Target Audience:
Owners, amateur mechanics, and professional ATV technicians.
Purpose:
To provide comprehensive guidance for maintaining, troubleshooting, and repairing the Suzuki LT80J Quad Runner.
Value Proposition:
Offers official factory data, ensuring accuracy and completeness for all service needs, saving time and money compared to guesswork or incomplete information.
Feature 1:
Authoritative source for official factory service procedures.
Feature 2:
Detailed diagnostic flowcharts and troubleshooting guides.
Feature 3:
Clear, step-by-step repair instructions with illustrations (implied by 'hundreds of pages').
Feature 4:
Essential for maintaining resale value and optimal performance.
Engine Section:
Engine overhaul, disassembly, assembly, inspection, adjustments, troubleshooting, and repair procedures for all engine components.
Fuel System:
Carburetor service, fuel pump, fuel lines, fuel tank maintenance and repair.
Ignition System:
CDI unit, ignition coil, spark plug, stator, troubleshooting of ignition faults.
Lubrication System:
Oil pump, oil passages, oil filter (if applicable), oil level checks, and lubrication points.
Transmission System:
Automatic transmission (CVT) service, clutch operation, gear inspection, lubrication, and adjustment.
Drive System:
Chain drive, sprockets, wheel hubs, maintenance and replacement procedures.
Braking System:
Front and rear brake caliper service, brake pads, brake shoes, brake fluid replacement, bleeding procedures, and master cylinder repair.
Suspension System:
Front and rear suspension linkage, shock absorbers, bushings, steering knuckle, and fork service.
Steering System:
Handlebar assembly, steering shaft, tie rods, steering knuckles, and alignment.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, starter motor, charging system (stator), and component testing.
Chassis And Frame:
Frame inspection, body panels, seat, footpegs, and general chassis maintenance.
Routine Maintenance:
Oil changes, air filter cleaning/replacement, spark plug inspection/replacement, chain adjustment, brake checks, and general lubrication.
Troubleshooting:
Diagnostic procedures for common issues, identifying causes of poor performance, starting problems, and system failures.
Repair Procedures:
Step-by-step instructions for disassembling, repairing, and reassembling all major vehicle components and systems.
Overhaul Procedures:
Detailed instructions for complete engine and transmission rebuilds.
Electrical Diagnostics:
Using wiring diagrams to trace faults, test components, and diagnose electrical problems.
Carburetor Tuning:
Jetting, adjustment, and cleaning procedures for optimal performance.
Diagnostic Capabilities:
Advanced diagnostic information, fault codes (if applicable), and specific troubleshooting trees for various issues.
Rebuild Level:
Comprehensive rebuild instructions for engine, transmission, and major sub-assemblies.
Special Tools:
Identification and usage of specialized tools required for certain repair and diagnostic procedures.
Torque Specifications:
Precise torque values for all fasteners and critical components.
Clearances And Tolerances:
Specifications for critical component clearances and wear limits.
Engine Type:
2-stroke, air-cooled
Displacement:
72 cc (4.39 cubic inches)
Bore X Stroke:
45.0 mm x 47.0 mm (1.77 in x 1.85 in)
Compression Ratio:
6.6 : 1
Cylinder Arrangement:
Single Cylinder
Valve Train:
Reed Valve Intake
Horsepower Est:
Approx. 6.5 - 7.5 HP (exact figure varies by source and tuning)
Torque Est:
Not widely published, but sufficient for its class.
Fuel Delivery:
Carburetor
Carburetor Model:
Mikuni VM16SS (or similar)
Fuel Type:
Unleaded Gasoline (87 octane or higher recommended)
Oil Mixture:
2-stroke oil mixed with gasoline at a ratio of 50:1 (refer to manual for specific Suzuki oil grades).
Engine Oil Change:
Every 20-30 operating hours or annually (refer to manual for precise interval).
Air Filter Cleaning:
Every 10-15 operating hours or as needed in dusty conditions.
Spark Plug Inspection:
Every 20-30 operating hours; replace as needed based on condition.
Chain Lubrication Adjustment:
Lubricate every 10-15 hours; check and adjust tension every 20-30 hours.
Brake Fluid Flush:
Every 1-2 years or as recommended by manual for optimal performance.
Engine Oil Type:
API SE, SF, or SG class 2-stroke engine oil (Suzuki recommends their own branded oil).
Transmission Oil Type:
Suzuki Gear Oil API GL-4 SAE 80W/90 (Part Number: 99000-22060-007 or equivalent).
Issue 1:
Carburetor clogging due to infrequent use or fuel degradation.
Issue 2:
Chain and sprocket wear requiring regular maintenance.
Issue 3:
Starting difficulties often related to fuel delivery, spark plug, or battery in older units.
Issue 4:
Wear and tear on suspension bushings and pivot points due to off-road use.
Manufacturer:
Suzuki Motor Corporation
Heritage Focus:
Known for lightweight, reliable, and performance-oriented motorcycles and ATVs.
Lt80 Lineage:
The LT80 was a foundational model in Suzuki's youth ATV lineup, designed for recreational use and introducing new riders to the sport.
Competitors Era:
Competed with similar youth ATVs from brands like Yamaha (YFM80), Honda (ATC70/80/125M predecessors), and Kawasaki (KLT85).
Production Years Range:
Mid-1980s to early 2000s (exact start/end varies by market and minor updates, but 1988 is a key year).
