Suzuki LT-Z400 User manual

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1st cover4th cover
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1st cover4th cover
LT-Z400
OWNER’S MANUAL
MANUEL DU PROPRIETAIRE
BRUGERVEJLEDNING
99011-07G54-28B/01BLT-Z400
Part No. 99011-07G54-28B
Part No. 99011-07G54-01B
April, 2006 EN, FR, DA
TK
K7 Printed in Japan
300 TAKATSUKA, HAMAMATSU, JAPAN
14 mm14 mmNo.16649 LT-Z400 99011-07G54-28B/01B 2/1No.16649 LT-Z400 99011-07G54-28B/01B 2/1 DIC184(TDP006) DIC157
This owner’s manual contains
important safety information.
Please read it carefully.
Never allow anyone under 16
years old to ride this ATV.
Ce ’Manuel du propriétaire contient
des informations importantes
concernant la sécurité.
Le lire soigneusement.
Ne jamais autoriser les enfants
âgés de moins de 16 ans à
piloter ce V.T.T.
Denne brugervejledning indeholder
vigtige sikkerhedsoplysninger.
Læs den omhyggeligt.
Lad aldrig børn på under 16 år
køre på denne ATV.

LT-Z400
OWNER’S MANUAL
ENGLISH
ENGLISH
This manual should be considered a permanent part of the vehi-
cle and should remain with the vehicle when resold or otherwise
transferred to a new owner or operator. The manual contains
important safety information and instructions which should be
read carefully before operating the vehicle.

IMPORTANT
 WARNING/CAUTION/ NOTE
Please read this manual and follow its
instructions carefully. To emphasize
special information, the symbol 
and the words WARNING or CAU-
TION and NOTE have special mean-
ings. Pay special attention to the
messages highlighted by these signal
words:
NOTE: Indicates special information
to make maintenance easier or
instructions clearer.
FOREWORD
• This owner’s manual contains
important safety and maintenance
information. Read it carefully
before you ride your new ATV.
Failure to follow the warnings con-
tained in this manual can result in
INJURY or DEATH.
• Do not allow anyone under age 16
to ride this ATV.
• It is important that this manual
remain with the vehicle when you
sell it. The next owner will need
this manual also. Store the
owner’s manual in the ATV’s tail
box.
© COPYRIGHT SUZUKI MOTOR
CORPORATION 2006
WARNING
Indicates a potential hazard that
could result in death or injury.
CAUTION
Indicates a potential hazard that
could result in vehicle damage.

NOTICE TO OWNER’S
AN ATV IS NOT A TOY AND CAN
BE HAZARDOUS TO OPERATE. An
ATV handles differently from other
vehicles including motorcycles and
cars. A collision or rollover can occur
quickly, even during routine maneu-
vers such as turning and driving on
hills or over obstacles, if you fail to
take proper precautions.
SEVERE INJURY OR DEATH can
result if you do not follow these
instructions:
• Read this manual and all labels
carefully and follow the operating
procedures described.
• Always follow this age recommen-
dation:
–A child under 16 years old
should never operate an ATV
with engine size greater than 90
cc.
• Only permit skilled, experienced
riders to use your ATV. Because
this is a performance ATV, it
should only be used by operators
who have already practiced and
become skilled at proper ATV
riding technique.
•Never carry a passenger on an
ATV.
• Always avoid operating an ATV
on paved surfaces, including side-
walks, paths, parking lots, drive-
ways, and streets.
• Never operate an ATV on any
public street, road or highway,
even a dirt or gravel one.
• Never operate an ATV without
wearing an approved motorcycle
helmet that fits properly. You
should also wear eye protection
(goggles or face shield), gloves,
boots, long-sleeved shirt or jacket,
and long pants.
• Never consume alcohol or drugs
before or while operating this
ATV.
• Never operate at excessive
speeds. Always go at a speed that
is proper for the terrain, visibility
and operating conditions, your
skills and experience.
• Never attempt wheelies, jumps, or
other stunts.
• Always inspect your ATV each
time you use it to make sure it is in
safe operating condition. Always
follow the inspection and mainte-
nance procedures and schedules
described in this manual.
• Always keep both hands on the
handlebars and both feet on the
footrests of the ATV during opera-
tion.
• Always go slowly and be extra
careful when operating on unfa-
miliar terrain. Always be alert to
changing terrain conditions when
operating the ATV.
• Never operate on excessively
rough, slippery or loose terrain
until you have learned and prac-
ticed the skills necessary to con-
trol the ATV on such terrain.
Always be especially cautious on
these kinds of terrain.
• Always follow proper procedures
for turning as described in this
manual. Practice turning at low
speeds before attempting to turn
at faster speeds. Do not turn at
excessive speed.

• Never operate the ATV on hills too
steep for the ATV or for your abili-
ties. Practice on smaller hills
before attempting larger hills.
• Always follow proper procedures
for climbing hills as described in
this manual. Check the terrain
carefully before you start up any
hill. Never climb hills with exces-
sively slippery or loose surfaces.
Shift your weight forward. Never
open the throttle suddenly or
make sudden gear changes.
Never go over the top of any hill at
high speed.
• Always follow proper procedures
for going down hills and for brak-
ing on hills as described in this
manual. Check the terrain care-
fully before you start down any
hill. Shift your weight backward.
Never go down a hill at high
speed. Avoid going down a hill at
an angle that would cause the
vehicle to lean sharply to one
side. Go straight down the hill
where possible.
• Always follow proper procedures
for crossing the side of a hill as
described in this manual. Avoid
hills with excessively slippery or
loose surfaces. Shift your weight
to the uphill side of the ATV.
Never attempt to turn the ATV
around on any hill until you have
mastered the turning technique
described in this manual on level
ground. Avoid crossing the side of
a steep hill if possible.
• Always use proper procedures if
you stall or roll backwards when
climbing a hill. To avoid stalling,
use the proper gear and maintain
a steady speed when climbing a
hill. If you stall or roll backwards,
follow the special procedure for
braking described in this manual.
Dismount on the uphill side or to a
side if pointed straight uphill. Turn
the ATV around and remount, fol-
lowing the procedure described in
this manual.
• Always check for obstacles before
operating in a new area. Never
attempt to operate over large
obstacles, such as large rocks or
fallen trees. Always follow proper
procedures when operating over
obstacles as described in this
manual.
• Always be careful when skidding
or sliding. Learn to safely control
skidding or sliding by practicing at
low speeds and on level, smooth
terrain. On extremely slippery sur-
faces, such as ice, go slowly and
be very cautious in order to
reduce the chance of skidding or
sliding out of control.
• Never operate an ATV in fast flow-
ing water or in water deeper than
that specified in this manual.
Remember that wet brakes may
have reduced stopping ability.
Test your brakes after leaving
water. If necessary, apply them
several times to let friction dry out
the linings.
• Always be sure there are no
obstacles or people behind you
when you operate in reverse.
When it is safe to proceed in
reverse, go slowly.

• Always use the size and type tires
specified in this manual. Always
maintain proper tire pressure as
described in this manual.
• Never modify an ATV through
improper installation or use of
accessories.
• Never exceed the stated load
capacity for an ATV. Cargo should
be properly distributed and
securely attached. Reduce speed
and follow instructions in this
manual for carrying cargo or pull-
ing a trailer. Allow greater dis-
tance for braking.
• Do not tow a trailer. This vehicle is
a performance ATV and is not
designed for such use.
WARNING
Indicates a potential hazard that
could result in injury or death.

TABLE OF CONTENTS
1
2
3
4
5
6
7
8
9
10
FUEL AND ENGINE OIL RECOMMENDATION
CONTROLS, EQUIPMENT AND ADJUSTMENTS
RIDING YOUR ATV
ACCESSORY USE AND VEHICLE LOADING
INSPECTION AND MAINTENANCE
TROUBLESHOOTING
PREPARATION FOR WINTER RIDING
TRANSPORTING
CLEANING PROCEDURE
CONSUMER INFORMATION
SPECIFICATIONS
INDEX

1-1
1
FUEL AND ENGINE OIL
RECOMMENDATION
FUEL .................................................................................................................... 1-2
ENGINE OIL ......................................................................................................... 1-2

1-2
FUEL AND ENGINE OIL
RECOMMENDATION
FUEL
Suzuki recommends that you use
unleaded gasoline containing no alco-
hol. Make sure it is rated at least 85
pump octane ((R+M)/2 method). You
may also use regular leaded gasoline
containing no alcohol.
NOTE: Unleaded gasoline will extend
spark plug life.
Blends of unleaded gasoline and eth-
anol (grain alcohol), also known as
gasohol, are commercially available
in some areas. You can use these
blends, provided they contain no
more than 5% ethanol. Be sure the
gasoline-ethanol blend you use is
rated at least 85 pump octane, as rec-
ommended for unleaded gasoline
without any alcohol.
DO NOT USE GASOLINES CON-
TAINING METHANOL (methyl or
wood alcohol), even if they contain
co-solvents and corrosion inhibitors
for methanol. Fuel system damage
and performance problems resulting
from the use of such fuels are not the
responsibility of Suzuki. The limited
warranty may not cover these prob-
lems. Some states require fuel suppli-
ers to label pumps which dispense
gasoline/alcohol blends containing
certain percentages of alcohol. These
labels may provided enough informa-
tion for you to determine if the fuel is
appropriate. In other states, pumps
may not be clearly labeled about the
content or type of alcohol. If you are
unsure about the content or type of
alcohol in the fuel you buy, check with
the service station operator.
ENGINE OIL
Oil quality is a major contributor to
your engine’s performance and life.
Always select good quality engine oil.
Use SF/SG or SH/SJ with JASO MA
in API (American Petroleum Institute)
classification.
API: American Petroleum Institute
JASO: Japanese Automobile Stan-
dards Organization
SAE Engine Oil Viscosity
Suzuki recommends the use of SAE
10W-40 engine oil. If SAE 10W-40
engine oil is not available, select an
alternative according to the following
chart.
NOTE: In very cold weather (below
14°F (–10°C)), use SAE 5W-30 for
good starting and smooth operation.
SAE API JASO
10W-40 SF or SG –
10W-40 SH or SJ MA

1-3
JASO T903
The JASO T903 standard is an index
to select engine oils for 4-stroke
motorcycle and ATV engines. Motor-
cycle and ATV engines lubricate
clutch and transmission gears with
engine oil. JASO T903 specifies per-
formance requirements for motorcy-
cle and ATV clutches and
transmissions.
There are two classes, MA and MB.
The oil container shows the classifica-
tion as follows.
1Code number of oil sales company
2Oil classification
Energy Conserving
Suzuki does not recommend the use
of “ENERGY CONSERVING” oils.
Some engine oils which have an API
classification of SH or higher have an
“ENERGY CONSERVING” indication
in the API classification doughnut
mark. These oils can affect engine life
and clutch performance.
Not recommended Recommended
E
N
E
R
G
Y
C
O
N
S
E
R
V
I
N
G
A
P
I
S
E
R
V
I
C
E
S
J
SAE
10W-40
A
P
I
S
E
R
V
I
C
E
S
J
SAE
10W-40

2-1
2
CONTROLS, EQUIPMENT AND
ADJUSTMENTS
LOCATION OF PARTS ....................................................................................... 2-2
KEY ...................................................................................................................... 2-5
IGNITION SWITCH .............................................................................................. 2-5
INDICATOR LIGHTS ........................................................................................... 2-6
GEARSHIFT LEVER ............................................................................................ 2-7
REVERSE SELECTION KNOB ........................................................................... 2-7
LEFT HANDLEBAR ............................................................................................. 2-8
CHOKE LEVER ................................................................................................... 2-9
RIGHT HANDLEBAR .......................................................................................... 2-9
THROTTLE LIMITER ......................................................................................... 2-10
REAR BRAKE PEDAL ...................................................................................... 2-10
FUEL VALVE ..................................................................................................... 2-10
FUEL TANK CAP .............................................................................................. 2-11
SEAT LOCK ....................................................................................................... 2-13
FLAG BRACKET ............................................................................................... 2-13
FRONT SUSPENSION ...................................................................................... 2-14
REAR SUSPENSION ......................................................................................... 2-15

2-2
CONTROLS, EQUIPMENT AND ADJUSTMENTS
LOCATION OF PARTS
1Clutch lever
2Left handlebar switches
3Choke lever
4Parking brake lock
5Indicator lights
6Ignition switch
7Front brake fluid reservoir
8Front brake lever
9Fuel tank cap
0Reverse selection knob
AThrottle lever

2-3
BSeat lock
CFuel valve
DGearshift lever
EFootrests

2-4
FRear brake pedal

2-5
KEY
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 mak-
ing a replacement key.
Please write down your key number
in the box provided for your future ref-
erence.
IGNITION SWITCH
The ignition switch has three posi-
tions.
“OFF” position
All electrical circuits are cut off. The
engine will not start. The key can be
removed.
“ON” position
The ignition circuit is on and the
engine can be started. The key can-
not be removed in this position.
“(LIGHTS)” position
The ignition circuit is complete and
the headlight and taillight turn on. The
key cannot be removed in this posi-
tion.
WARNING
Indicates a potential hazard that
could result in injury or death.
Key No.:
CAUTION
Leaving the ignition switch in the
“
 ” position without the engine
running for a long time can dam-
age the ATV’s battery.
The battery will run down if the
lights are no for a long time when
the engine is not running.
Always leave the ignition switch in
the “OFF” position when not oper-
ating the ATV.

2-6
INDICATOR LIGHTS
Reverse Indicator 1
A red light will come on when the
transmission is in reverse gear.
Neutral Indicator 2
A green light will come on when the
transmission is in neutral. The light
will go out when you shift into any
gear other than neutral.
Coolant temperature Indicator 3
A red light will come on when:
• The engine oil gets too hot while
operating.
• The electric starter is pushed for
starting the engine. This is for
checking light bulb.
NOTE:
• High engine speed, low vehicle
speeds, or heavy load can
increase engine coolant tempera-
ture. Decrease engine speed,
reduce load and select an appro-
priate transmission gear to lower
the temperature.
• Debris or mud in front of the
engine or packed between the
radiator fins can reduce cooling
ability. Remove any debris or mud
preventing any debris or mud pre-
venting air flow to the engine.
CAUTION
Operating the ATV while the cool-
ant temperature indicator is lit can
damage your ATV.
Continued operation of the ATV
with high engine coolant tempera-
ture may result in engine damage
or premature wear.
If the coolant temperature indica-
tor comes on, stop the engine and
allow it to cool before restarting.
Refer to the note below.

2-7
GEARSHIFT LEVER
This vehicle has a 5-speed transmis-
sion which operates as shown in the
illustration. The shift lever is attached
to a ratchet type mechanism in the
transmission. Each time you select a
gear, the gearshift lever will return to
its normal position ready to select the
next gear. Engage first gear by pulling
the clutch lever in then depressing the
lever from the neutral position. You
can shift into higher gears by lifting on
the shift lever once for each gear. The
ratchet mechanism makes it impossi-
ble to upshift or downshift more than
one gear at a time.
REVERSE SELECTION KNOB
This vehicle has a reverse gear. To
shift into reverse gear, completely
stop the vehicle and shift the trans-
mission into 1st gear while holding
the clutch lever in. Turn the reverse
selection knob clockwise and push
down the gearshift lever. Lift up the
gearshift lever to shift into 1st gear.
NOTE:
• Depress the rear brake pedal and
engage clutch partially if it is hard
to shift into reverse or return to 1st
gear.
• Check that the reverse indicator is
lit after shifting into reverse.
WARNING
Shifting into reverse gear when
the ATV is moving can be hazard-
ous.
If you shift the ATV into reverse
gear when the ATV is moving, it
could stop suddenly, throwing
you from the ATV.
Always come to a complete stop
and shift into neutral before shift-
ing into reverse gear.
REV.