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Table of Contents
- 3. Table of Contents
- 4. WARNING/CAUTION/NOTE
- 6. SUZUKI LT-Z400K3 (2003-MODEL)
- 7. ENGINE OIL
- 8. BREAK-lN PROCEDURES
- 9. INFORMATION LABELS
- 10. SPECIFICATIONS
- 12. COUNTRY AND AREA CODES
- 16. PERIODIC MAINTENANCE SCHEDULE
- 17. MAINTENANCE AND TUNE-UP PROCEDURES
- 18. EXHAUST PIPE NUTS AND MUFFLER BOLTS
- 19. VALVE CLEARANCE
- 24. SPARK PLUG
- 25. FUEL HOSE
- 26. ENGINE OIL AND OIL FILTER
- 27. ENGINE OIL HOSES
- 28. ENGINE COOLANT
- 29. RADIATOR HOSES
- 30. CLUTCH
- 32. BRAKE FLUID
- 34. BRAKE HOSES
- 35. STEERING
- 36. DRIVE CHAIN
- 37. Drive chain slack
- 38. SUSPENSIONS
- 39. CHASSIS BOLTS AND NUTS
- 42. GENERAL LUBRICATION
- 43. COMPRESSION PRESSURE CHECK
- 44. OIL PRESSURE CHECK
- 46. ENGINE COMPONENTS REMOVABLE WITH ENGINE ...
- 47. ENGINE REMOVAL AND REMOUNTING
- 51. ENGINE REMOUNTING
- 53. ENGINE DISASSEMBLY
- 63. ENGINE COMPONENTS INSPECTION AND SERVICE
- 72. CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBL...
- 73. Camshaft runout
- 74. CAM CHAIN TENSION ADJUSTER AND TENSIONER
- 75. PISTON AND PISTON RING
- 77. CONROD
- 78. BALANCER SHAFT AND BALANCER DRIVEN GEAR
- 79. STARTER CLUTCH
- 80. STARTER TORQUE LIMITER
- 81. CLUTCH
- 82. GEARSHIFT FORK AND GEAR
- 83. TRANSMISSION
- 86. CRANKCASE
- 90. CLUTCH COVER
- 91. ENGINE REASSEMBLY
- 92. GEARSHIFT CAM, FORK AND REVERSE LOCK SHA...
- 93. CRANKCASE
- 94. STARTER CLUTCH AND GENERATOR ROTOR
- 95. PRIMARY DRIVE GEAR AND BALANCER GEAR
- 96. GEARSHIFT CAM DRIVEN GEAR
- 97. OIL PUMP
- 98. CLUTCH
- 100. NEUTRAL SWITCH
- 101. PISTON RING
- 102. PISTON AND CYLINDER
- 103. CYLINDER HEAD
- 104. CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBL...
- 106. CYLINDER HEAD COVER
- 107. CAM CHAIN TENSION ADJUSTER
- 108. FUEL SYSTEM
- 109. FUEL TANK
- 110. FUEL LINE INSPECTION
- 111. FUEL VALVE
- 112. CARBURETOR
- 113. SPECIFICATIONS
- 114. REMOVAL
- 115. DISASSEMBLY
- 119. CLEANING
- 120. REASSEMBLY
- 121. REMOUNTING
- 122. COOLING AND LUBRICATION SYSTEM
- 123. COOLING SYSTEM
- 124. ENGINE COOLANT
- 125. RADIATOR AND HOSES
- 126. RADIATOR HOSE INSPECTION
- 127. RADIATOR REMOUNTING
- 128. COOLING FAN
- 129. REMOUNTING
- 130. COOLING FAN THERMO-SWITCH
- 131. INSPECTION
- 132. ENGINE COOLANT TEMPERATURE SWITCH
- 133. THERMOSTAT
- 134. WATER PUMP
- 135. REMOVAL AND DISASSEMBLY
- 137. INSPECTION
- 138. REASSEMBLY AND INSTALLATION
- 142. OIL TANK AND HOSES
- 143. REMOVAL
- 144. REMOUNTING
- 145. LUBRICATION SYSTEM
- 146. ENGINE LUBRICATION SYSTEM CHART
- 149. EXTERIOR PARTS
- 151. REMOVAL
- 155. REMOUNTING
- 156. FRONT AND REAR WHEELS
- 157. REMOVAL
- 158. INSPECTION AND DISASSEMBLY
- 159. REASSEMBLY AND REMOUNTING
- 162. TIRES
- 164. FRONT BRAKE
- 165. BRAKE PAD REPLACEMENT
- 166. BRAKE FLUID REPLACEMENT
- 168. BRAKE CALIPER INSPECTION
- 169. BRAKE CALIPER REASSEMBLY AND REMOUNTING
- 171. BRAKE DISC REMOVAL AND DISASSEMBLY
- 172. MASTER CYLINDER REMOVAL AND DISASSEMBLY
- 173. MASTER CYLINDER INSPECTION
- 175. FRONT SUSPENSION
- 176. REMOVAL
- 177. INSPECTION AND DISASSEMBLY
- 180. REASSEMBLY AND REMOUNTING
- 183. SUSPENSION SETTING
- 184. STEERING
- 185. REMOVAL
- 188. INSPECTION AND DISASSEMBLY
- 190. REASSEMBLY AND REMOUNTING
- 194. TOE-IN ADJUSTMENT
- 195. FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSI...
- 196. REAR BRAKE
- 197. BRAKE PAD REPLACEMENT
- 198. BRAKE FLUID REPLACEMENT
- 199. BRAKE CALIPER REMOVAL AND DISASSEMBLY
- 201. BRAKE CALIPER INSPECTION
- 202. BRAKE CALIPER REASSEMBLY AND REMOUNTING
- 205. BRAKE DISC REMOVAL AND REMOUNTING
- 206. MASTER CYLINDER REMOVAL AND DISASSEMBLY
- 207. MASTER CYLINDER INSPECTION
- 208. MASTER CYLINDER REASSEMBLY AND REMOUNTIN...
- 209. REAR SHOCK ABSORBER
- 211. INSPECTION
- 212. REMOUNTING
- 214. REAR SUSPENSION
- 215. REMOVAL
- 217. INSPECTION AND DISASSEMBLY
- 221. REASSEMBLY
- 224. REMOUNTING
- 226. REAR AXLE
- 227. REMOVAL
- 228. INSPECTION AND DISASSEMBLY
- 230. REASSEMBLY AND REMOUNTING
- 236. REAR WHEEL, REAR BRAKE, REAR SUSPENSION,...
- 238. REVERSE LOCK RELEASE CABLE
- 239. REMOUNTING
- 241. ELECTRICAL SYSTEM
- 242. CAUTIONS IN SERVICING
- 243. BATTERY
- 244. LOCATION OF ELECTRICAL COMPONENTS
- 246. CHARGING SYSTEM
- 248. INSPECTION
- 251. STARTER SYSTEM
- 252. STARTER MOTOR REMOVAL AND DISASSEMBLY
- 253. STARTER MOTOR INSPECTION
- 254. STARTER MOTOR REASSEMBLY AND REMOUNTING
- 255. STARTER RELAY INSPECTION
- 257. IGNITION SYSTEM
- 259. INSPECTION
- 262. INDICATOR LIGHT POSITION
- 263. LAMPS
- 264. BRAKE LIGHT/TAILLIGHT
- 265. SWITCHES
- 266. BATTERY
- 268. SERVICING
- 269. SERVICING INFORMATION
- 270. TROUBLESHOOTING
- 273. RADIATOR
- 274. CHASSIS
- 275. BRAKES
- 276. ELECTRICAL
- 277. BATTERY
- 278. WIRING DIAGRAM
- 279. WIRING HARNESS, CABLE AND HOSE ROUTING
- 281. CABLE ROUTING
- 283. FUEL HOSE ROUTING
- 284. ENGINE OIL HOSE AND PIPE ROUTING
- 286. COOLING SYSTEM HOSE ROUTING
- 287. FRONT BRAKE HOSE ROUTING
- 288. REAR BRAKE HOSE ROUTING
- 289. SEAT RAIL AND CHAIN ROLLER INSTALLATION
- 290. SPECIAL TOOLS
- 293. TIGHTENING TORQUE
- 294. CHASSIS
- 295. TIGHTENING TORQUE CHART
- 296. SERVICE DATA
- 302. Tire pressure
Page 1 of 304
Table of Contents
- 3. Table of Contents
- 4. WARNING/CAUTION/NOTE
- 6. SUZUKI LT-Z400K3 (2003-MODEL)
- 7. ENGINE OIL
- 8. BREAK-lN PROCEDURES
- 9. INFORMATION LABELS
- 10. SPECIFICATIONS
- 12. COUNTRY AND AREA CODES
- 16. PERIODIC MAINTENANCE SCHEDULE
- 17. MAINTENANCE AND TUNE-UP PROCEDURES
- 18. EXHAUST PIPE NUTS AND MUFFLER BOLTS
- 19. VALVE CLEARANCE
- 24. SPARK PLUG
- 25. FUEL HOSE
- 26. ENGINE OIL AND OIL FILTER
- 27. ENGINE OIL HOSES
- 28. ENGINE COOLANT
- 29. RADIATOR HOSES
- 30. CLUTCH
- 32. BRAKE FLUID
- 34. BRAKE HOSES
- 35. STEERING
- 36. DRIVE CHAIN
- 37. Drive chain slack
- 38. SUSPENSIONS
- 39. CHASSIS BOLTS AND NUTS
- 42. GENERAL LUBRICATION
- 43. COMPRESSION PRESSURE CHECK
- 44. OIL PRESSURE CHECK
- 46. ENGINE COMPONENTS REMOVABLE WITH ENGINE ...
- 47. ENGINE REMOVAL AND REMOUNTING
- 51. ENGINE REMOUNTING
- 53. ENGINE DISASSEMBLY
- 63. ENGINE COMPONENTS INSPECTION AND SERVICE
- 72. CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBL...
- 73. Camshaft runout
- 74. CAM CHAIN TENSION ADJUSTER AND TENSIONER
- 75. PISTON AND PISTON RING
- 77. CONROD
- 78. BALANCER SHAFT AND BALANCER DRIVEN GEAR
- 79. STARTER CLUTCH
- 80. STARTER TORQUE LIMITER
- 81. CLUTCH
- 82. GEARSHIFT FORK AND GEAR
- 83. TRANSMISSION
- 86. CRANKCASE
- 90. CLUTCH COVER
- 91. ENGINE REASSEMBLY
- 92. GEARSHIFT CAM, FORK AND REVERSE LOCK SHA...
- 93. CRANKCASE
- 94. STARTER CLUTCH AND GENERATOR ROTOR
- 95. PRIMARY DRIVE GEAR AND BALANCER GEAR
- 96. GEARSHIFT CAM DRIVEN GEAR
- 97. OIL PUMP
- 98. CLUTCH
- 100. NEUTRAL SWITCH
- 101. PISTON RING
- 102. PISTON AND CYLINDER
- 103. CYLINDER HEAD
- 104. CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBL...
- 106. CYLINDER HEAD COVER
- 107. CAM CHAIN TENSION ADJUSTER
- 108. FUEL SYSTEM
- 109. FUEL TANK
- 110. FUEL LINE INSPECTION
- 111. FUEL VALVE
- 112. CARBURETOR
- 113. SPECIFICATIONS
- 114. REMOVAL
- 115. DISASSEMBLY
- 119. CLEANING
- 120. REASSEMBLY
- 121. REMOUNTING
- 122. COOLING AND LUBRICATION SYSTEM
- 123. COOLING SYSTEM
- 124. ENGINE COOLANT
- 125. RADIATOR AND HOSES
- 126. RADIATOR HOSE INSPECTION
- 127. RADIATOR REMOUNTING
- 128. COOLING FAN
- 129. REMOUNTING
- 130. COOLING FAN THERMO-SWITCH
- 131. INSPECTION
- 132. ENGINE COOLANT TEMPERATURE SWITCH
- 133. THERMOSTAT
- 134. WATER PUMP
- 135. REMOVAL AND DISASSEMBLY
- 137. INSPECTION
- 138. REASSEMBLY AND INSTALLATION
- 142. OIL TANK AND HOSES
- 143. REMOVAL
- 144. REMOUNTING
- 145. LUBRICATION SYSTEM
- 146. ENGINE LUBRICATION SYSTEM CHART
- 149. EXTERIOR PARTS
- 151. REMOVAL
- 155. REMOUNTING
- 156. FRONT AND REAR WHEELS
- 157. REMOVAL
- 158. INSPECTION AND DISASSEMBLY
- 159. REASSEMBLY AND REMOUNTING
- 162. TIRES
- 164. FRONT BRAKE
- 165. BRAKE PAD REPLACEMENT
- 166. BRAKE FLUID REPLACEMENT
- 168. BRAKE CALIPER INSPECTION
- 169. BRAKE CALIPER REASSEMBLY AND REMOUNTING
- 171. BRAKE DISC REMOVAL AND DISASSEMBLY
- 172. MASTER CYLINDER REMOVAL AND DISASSEMBLY
- 173. MASTER CYLINDER INSPECTION
- 175. FRONT SUSPENSION
- 176. REMOVAL
- 177. INSPECTION AND DISASSEMBLY
- 180. REASSEMBLY AND REMOUNTING
- 183. SUSPENSION SETTING
- 184. STEERING
- 185. REMOVAL
- 188. INSPECTION AND DISASSEMBLY
- 190. REASSEMBLY AND REMOUNTING
- 194. TOE-IN ADJUSTMENT
- 195. FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSI...
- 196. REAR BRAKE
- 197. BRAKE PAD REPLACEMENT
- 198. BRAKE FLUID REPLACEMENT
- 199. BRAKE CALIPER REMOVAL AND DISASSEMBLY
- 201. BRAKE CALIPER INSPECTION
- 202. BRAKE CALIPER REASSEMBLY AND REMOUNTING
- 205. BRAKE DISC REMOVAL AND REMOUNTING
- 206. MASTER CYLINDER REMOVAL AND DISASSEMBLY
- 207. MASTER CYLINDER INSPECTION
- 208. MASTER CYLINDER REASSEMBLY AND REMOUNTIN...
- 209. REAR SHOCK ABSORBER
- 211. INSPECTION
- 212. REMOUNTING
- 214. REAR SUSPENSION
- 215. REMOVAL
- 217. INSPECTION AND DISASSEMBLY
- 221. REASSEMBLY
- 224. REMOUNTING
- 226. REAR AXLE
- 227. REMOVAL
- 228. INSPECTION AND DISASSEMBLY
- 230. REASSEMBLY AND REMOUNTING
- 236. REAR WHEEL, REAR BRAKE, REAR SUSPENSION,...
- 238. REVERSE LOCK RELEASE CABLE
- 239. REMOUNTING
- 241. ELECTRICAL SYSTEM
- 242. CAUTIONS IN SERVICING
- 243. BATTERY
- 244. LOCATION OF ELECTRICAL COMPONENTS
- 246. CHARGING SYSTEM
- 248. INSPECTION
- 251. STARTER SYSTEM
- 252. STARTER MOTOR REMOVAL AND DISASSEMBLY
- 253. STARTER MOTOR INSPECTION
- 254. STARTER MOTOR REASSEMBLY AND REMOUNTING
- 255. STARTER RELAY INSPECTION
- 257. IGNITION SYSTEM
- 259. INSPECTION
- 262. INDICATOR LIGHT POSITION
- 263. LAMPS
- 264. BRAKE LIGHT/TAILLIGHT
- 265. SWITCHES
- 266. BATTERY
- 268. SERVICING
- 269. SERVICING INFORMATION
- 270. TROUBLESHOOTING
- 273. RADIATOR
- 274. CHASSIS
- 275. BRAKES
- 276. ELECTRICAL
- 277. BATTERY
- 278. WIRING DIAGRAM
- 279. WIRING HARNESS, CABLE AND HOSE ROUTING
- 281. CABLE ROUTING
- 283. FUEL HOSE ROUTING
- 284. ENGINE OIL HOSE AND PIPE ROUTING
- 286. COOLING SYSTEM HOSE ROUTING
- 287. FRONT BRAKE HOSE ROUTING
- 288. REAR BRAKE HOSE ROUTING
- 289. SEAT RAIL AND CHAIN ROLLER INSTALLATION
- 290. SPECIAL TOOLS
- 293. TIGHTENING TORQUE
- 294. CHASSIS
- 295. TIGHTENING TORQUE CHART
- 296. SERVICE DATA
- 302. Tire pressure
File size: 21.10 MB
Created: March 10, 2023
Last updated: March 30, 2023
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