Suzuki LT80J Quad Runner 1988 Workshop Repair Service Manual

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The Suzuki LT80J Quad Runner, manufactured in 1988, represents a significant entry in the youth ATV market. Engineered for recreational use by younger riders, this model is characterized by its...

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Typ: Atv

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Art.-Nr: 90529

Stichworte: 1988 Atv LT80J Misc Motorcycles Quad Runner Suzuki

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Beschreibung

The Suzuki LT80J Quad Runner, manufactured in 1988, represents a significant entry in the youth ATV market. Engineered for recreational use by younger riders, this model is characterized by its compact 82cc two-stroke engine, known for its reliable performance and straightforward operation. The automatic Continuously Variable Transmission (CVT) enhances ease of use, making it an accessible option for new riders. With independent front suspension and a single rear shock, the LT80J provides a comfortable ride, complemented by durable drum brakes for adequate stopping power. Its robust steel tube frame construction underscores Suzuki's commitment to building dependable powersports vehicles. This Workshop Repair Service Manual provides comprehensive guidance for the maintenance and repair of the 1988 Suzuki LT80J Quad Runner. It covers all essential systems, including the engine, transmission, chassis, electrical system, bodywork, suspension, and brakes. Detailed procedures for routine maintenance, troubleshooting common issues, and performing in-depth repairs are included. The manual offers technical specifications, critical torque values, and essential clearances and tolerances, ensuring accurate servicing. It is an invaluable resource for owners, mechanics, and technicians seeking to preserve the performance and longevity of their LT80J.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

LT80J Quad Runner

Year:

Codes

Model Code:

LT80J

👋 Introduction

Market Position

Category:

Entry-level youth ATV

Target Audience:

Youth riders, recreational users.

Competitive Analysis

Competitors 1988:

Honda TRX70/125, Yamaha YFM80 Badger, Kawasaki KLF80 Bayou.

Key Features

Engine Type:

Compact 2-stroke engine, known for simplicity and power delivery for its class.

Transmission:

Automatic CVT for ease of use, ideal for younger riders.

Suspension:

Independent front suspension and single shock rear suspension for a comfortable ride.

Braking:

Drum brakes front and rear, providing adequate stopping power for the application.

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Chassis:

Electrical System:

Bodywork:

Suspension:

Brakes:

Fuel System:

Cooling System:

Lubrication System:

Troubleshooting:

Maintenance:

Specifications:

Page Count

Estimated Pages:

250-350

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Disassembly Reassembly:

Complete engine teardown, inspection, and reassembly procedures for the 82cc two-stroke engine.

Carburetor Overhaul:

Detailed instructions for cleaning, adjusting, and rebuilding the carburetor.

Ignition System:

Diagnosis and repair of the CDI ignition system, including stator, coil, and spark plug.

Exhaust System:

Maintenance and replacement of the exhaust pipe and muffler.

Cooling System Type:

Air-cooled design principles and maintenance.

Lubrication System Type:

Premix lubrication system specifications and procedures.

Transmission Type:

Automatic CVT (Continuously Variable Transmission) system servicing, including clutch and drive belt inspection.

Final Drive:

Chain drive maintenance, adjustment, and lubrication.

Frame And Suspension:

Front and rear suspension component inspection, adjustment, and replacement (shocks, springs, linkages).

Steering System:

Handlebar, steering shaft, and tie rod end maintenance and alignment procedures.

Brake System Front:

Drum brake system service, including adjustment and lining replacement.

Brake System Rear:

Drum brake system service, including adjustment and lining replacement.

Wheel And Tires:

Tire pressure recommendations, wheel bearing maintenance, and tire replacement.

Electrical Components:

Headlight, taillight, brake light, horn, and starter system troubleshooting and repair.

Body Panels:

Removal and installation procedures for fenders, seat, and plastic body components.

Procedures Included

Routine Maintenance:

Scheduled maintenance tasks, lubrication points, and inspection routines.

Engine Troubleshooting:

Diagnostic flowcharts and solutions for common engine problems like starting issues, misfires, and power loss.

Transmission Troubleshooting:

Diagnosis of clutch slip, belt wear, and shifting issues.

Brake Adjustment:

Step-by-step guide for adjusting front and rear drum brakes for optimal performance.

Carburetor Adjustment:

Idle speed and mixture screw adjustments for smooth running.

Spark Plug Replacement:

Correct spark plug type, gap, and installation procedure.

Air Filter Cleaning Replacement:

Procedures for maintaining optimal engine breathing.

Chain Tension Adjustment:

Ensuring correct chain slack for longevity and performance.

Suspension Adjustment:

Settings for preload and damping where applicable.

Electrical Diagnostics:

Wiring diagrams and troubleshooting steps for electrical faults.

Engine Rebuilding:

Detailed instructions for piston, ring, cylinder, and crankshaft service.

Technical Depth

Depth:

Comprehensive, from basic maintenance to full engine and transmission overhauls.

Diagnostic Tools:

Covers basic tools required and diagnostic procedures without specialized electronic testers.

Torque Specifications:

Includes critical torque values for fasteners across all major components.

Clearances Tolerances:

Provides essential engine and mechanical clearances and tolerances for proper assembly.

📊 Manual Specifications

File Format

File Type:

Searchable:

Likely text-searchable if professionally scanned.

Print Quality

Quality:

High-resolution scans suitable for printing.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Two-stroke, air-cooled

Displacement:

82 cc (5.0 cu in)

Bore X Stroke:

49.0 mm x 44.0 mm (1.93 in x 1.73 in)

Compression Ratio:

7.0:1

Carburetor:

Mikuni VM10/1, single barrel

Ignition:

CDI (Capacitor Discharge Ignition)

Lubrication System:

Premix (20:1 fuel/oil ratio recommended for standard use)

Performance

Horsepower Approx:

Approximately 6-8 HP (Exact figures often not published for youth ATVs)

Torque Approx:

Not officially published, but designed for low-end grunt.

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

2.7 L (0.7 US gal)

🔧 Transmission

Standard

Transmission Type:

Automatic, CVT (Continuously Variable Transmission)

Drive System:

Chain drive to rear axle

Optional

Optional Transmission:

Features

Clutch Type:

Centrifugal clutch

Gear Reduction:

Primary and secondary gear reduction within CVT housing.

📐 Dimensions

Exterior

Length:

1475 mm (58.1 in)

Width:

795 mm (31.3 in)

Height:

940 mm (37.0 in)

Wheelbase:

1030 mm (40.6 in)

Ground Clearance:

100 mm (3.9 in)

Weights

Dry Weight:

110 kg (242.5 lbs)

Gross Vehicle Weight Rating Gvwr:

Not specified in manual, but typically around 200-250 lbs for rider + ATV.

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (ATVs are not subject to the same crash testing as passenger vehicles).

Active Features

Throttle Limiter:

Often equipped with a throttle limiter screw to control top speed for younger riders.

Parking Brake:

Yes, typically handlebar-mounted mechanical parking brake.

Passive Features

Frame Construction:

Steel tube frame for durability.

Handguards:

Standard for protecting rider's hands.

Footwells:

Standard safety footwells with grip.

💡 Technology Features

Infotainment

Infotainment System:

None (Basic mechanical controls only).

Driver Assistance

Driver Assistance Features:

None (Focus on simple, mechanical operation).

Connectivity

Connectivity Options:

None.

🔧 Maintenance

Service Intervals

Oil Change Frequency:

Not applicable for 2-stroke premix; oil is mixed with fuel.

Spark Plug Check Replace:

Check every 10-15 hours of operation, replace as needed (refer to manual for specific recommendations and plug type).

Air Filter Cleaning:

Clean every 20-30 hours, replace as needed (crucial for engine health).

Chain Lubrication Adjustment:

Lubricate chain every 5-10 hours, adjust tension every 20-30 hours.

Brake Adjustment:

Check and adjust every 20-30 hours of operation.

Transmission Belt Inspection:

Inspect belt condition and tension every 50-75 hours of operation; replacement typically around 100-150 hours or as wear dictates.

Fluid Specifications

Fuel Oil Mix Ratio:

20:1 (1 part 2-stroke oil to 20 parts gasoline) recommended for standard use. Consult manual for specific oil type and any variations.

Recommended 2 Stroke Oil:

Suzuki recommends API-TC or JASO FD certified 2-stroke oil.

Known Issues

Common Problem 1:

Carburetor gumming/clogging due to infrequent use or poor fuel quality.

Common Problem 2:

Drive belt wear or slippage, leading to poor acceleration.

Common Problem 3:

Starter recoil issues (pull start mechanism).

Common Problem 4:

Carburetor flooding or lean conditions if not properly adjusted.

Common Problem 5:

Electrical gremlins, particularly with aging wiring harnesses or grounds.

📚 Vehicle History

Brand Heritage

Brand Focus:

Suzuki has a long history in powersports, known for reliable and capable motorcycles and ATVs.

Model Evolution

Lt80 Lineage:

The LT80 Quad Runner was a foundational model in Suzuki's youth ATV lineup, evolving into later models like the LT-Z50 and LT-80 (which likely continued the basic platform).

Production

Production Period:

Mid-1980s to early 2000s for the LT80 platform (specific 1988 model identified).

Manufacturing Location:

Likely Japan or a Suzuki manufacturing facility overseas.

🏆 Awards & Recognition

Recognitions

Industry Awards:

None specifically documented for this model year, but the LT80 platform was widely recognized as a reliable and popular entry-level ATV.