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2. Repair Manual

. 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. 2016 ktm 350 freeride repair manual. 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.

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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.

Suzuki LTZ400 ManualThis Clymer ATV manual covers the Suzuki lt Z400 for these years: 2003, 2004, 2005, 2006, 2007, 2008 Clymer ATV repair manuals are the best reference book for repair and service information. Every Clymer service manual is written for the do-it-yourselfer as well as the experienced mechanic, Clymer repair manuals are the cheapest way to keep your four wheeler running properly. Every Clymer ATV service manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the ATV covered. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail, accuracy and clarity to guide the reader through each service, troubleshooting and repair procedure. The Suzuki LT Z400 manual includes the following chapters:.

General Information. Troubleshooting. Lubrication, Maintenance and Tune-up.

Engine Top End. Engine Lower End. Clutch and External Shift Mechanism. Transmission and Internal Shift Mechanism. Fuel System. Electrical System.

Cooling System. Front Suspension and Steering. Rear Suspension. Brakes. Body.

Index. Color Wiring Diagram The Suzuki LT Z400 manual contains the following:. Handy thumb-tabs put the chapter you need right at your fingertips. Detailed substeps expand on service procedure information. Notes, cautions and warnings throughout each chapter pinpoint critical information.

Numbered instructions guide you through every repair procedure step by step. Bold figure numbers help you quickly match illustrations with instructions.

Repair Manual

Detailed illustrations, drawings and photos guide you through every service procedure. Exploded views help you identify and examine parts in detail. Numbered table of contents. Easy to use so that you can find the information you need fast. Clymer repair manuals also make it easy to diagnose and repair electrical system problems on your all terrain vehicle. Troubleshooting and electrical service procedures are combined with detailed wiring diagrams (color on select titles) for ease of use. Suzuki LT Z400 Repair Manual Suzuki LT Z400 Service Manual Suzuki LT Z400 Shop Manual.