🏷️ Basic Information

Make:

Suzuki

Model:

DS80

Engine Type:

2-stroke, air-cooled

Engine Displacement Cc:

79

Configuration:

Single Cylinder

Fuel Type:

Gasoline

Vehicle Type:

Off-road Motorcycle / Dirt Bike

👋 Introduction

Target Audience:

Do-it-yourself mechanics, motorcycle enthusiasts, and owners seeking to perform maintenance and repairs.

Cost Savings:

Enables users to save on dealer labor costs by providing factory-level repair information.

Manual Quality:

Exact same manual provided to factory dealers, offering the highest level of accuracy and detail.

Data Availability:

Includes detailed diagrams, illustrations, and exploded views crucial for accurate assembly and disassembly.

Market Segment:

Small displacement youth dirt bikes, competing with models from Yamaha (e.g., YZ80), Honda (e.g., CR80R), and Kawasaki (e.g., KX80).

📋 Manual Details

Applicable Years:

1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000

File Format:

PDF

Page Count:

170

Language:

English

Manual Type:

Service Repair Manual

Manual Part Number:

99500-20173-03E

📖 Manual Coverage

Systems Covered:

General Information, Periodic Maintenance, Fuel System, Cooling System, Engine Top End, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Crankcase, Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Troubleshooting

Engine Top End Coverage:

Detailed procedures for cylinder head removal, piston and ring inspection/replacement, cylinder inspection, and reassembly.

Fuel System Coverage:

Carburetor disassembly, cleaning, adjustment, and troubleshooting procedures.

Electrical System Coverage:

Wiring diagrams, ignition system troubleshooting, lighting, charging system (if applicable), and component testing.

Brakes Coverage:

Details on drum brake inspection, adjustment, and shoe replacement.

Suspension Coverage:

Front fork and rear shock absorber maintenance, adjustment, and seal replacement.

Frame Steering Coverage:

Headset bearing maintenance, frame integrity checks, and steering system component inspection.

Procedures Included:

Detailed Diagrams, Illustrations, Photos, Exploded Views, Step-by-step Instructions, Diagnostics

Troubleshooting Guide:

Systematic approach to diagnosing common problems and their solutions, organized by symptom.

Rebuild Instructions:

Comprehensive step-by-step instructions for major component rebuilds, including engine and transmission.

Technical Depth:

Comprehensive repair and maintenance procedures covering all aspects from basic upkeep to complex component overhauls.

Torque Specifications:

Provides essential torque values for critical fasteners throughout the motorcycle.

Clearances:

Specifies required clearances for components like piston-to-cylinder, ring end gap, and valve clearances (if applicable, though unlikely for this 2-stroke).

📊 Manual Specifications

Searchability:

Keyword Searchable

Compatibility:

All Versions of Windows & Mac

Requirements:

Adobe PDF Reader

Menu Structure:

Clickable Menu, Bookmarks

Print Options:

Fully Printable, Single Page Printing, Chapter Printing, Full Manual Printing

Resolution:

High Resolution

Recommended Binding:

3-ring Binder (user adaptable)

⚙️ Engine Specifications

Bore X Stroke:

49.0 mm x 42.0 mm

Compression Ratio:

6.9:1 (approx.)

Horsepower Estimate:

7.5 HP @ 8000 RPM (estimated, varies by year/tune)

Torque Estimate:

6.0 Nm @ 7000 RPM (estimated, varies by year/tune)

Carburetor Type:

Mikuni VM Series (e.g., VM18) or equivalent

Fuel Mixture:

Pre-mix (gasoline and 2-stroke oil)

Cooling Method:

Air-cooled

Lubrication System:

Premix lubrication

🔧 Transmission

Transmission Type:

Constant Mesh, 6-speed Manual

Gear Ratios:

Specific gear ratios detailed in manual (e.g., 1st: 2.916, 2nd: 2.062, 3rd: 1.555, 4th: 1.222, 5th: 1.045, 6th: 0.913)

Clutch Type:

Wet multi-plate

Final Drive Type:

Chain Drive

📐 Dimensions

Dry Weight Kg:

approx. 70-75 kg (varies by year)

Wet Weight Kg:

approx. 75-80 kg (varies by year)

Front Wheel Size:

16 inch

Rear Wheel Size:

14 inch

Front Tire Size:

2.50-16 (e.g., 2.50-16 4PR)

Rear Tire Size:

3.00-14 (e.g., 3.00-14 4PR)

🔧 Maintenance

Oil Change Interval:

Recommended every 1000-1500 km or annually (specific to gearbox/2-stroke oil).

Spark Plug Replacement:

Recommended every 2000-3000 km or annually.

Air Filter Cleaning:

Frequent cleaning/replacement based on operating conditions (e.g., every 500-1000 km).

Engine Oil Type:

2-stroke engine oil (specific API/JASO grades detailed in manual).

Transmission Oil Type:

Gear Oil (e.g., SAE 80 or SAE 10W-30 API GL-4, capacity approx. 0.5-0.7L)

Brake Fluid Type:

DOT 3 or DOT 4 (for hydraulic brakes, if equipped; drum brakes typically do not use fluid).

Fork Oil Type:

Suspension fork oil (specific viscosity grade provided in manual, e.g., SAE 10W).

Common Wear Items:

Piston rings, clutch plates, swingarm bushings, wheel bearings, fork seals, brake shoes.

Carburetion Issues:

Clogged jets, pilot circuit issues leading to poor idling or stalling.

2-Stroke Specifics:

Importance of correct fuel/oil mixture, carbon buildup in exhaust and cylinder head.

Pre Ride Inspection:

Emphasis on checking tire pressure, chain tension, brakes, and fluid levels before each ride.

📚 Vehicle History

Manufacturer:

Suzuki Motor Corporation

Segment:

Entry-level/youth off-road motorcycle

Target Demographic:

Young riders learning to ride off-road or compete in junior motocross events.

Production Period:

Introduced in the early 1980s, with this manual covering models up to 2000, indicating a long production run with potential minor updates.