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FOREWORD This service manual has been specially prepared to provide all the necessary information for the proper maintenance and repair of the LT80. The LT80 is a new type of vehicle that has many technical features such as: * * * * *

V-belt drive automatic transmission Forced air-cooling system P. E. Ignition system Electric starter system Starter interlock mechanism

This manual contains up-to-date information at the time of its issue. Later made modifications and changes will be explained to each SUZUKI distributor in respective markets, to whom you are kindly requested to make query about up dated information, if any. The LT80 vehicles distributed in your country might differ in minor respects from the standard-specification and, if they do, it is because some minor modifications (which are of no consequence in most cases as far as servicing is concerned) had to be made to comply with the statutory requirements of your country.

SUZUKI MOTOR CORPORATION Motorcycle Service Department


VIEW OF SUZUKI LT80

LEFTSIDE

RIGHT SIDE


GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE ENGINE SERVICING FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASIS SERVICING INFORMATION Revised 05/06


SUPPLEMENTS

LT80J ('88-,MODEL) LT80K ('89-,MODEL) LT80L ('90-,MODEL) LT80M /N/P/R/S/T/V/W/X/Y/K1 (1991 TO 2001 models) LT80K2/K3/K4/K5 (2002 TO 2005 models) LT80K6 ('06 MODEL)


CONTENTS VIN AND SERIAL NUMBER LOCATIONS................................ 1 - 1 SPECIFICATIONS.....................................................................1 - 2 FUEL AND OIL RECOMMENDATIONS.................................... 1 - 4 BREAK-IN PROCEDURE..........................................................1 - 4 PRECAUTIONS

AND

GENERAL

INSTRUCTIONS.....1 - 5

SPECIAL MATERIALS..............................................................1 - 6 SPECIAL FEATURES................................................................1- 8 POWER TRANSMISSION..................................................1 - 8 FORCED AIR-COOLING SYSTEM.................................... 1 -11


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GENERAL INFORMATION

VIN AND SERIAL NUMBER LOCATIONS ENGINE NUMBER The engine serial number is stamped on the upside of the crankcase. This number is required especially for registering the vehicle and ordering spare parts.

FRAME NUMBER The frame number or VIN (Vehicle Identification Number) is stamped on the front frame, left side. This number is required especially for registering the vehicle and ordering spare parts.


GENERAL INFORMATION

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GENERAL INFORMATION

CHASSIS Front suspension Rear suspension Steering angle Caster Trail Turning radius Front brake Rear brake Front tire size Rear tire size

ELECTRICAL Ignition type Ignition timing Spark plug

Battery Generator Fuse

CAPACITIES Fuel tank including reserve reserve Engine oil tank Final gear oil * These specifications are subject to change without notice.


GENERAL INFORMATION

FUEL AND OIL RECOMMENDATIONS Be sure to use the specified fuel and oils. The fallowings are the specifications.

FUEL Use only unleaded or low-lead type gasoline of at least 85—95 pump octane method) 89 octane or higher rated by the Research Method. For other models Gasoline used should be graded 85 — 95 octane or higher. An unleaded or low-lead gasoline type is recommended.

ENGINE OIL For the SUZUKI CCI system, use of SUZUKI CCI or CCI SUPER OIL is highly recommended, but if they are not available, a good quality two-stroke oil (non-diluent type) should be used.

FINAL GEAR OIL Use a good quality SAE 20W/40 multi-grade motor oil.

BREAKING-IN PROCEDURE During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to " B R E A K - I N " before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows: • Keep to these breaking-in speed limit: Up to 10 hours

Less than 1/2 throttle

Upon passing 10 hours you can subject the motorcycle to full throttle operation.

Do not maintain constant engine speed for an extended time period during any portion of the break-in. Try to vary the throttle position.

or

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GENERAL INFORMATION

PREAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when disassembling and reassembling AT V s . • Do not run engine indoors with little or no ventilation. • Be sure to replace packings, gaskets, circlips, O-rings and cotter pins with new ones. CAUTION: Never reuse a circlip. After a circlip has been removed from 3 shaft, if should be discarded and a new circlip must be installed, When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always insure that it is completely seated in its groove and securely fitted. • Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter, and from inside to outside diagonally, to the specified tightening torque. • Use special tools where specified. •

Use genuine parts and recommended oils.

• When 2 or more persons work together, pay attention to the safety of each other. • After the reassembly, check parts for tightness and operation. • Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use gasoline as cleaning solvent. Warning, Caution and Note are included in this manual occasionally, describing the following contents. WARNING CAUTION NOTE

The personal safety of the rider or bystanders may be involved. Disregarding this information could result in personal injury. These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine. This provides special information to make maintenance easier or important instructions clearer.

REPLACEMENT PARTS W h e n you replace any parts, use only genuine SUZUKI replacement parts, or their equivalent. Genuine SUZUKI parts are high quality parts which are designd and built specifically for SUZUKI vehicles. CAUTION: Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems and damage.


GENERAL INFORMATION

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SPECIAL MATERIALS The materials listed below are needed for'maintenance work on the LT80 and should be kept on hand fo ready use. These items supplement such standard materials as cleaning fluids, lubricants, emery cloth and the like. How to use them and where to use them are described in the text of this manual.

SUZUKI SUPER GREASE " A " 99000-25030

SUZUKI SUPER GREASE " A " 99000-25010


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GENERAL INFORMATION


GENERAL INFORMATION

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SPECIAL FEATURES The LT80 is equipped with a 2-stroke, 82.5cc engine with a reed valve intake system. Aluminum head is used to improve the cooling efficiency of the fully encased engine. Moreover, the covered cylinder and cylinder head are forcibly cooled by a fan attached to the magneto rotor, which serves to maintain the engine temperature at optimum operaiting efficiency.


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GENERAL INFORMATION

LT80 POWER TRANSMISSION The three mechanism are installed in the left-side crankcase. The first is the V-belt drive mechanism using the centrifugal force for automatic speed change. The second is the clutch mechanism for transmission control of the drive power to the countershaft. The third is the reduction gears mechanism for reduction of the drive power from the clutch and for transmission of the power to the driveshaft. The power of the driveshaft is transmitted to the rear axleshaf t by the drive chain.


GENERAL INFORMATION

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GENERAL INFORMATION .

FORCED AIR-COOLING SYSTEM This system is utilized to cool the cylinder/cylinder head and V-belt forcibly by the fresh air. The fresh air from the air cleaner intake duct separates into three ways; carburetor air, cylinder/cylinder head cooling air and V-belt cooling air. The carburetor air goes through the right hole in the air cleaner case and the air cleaner element, and then into the carburetor. The cylinder/cylinder head cooling air forcibly sent by the cooling fan goes through the main hole in the air cleaner case and into the cylinder cover to cool the cylinder/cylinder head, and is given off from the outlet duct. The V-belt cooling air forcibly drawn by the cooling fan goes through! the left hole in the air cleaner case and into the left crankcase cover to cool the V-belt, and is given off through the pipe and mixed w i t h the cylinder/cylinder head cooling air at the cooling fan. The V-belt cooling air is stirred by the fan installed on the fixed drive face for the effective V-belt cooling.


PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE


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PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE


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