaded trailer  WARNING (Gross Trailer Weight) should never exceed 180 kg (400 lbs) Allowing cargo to shift in a when towing on uneven surfaces. Trailer while moving can be When towing at low speed along hazardous.

www.quad-forum.sk. TROUBLESHOOTING FUEL SYSTEM CHECK.6-2 IGNITION SYSTEM CHECK.6-3 www.quad-forum.sk. Loosen the drain screw If you are not sure about the which is located under the proper action, consult your carburetor. Drain the fuel Suzuki dealer about the prob- from the carburetor into a container.  WARNING COMPLAINT. 1400 – 1600 r/min.

If the ignition system is operating properly, blue spark should jump across the spark plug gap. If there is no spark, take your machine to your authorized Suzuki dealer. www.quad-forum.sk. PREPARATION FOR WINTER RIDING ENGINE OIL CHANGE.7-2 www.quad-forum.sk. PREPARATION FOR WINTER RIDING Use of some engine oils in cold weather may make the engine hard to start. It may also cause clutch drag and stiff transmission operation. Select the right oil for cold weather according to the chart in the FUEL AND OIL REC- OMMENDATIONS section.

TRANSPORTING TRANSPORTING.8-2 www.quad-forum.sk. TRANSPORTING CAUTION TRANSPORTING Failure to properly secure the It is best to transport the LT-F400/ ATV when transporting it can F in the normal position. It may be hazardous. Also be transported on its back wheels, but this is not as stable as Failure to properly secure the the normal position.  WARNING Draining fuel from the carbure- tor can be hazardous. Fuel can catch on fire if you do not handle it properly.

When draining the carburetor, always shut the engine off. Do not smoke, and never drain or refuel in an area where there are open flames or sparks. www.quad-forum.sk. CLEANING PROCEDURE AND STORAGE PROCEDURE PREPARATION FOR CLEANING. 9-2 WASHING YOUR ATV.9-3 INSPECTION AFTER CLEANING. 9-4 STORAGE PROCEDURE.9-4 MAINTENANCE DURING STORAGE.9-5 PROCEDURE FOR RETURNING TO SERVICE.9-5 www.quad-forum.sk.

PREPARATION FOR CLEANING CLEANING PROCEDURE Wash the ATV before any mud AND STORAGE dries on the ATV. PROCEDURE Block or seal the end or the A thorough cleaning of your ATV exhaust pipe (muffler) using a is a necessary part of mainte- piece of plastic wrap, cloth rag or nance and will help keep your another method to prevent water. WASHING YOUR ATV CAUTION With some care, your ATV can be washed in a similar manner to Improper cleaning can damage washing an automobile. The oil cooler. NOTE: Avoid spraying or allowing Oil cooler fins can be damaged water to flow over the following by spraying high pressure places: water on them. For this reason, Suzuki rec- extended life of your ATV, lubri- ommends that you trust this main- cate it according to the “GEN- tenance work to your dealer. ENGINE PROCEDURE FOR RETURNING Remove the spark plug and pour TO SERVICE one tablespoon of motor oil into.

Clean the entire vehicle. The spark plug hole. Reinstall the. Drain all the engine oil. Install spark plug and crank the engine a a new oil filter and fill the few times to spread the oil in the engine with fresh oil as out. www.quad-forum.sk. CONSUMER INFORMATION EMISSION CONTROL WARRANTY.10-2 SERIAL NUMBER LOCATION.10-2 LOCATION OF LABELS.

10-3 www.quad-forum.sk 10-1. SERIAL NUMBER LOCATION CONSUMER You need to know the frame and INFORMATION engine serial numbers to get title EMISSION CONTROL documents for your ATV. You also WARRANTY need these numbers to help your dealer when you order parts. WARRANTIES The warranties for your ATV are explained in a separate warranty policy booklet given to you at the time of sale. Suzuki dealer. WARNING NEVER c a r r y a p a s s e n g e r o n c a r g o r a c k o r o n AT V. WARNING UNDER UNDER Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.

NEVER operate this ATV if you are under age 16. WARNING Improper ATV use can result in SEVERE INJURY or DEATH A L W A Y S U S E N E V E R U S E N E V E R C A R R Y. Rear AT25 10–12 read carefully before operating the vehicle. If the vehicle has been resold, obtain the owner’s manual from the previous owner or contact your local SUZUKI dealer for assistance.

WARNING NEVER ride as a passenger. CAUTION Passengers can cause. Front track.880 mm (34.6 in) Rear track.900 mm (35.4 in) Seat height.840 mm (33.1 in) Curb mass.263 kg (579 lbs).

LT-F400 279 kg (615 lbs). LT-F400F ENGINE Type.Four-stroke, air-cooled with SACS, OHC Number of cylinders.1. CHASSIS Front suspension.Independent, double wishbone, coil spring, oil damped Rear suspension.Swingarm type, coil spring, oil damped Front wheel travel.170 mm (6.7 in) Rear wheel travel.170 mm (6.7 in) Caster.3° Trail.14 mm (0.55 in) Toe-in.10 mm (0.39 in) Camber.0.3°. INDEX AIR CLEANER. 5-16 FLAG BRACKET.2-18 AIR CLEANER DRAIN FRONT AND REAR WHEEL TUBE.5-19 REMOVAL.5-31 ATV WINCH LEAD FRONT BRAKE.5-25 WIRES.4-4 FRONT DIFFERENTIAL GEAR OIL (LT-F400F) AND FINAL GEAR OIL.1-4 BATTERY. 5-5 FUEL.1-2 BOX. KEY.2-5 RANGE LEVER.2-8 REAR BRAKE.5-28 REAR BRAKE LINING LEFT HANDLEBAR.2-10 WEAR LIMIT.5-30 LIGHT BULB REAR BRAKE PEDAL.2-14 REPLACEMENT.5-33 RECOIL STARTER.2-16 LOCATION OF LABELS.10-3 RIDING IN COLD LOCATION OF PARTS.2-2 WEATHER.3-25 RIDING IN REVERSE.3-29 RIDING OVER.

THROTTLE CABLE ADJUSTMENT. 5-9 THROTTLE LIMITER. 2-14 TIRES.5-21 TOOL.5-5 TRAILER TOWING.5-38 TRANSPORTING.8-2 TURNING.3-16 WASHING YOUR ATV. 9-3 WHAT TO WEAR.3-6 WHAT YOU SHOULD KNOW BEFORE RIDING.3-2 Total page: 136 www.quad-forum.sk. WARNING Indicates a potential hazard that could result in injury or death.

www.quad-forum.sk. www.quad-forum.sk. www.quad-forum.sk. This ATV is for RECREATIONAL or UTILITY USE, NO OPERATOR UNDER AGE OPERATOR ONLY-NO PASSENGERS This category G (GENERAL USE) ATV is for off road use only, for recreation and utility purposes. Training courses to teach ATV riding are available. For information contact your dealer.

WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate:. without proper training or instruction.