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
Revised 05/06 SERVICING INFORMATION CHASIS ELECTRICAL SYSTEM FUEL AND LUBRICATION SYSTEM ENGINE SERVICING PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE GENERAL INFORMATION
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
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
1-1 GENERAL INFORMATION
GENERAL INFORMATION 1-2
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.
1-3 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) or 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 "BREAK-IN" 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
GENERAL INFORMATION 1-1
PREAUTIONS AND GENERAL INSTRUCTIONS
Observe the following items without fail when disassembling and reassembling AT Vs
• 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 The personal safety of the rider or bystanders may be involved Disregarding this information could result in personal injury
CAUTION
These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine
NOTE This provides special information to make maintenance easier or important instructions clearer.
REPLACEMENT PARTS
When 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.
1-5 GENERAL INFORMATION
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
GENERAL INFORMATION 1-6
1-7 GENERAL INFORMATION
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
GENERAL INFORMATION 1-B
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.
1-9 GENERAL INFORMATION
GENERAL INFORMATION 1-10
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 with 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
1-11 GENERAL INFORMATION .
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE
2-1 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE
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