PAGE: 1 OF 11 SUBJECT: NOTICE OF SET-UP MANUAL APPLICABLE MODEL: LT-Z400K8 EFFECTIVE ENGINE OR FRAME NO.: REFERENCE: This bulletin is to inform you of set-up procedures of LT-Z400K8. Please inform your dealers of this notice. LT-Z400K8 Set-Up Manual will not be issued because the set-up procedures for this model remain unchanged from LT-Z400K3 except the differences described below. To set-up LT-Z400K8, please use the LT-Z400K3 Set-Up Manual and this Service Bulletin. LT-Z400K3 Set-Up Manual: 99505-01003-01T DIFFERENCE BETWEEN LT-Z400K3 AND LT-Z400K8 1. UNCRATING THE VEHICLE FRONT REAR [Page: 1, 2 Paragraph: 1] Remove the carton. Remove the bolts and brackets. The brackets, bolts and vinyl tube are no longer needed and these may be discarded. A: Bolt B: Bracket C: Vinyl tube [Page: 1, 2 Paragraph: 2] Remove the bolt to take off the front brake master cylinder from the bracket. Keep the position of front brake master cylinder with its cap facing upwards until it is installed. The bolt is no longer needed and this may be discarded. A: Front brake master cylinder B: Bolt
2. LOCATION OF PARTS [Page: 3, 5] Item Part Name Q ty Remarks Under cover 1 A Stepped Allen screw 3 8 16 mm Stepped Allen screw 2 8 20 mm Washer 2 OD:18.0 ID:10.5 B Fastener 2 C Fuel vent hose 1 D Battery holder 1 Flange bolt 2 6 16 mm Battery 1 E Battery electrolyte container 1 PAGE: 2 OF 11 Item Part Name Q ty Remarks F Owner s manual set 1 3 For E-19 CG selection G Warning label set 2 For E-19 CH selection 3 For E-19 CI selection H Fuel label 1 For limited market I Safety DVD 1 For E-19 market For front brake Holder 1 J master cylinder Flange bolt 2 6 25 mm OD ID T L OD : Outside diameter (mm) ID : Inside diameter (mm) L : Length (mm) T : Thickness (mm) The parts shown as Item G, H and I in the above table are supplied for limited markets. Please hand over the parts shown as Item F and I in the above table to your customer together with vehicle. 3. ASSEMBLY HANDLEBARS [Page: 7, 8 Paragraph: 3] Tighten the handlebar clamp bolts to the specified torque. To install the handlebars correctly, first tighten the bolt A of the front side with specified torque and then tighten the bolt B of the rear side. Make sure that the clamp has no clearance at the front side as shown in the illustration. Handlebar clamp bolt: 26 N m (2.6 kgf-m) A: Flange bolt B: Flange bolt C: Dot mark
PAGE: 3 OF 11 FRONT BRAKE MASTER CYLINDER [Page: 9, 10 Paragraph: 1] Install the front brake master cylinder onto the handlebars. Align the dot mark on the handlebars with the master cylinder-to-holder fitting surface. Tighten the front brake master cylinder mounting bolts to the specified torque. Front brake master cylinder mounting bolt: 10 N m (1.0 kgf-m) To install the holder correctly, first tighten the bolt C of the upper side with specified torque and then tighten the bolt D of the lower side. A: Front brake master cylinder B: Holder C: 6 25 mm flange bolt D: 6 25 mm flange bolt E: Dot mark CLUTCH LEVER HOLDER [Page: 9, 10 Paragraph: The next of 3] Loosen the bolts. Move the clutch lever holder at the correct position. Align the dot mark on the handlebars with the clutch lever holder fitting surface. Tighten the clutch lever holder bolts. A: Clutch lever holder B: Bolt C: Dot mark UNDER COVER [Page: 13, 14 Paragraph: 1] Install the under cover to the swingarm with screw. A: Under cover B: 8 16 mm stepped Allen screw C: 8 20 mm stepped Allen screw D: Washer OD:18.0 mm ID:10.5 mm
PAGE: 4 OF 11 WARNING TAG (FOR LIMITED MARKETS) [Page: 13, 14 Paragraph: 4] Check the warning tag place to the handlebar. This warning tag is not to be removed before sale. A: Warning tag WARNING LABEL (FOR E-19 MARKET) [Page: 13, 14] Select the appropriate language label for your country. For E-19 CG selection: German, Spanish, Portuguese For E-19 CH selection: French, Dutch For E-19 CI selection: Swedish, Finnish, Danish Stick the label selected for your country. A: Warning label (General warning) B: Warning label (Tire information) C: Warning label (Age 16) D: Warning label (Gear shifting)...for French only E: Warning label (Chain adjuster)...for French only F: Front fender (Right) G: Rear fender (Right) H: Rear axle housing
PAGE: 5 OF 11 FUEL LABEL (FOR LIMITED MARKET) [Page: 13, 14] Stick the label on the fuel tank cover. A: Fuel tank cover B: Fuel label 4. SERVICING BATTERY [Page: 17, 18 Paragraph: 3, 4] Charge the battery with a battery charger. For charging the battery, make sure to use the charger specially designed for MF battery. Otherwise, the battery may be overcharged resulting in shortened service life. Do not remove the cap during charging. Position the battery with the cap facing upward during charging. After charging the battery, install the battery in the vehicle as follows. When attaching the wiring harness battery leads to the battery terminals, observe the correct polarity. The terminal bolts and nuts are attached to the battery.
PAGE: 6 OF 11 FRONT BRAKE AIR BLEEDING [Page: 21, 22 Paragraph: 3] After bleeding the brake circuit, tighten the bleeder valve to the specified torque. Replace the rubber protective cap. Be sure to check the brake fluid level in the reservoir. Brake caliper air bleeder valve: 6.0 N m (0.60 kgf-m) A: Bleeder valve PARKING BRAKE [Page: 25, 26 Paragraph: 3, 4] Parking brake adjustment may be required if the parking brake does not work properly. Parking brake cable length: 47 51 mm 1. Loosen the lock nut A. Turn out the adjuster bolt B. 2. Loosen the lock nut D. Turn the adjuster C so that cable length is correct length. Tighten the lock nut D. 3. Turn the adjuster bolt B clockwise until it stops, then turn the adjuster counterclockwise 1/8 1/4 turn. 4. Tighten the lock nut A while holding the adjuster bolt B in position. 47 51 mm After adjusting the parking brake, check that there is no dragging when turning the rear wheel with the wheel off the ground. Also check the rear wheels are locked when the parking brake is set.
PAGE: 7 OF 11 DRIVE CHAIN [Page: 27, 28 Paragraph: 1, 2] Check the drive chain slack. Drive chain slack: 30 40 mm 30 40 mm If adjustment is necessary, carry out the procedure below: 1. Loosen the rear axle housing bolts A. 2. Adjust the slack in the drive chain by turning the chain adjuster nut B. Proper chain slack is obtained when the drive chain slack is up and down, at a point midway between the two sprockets. 3. Retighten the rear axle housing bolts A to the specified torque, then tighten the chain adjuster nut B to the specified torque. 4. Recheck the chain slack after tightening and readjust if necessary. Rear axle housing bolt A: 100 N m (10.0 kgf-m) Chain adjuster nut B: 30 N m (3.0 kgf-m) S H FRONT SUSPENSION [Page: 27, 28 Paragraph: 4] Rebound Damping Force Adjustment Adjust the setting of the rebound damping force to the standard position. Standard setting: 1-1/2 turns back To adjust, turn the adjuster A clockwise until it stops and then turn it counterclockwise until approximately 1-1/2 turns and the two punch marks align. Do not force the adjuster A past the stopped position or you may damage the adjuster. Be sure to adjust the damping force on both front suspensions equally.
PAGE: 8 OF 11 Compression Damping Force Adjustment Adjust the setting of the compression damping force to the standard position. Standard setting: 1-3/4 turns back To adjust, turn the adjuster B clockwise until it stops and then turn it counterclockwise until approximately 1-3/4 turns and the two punch marks align. Do not force the adjuster B past the stopped position or you may damage the adjuster. Be sure to adjust the damping force on both front suspensions equally. REAR SUSPENSION [Page: 29, 30 Paragraph: 2] Rebound Damping Force Setting Adjust the setting of the rebound damping force to the standard position. Standard setting: 1-1/2 turns back To adjust, turn the adjuster B clockwise until it stops and then turn it counterclockwise until approximately 1-1/2 turns and the two punch marks align. Do not force the adjuster B past the stopped position or you may damage the adjuster. SAE API JASO 10W-40 SF or SG 10W-40 SH or SJ MA ENGINE OIL [Page: 33, 34 Paragraph: 1] Engine oil Oil quality is a major contributor to your engine s performance and life. Always select good quality engine oil. Use oil with an API (American Petroleum Institute) classification of SF/SG or SH/SJ, or with a JASO classification of MA. API: American Petroleum Institute JASO: Japanese Automobile Standards Organization
PAGE: 9 OF 11 ENGINE OIL VISCOSITY RATING SELECTION CHART 20W - 50 15W - 40 15W - 50 ENGINE OIL 10W - 40 10W - 50 10W - 30 5W - 30 C -30-20 -10 0 10 20 30 40 TEMP. F -22-4 14 32 50 68 86 104 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 left chart. If the vehicle is used in very cold weather (below 10 C (14 F)), use SAE 5W-30 for good engine starting and smooth operation. JASO T903 The JASO T903 standard is an index to select engine oils for 4-stroke motorcycle and ATV engines. Motorcycle and ATV engines lubricate clutch and transmission gears with engine oil. JASO T903 specifies performance requirements for motorcycle and ATV clutches and transmission. There are two classes, MA and MB. The oil container shows the classification as shown. A: Code number of oil sales company B: Oil classification ENERGY API SERVICE SJ SAE 10W-40 CONSERVING API SERVICE SJ SAE 10W-40 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
5. TIGHTENING TORQUE [Page: 35, 36] ltem Part Name N m kgf-m STEERING, FRONT SUSPENSION AND FRONT BRAKE A Handlebar clamp bolt 26 2.6 B Handlebar holder nut 60 6.0 C Front hub nut 65 6.5 D Front wheel set nut 60 6.0 E Front shock absorber mounting bolt and nut (upper) 60 6.0 F Front shock absorber mounting bolt and nut (lower) 60 6.0 BRAKE G Front brake master cylinder mounting bolt 10 1.0 H Front brake caliper mounting bolt 26 2.6 I Rear brake master cylinder mounting bolt 10 1.0 J Rear brake caliper mounting bolt 26 2.6 K Rear brake push rod lock nut 18 1.8 L Brake caliper air bleeder 6.0 0.60 PAGE: 10 OF 11 ltem Part Name N m kgf-m REAR SUSPENSION M Rear shock absorber mounting bolt and nut (upper) 60 6.0 N Rear shock absorber mounting bolt and nut (lower) 60 6.0 O Rear hub nut 100 10.0 P Rear wheel set nut 60 6.0 OTHERS Q Footrest bolt 55 5.5 R Rear swingarm pivot nut 95 9.5 S Rear axle housing bolt 100 10.0 T Chain adjuster nut 30 3.0 U Brake pedal boss bolt 11 1.1 For other bolts and nuts not listed, refer to this chart. Bolt Diameter (mm) Conventional or 4 marked bolt 7 marked bolt N m kgf-m N m kgf-m 4 1.5 0.15 2.3 0.23 5 3 0.3 4.5 0.45 6 5.5 0.55 10 1.0 8 13 1.3 23 2.3 10 29 2.9 50 5.0 12 45 4.5 85 8.5 14 65 6.5 135 13.5 16 105 10.5 210 21.0 18 160 16.0 240 24.0 G Conventional bolt 4 marked bolt 7 marked bolt A I M E F B L J S P O K N U Q R D C HL T
PAGE: 11 OF 11 6. SAFETY CHECK OUT [Page: 41, 42] After completion of the setting-up the vehicle all the following items should be double-checked to confirm that the operation and function of the vehicle are satisfactory. Now, setting-up the vehicle and pre-delivery inspection have been completed and the vehicle can be passed to the customer. ENGINE AND TRANSMISSION ITEM MEASURE SPECIFICATIONS Engine oil Check/Refill 2 000 ml Fuel tank Drain/Fill 10.0 L Throttle cable Check/Adjust 3.0 5.0 mm Choke cable Check/Adjust 0.5 1.0 mm Reverse lock release cable Check/Adjust 1.0 2.0 mm Idle r/min Check/Adjust 1 400 1 600 r/min Exhaust system Leakage Fuel system connection Leakage/Circlip Engine coolant Check/Refill 1.2 L CHASSIS ITEM MEASURE SPECIFICATIONS Disc brake (s) Clean/Fluid level Parking brake cable length Check/Adjust 47 51 mm Rear brake pedal Check/Adjust 0 10 mm Clutch cable Check/Adjust 10 15 mm Drive chain Check/Adjust/ Lubricate 30 40 mm Oiling points All necessary points Battery Filling electrolyte Wiring and cable Routing/Operation Wiring connectors Clean/Tight Front suspension Check/Adjust R.DF: 1-1/2 turn back C.DF: 1-3/4 turn back Rear suspension Check/Adjust R.DF: 1-1/2 turn back C.DF: 2 turn back Tighten all nuts and bolts Cotter pins, circlip and fasteners Paint and chrome Warning label (For E-19 market) Torque those listed in this manual Check Inspect/ Wash and polish Select/Stick COLD TIRE INFLATION PRESSURE LOAD UP TO 110 kg 243 lbs TIRE PRESSURE FRONT REAR 30 kpa 0.30 kg/cm 2 4.4 psi ITEM Light Headlight high/low beam Taillight/Brake light Instrument Lights Reverse indicator light Neutral indicator light Coolant temperature indicator light Switch Operations Ignition switch Dimmer switch Engine stop switch Starter button Stop lamp switch Brake switch Clutch lever position switch Engine ELECTRICALS ROAD TEST INSPECTION ITEM Transmission Drive chain Clutch Gearshift lever Reverse selection knob Brake Steering Suspension Control cables Leakage 27.5 kpa 0.275 kg/cm 2 4.0 psi CHECK FOR Lighting/Adjust Lighting Operation CHECK FOR Starting/Acceleration/ Smoothness/Noise Operation/Noise Operation/Noise Operation/Noise Operation Operation Operation/Noise Stability Operation Operation/Proper return Fuel/Oil/Coolant/Exhaust R.DF: Rebound Damping Force Adjustment C.DF: Compression Damping Force Adjustment