Suzuki LT-Z400, Kawasaki KFX400, Arctic Cat DVX400 Repair Manual 2003-2009

The 2003-2009 Suzuki LT-Z400, Kawasaki KFX400, Arctic Cat DVX400 repair manual by Haynes covers:

• Suzuki LT-Z400 (398cc), 2003-2009
• Kawasaki KFX400 (398cc), 2003-2006
• Arctic Cat DVX400 (398cc), 2004-2008

These ATVs are powered by 398 cubic centimeter, liquid-cooled, single-cylinder, four-stroke, four-valve DOHC engines. The transmission is a 5-speed forward, 1 reverse gear, multi-plate clutch unit.

Book Excerpt: 2003-2009 Suzuki LT-Z400, Kawasaki KFX400, Arctic Cat DVX400 Repair Manual ENGINE, CLUTCH AND TRANSMISSION

ENGINE REMOVAL

1. Remove the seat and engine skid plate (see Chapter 8).
2. Disconnect negative cable from the battery (see Chapter 4).
3. Remove the fuel tank and exhaust system (see Chapter 4).
4. Drain the engine oil and coolant (see Chapter 1).
5. Disconnect the radiator hoses from the engine (see Chapter 3). Remove the radiator lower mounting bolts and push the bottom of the radiator far enough forward to provide removal clearance for the engine. Remove the thermostat.
6. Remove the carburetor or throttle body (see Chapter 4).
7. Unbolt the clutch cable bracket from the valve cover and disconnect the clutch cable from the engine (see Section 20).
8. Disconnect the spark plug wire (see Chapter 1).
9. Disconnect the oil hoses. Remove the oil tank and oil return tank (see Section 18).
10. Remove the drive sprocket from the engine, together with the chain (see Chapter 6).
11. Disconnect the breather hose(s) from the valve cover (see illustration 7.16a).

COOLING SYSTEM

GENERAL INFORMATION The vehicles covered by this manual are equipped with a liquid cooling system which utilizes a water/antifreeze mixture to carry away excess heat produced during combustion. The combustion chamber and cylinder are surrounded by a water jacket, through which the coolant is circulated by the water pump. The pump is mounted to the right side of the crankcase near the front and is driven by a gear. The radiator is mounted at the front of the frame. The coolant is pumped upward through the cylinder water jacket and cylinder head, then flows from the cylinder head to the radiator where it is cooled, then flows through the radiator bottom hose and water pump, then back into the engine. A thermostat, mounted in the cylinder head, regulates coolant flow. When the engine is cold, the thermostat closes and coolant circulates through the water pump, thermostat by-pass hole, coolant hoses and radiator. As the engine warms up, the thermostat opens, allowing coolant to be circulated through the engine coolant passages. The cooling system includes a temperature warning light and fan, but does not include a thermostat. All models have a reservoir tank. As the coolant heats up, it expands and flows into the reservoir tank. As it cools, the coolant is pulled back into the cooling system.

Subject: 2003, 2004, 2005, 2006, 2007, 2008, 2009 Suzuki LT-Z400, Kawasaki KFX400, Arctic Cat DVX400 service, maintenance, repair. ISBN-10: 1563929104 | ISBN-13: 9781563929106 | Haynes 2910