Suzuki Quad Runner 80 1987-2006 Service Repair Manual

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This manual covers the Suzuki Quad Runner 80 (LT80) model, produced from 1987 through 2006. The Quad Runner 80 is a well-regarded, youth-oriented all-terrain vehicle known for its reliability and...

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Taper: Atv

Distributeur:

UGS: 91189

Mots clés: 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 Atv Misc Motorcycles Quad Runner 80 Suzuki

Variantes de produits

Description

This manual covers the Suzuki Quad Runner 80 (LT80) model, produced from 1987 through 2006. The Quad Runner 80 is a well-regarded, youth-oriented all-terrain vehicle known for its reliability and ease of use. Engineered in Japan, this two-stroke, air-cooled ATV features a 72.7 cc engine and an automatic Continuously Variable Transmission (CVT) drive system, making it an accessible option for younger riders. Its design prioritizes safety with features like an adjustable throttle limiter and integrated footwells, contributing to its enduring popularity in the entry-level ATV market. This comprehensive Service Repair Workshop Manual provides detailed guidance for owners, mechanics, and technicians. It encompasses all essential aspects of maintenance, repair, and troubleshooting for the Suzuki LT80. Coverage includes complete engine overhauls, transmission servicing, drivetrain and suspension maintenance, brake system repairs, and electrical system diagnostics. With step-by-step instructions, detailed diagrams, and specifications, this manual is an indispensable resource for keeping the Quad Runner 80 in optimal operating condition and ensuring its longevity.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

Quad Runner 80

Model Designation:

Product Type:

Service Repair Workshop Manual

👋 Introduction

Market Position

Target Audience:

Owners, independent repair shops, and mechanics working on Suzuki LT80 Quad Runner ATVs.

Competitive Analysis

Value Proposition:

Provides essential information for maintaining and repairing a popular youth ATV, saving on dealership service costs and extending vehicle lifespan.

Key Features

Comprehensiveness:

Covers a wide range of model years and all major mechanical and electrical systems.

Detail Level:

Includes detailed diagrams, torque specifications, and troubleshooting guides.

📋 Manual Details

Coverage Areas

Covered Years:

1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006

Page Count

Estimated Page Count:

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, disassembly, assembly, inspection, tuning, carburetor, ignition system, cooling system (air-cooled), exhaust system.

Transmission:

Automatic transmission (CVT) service, clutch assembly, drive belt, gear reduction inspection and adjustment.

Drivetrain:

Front and rear axle service, differential inspection, drive shafts, wheel bearings, chain drive maintenance (if applicable for specific sub-models).

Suspension:

Front and rear suspension components, shock absorbers, A-arms, bushings, steering system components, linkage maintenance.

Brakes:

Front and rear brake systems (drum or disc depending on year/variant), brake shoe/pad replacement, hydraulic system bleeding, brake cable adjustment.

Electrical:

Ignition system, lighting, charging system (stator, regulator/rectifier), battery service, starter motor, wiring diagrams, component testing.

Fuel System:

Fuel tank, fuel lines, fuel filter replacement, carburetor disassembly, cleaning, adjustment, and troubleshooting.

Frame And Body:

Frame inspection, body panel removal/installation, fenders, handlebars, seat, plastic components, graphics.

Procedures Included

Maintenance:

Routine maintenance checks, oil changes, filter replacements, spark plug service, chain lubrication and adjustment, battery maintenance, air filter cleaning/replacement.

Troubleshooting:

Diagnostic procedures for common starting, running, and performance issues. Fault finding based on symptoms.

Repair:

Step-by-step instructions for component removal, repair, and reinstallation for all major systems.

Rebuilds:

Complete engine and transmission rebuild procedures with detailed specifications.

Adjustments:

Carburetor adjustments, brake adjustments, clutch adjustments, chain tension adjustments.

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic information and specifications.

📊 Manual Specifications

File Format

Quality:

High-resolution, searchable PDF with clear diagrams and text.

Print Quality

Printability:

Printable pages for easy workshop reference.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Two-stroke, single-cylinder

Displacement:

72.7 cc

Bore X Stroke:

43.0 mm x 50.0 mm

Cooling System:

Air-cooled

Ignition System:

CDI (Capacitor Discharge Ignition)

Compression Ratio:

6.5 : 1

Starting System:

Kick starter

Performance

Horsepower:

Approximately 7-8 HP (Varies slightly by year and tuning)

Torque:

N/A (Specific figures often not published for this class of ATV)

Fuel System

Fuel Delivery:

Mikuni VM14SC carburetor

Fuel Type:

Unleaded gasoline (87 octane recommended)

Fuel Tank Capacity:

2.0 L (0.5 US gal)

Oil Type:

2-stroke premix oil (typically 10W-30 or specific 2T oil)

Oil Mixture Ratio:

50:1 (Gasoline to Oil)

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Optional

Optional Transmission:

Features

Drive:

Shaft drive (single speed forward, reverse)

Clutch:

Automatic centrifugal clutch

Transmission Fluid:

Typically Suzuki Gear Oil 80W API GL-3 (or equivalent, check manual for exact spec)

📐 Dimensions

Exterior

Overall Length:

1,455 mm (57.3 in)

Overall Width:

760 mm (29.9 in)

Overall Height:

930 mm (36.6 in)

Wheelbase:

970 mm (38.2 in)

Ground Clearance:

100 mm (3.9 in)

Weights

Dry Weight:

95 kg (209 lbs)

Gross Vehicle Weight Rating:

230 kg (507 lbs)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Designed to meet American National Standards Institute (ANSI) standards for ATVs. Parental supervision and protective gear are always recommended.

Active Features

Throttle Limiter:

Adjustable throttle limiter screw for speed control.

Parking Brake:

Hand-operated parking brake lever.

Passive Features

Footwells:

Wide, integrated footwells with grip treads for rider stability.

Handlebar Design:

Comfortable handlebar grip with safety features like thumb throttle guard.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic youth ATV with no infotainment features).

Driver Assistance

Assistance Features:

Throttle limiter for speed control.

Connectivity

Connectivity Features:

N/A (No electronic connectivity features).

🔧 Maintenance

Service Intervals

Oil Change Engine:

Every 20 hours or annually (refer to manual for specific recommendations based on usage).

Air Filter Service:

Clean every 10 hours, replace as needed. Critical for 2-stroke engine longevity.

Spark Plug Service:

Check and clean every 20 hours, replace every 100 hours or as needed.

Drive Chain Lubrication:

Lubricate and adjust chain tension every 10 hours of riding.

Fluid Specifications

Engine Oil:

Suzuki recommends a high-quality SAE 10W-30 API SE/SF 2-stroke oil for oil injection, or for premix, a specific 2-stroke engine oil compatible with Suzuki's recommendations (e.g., 50:1 ratio).

Transmission Gear Oil:

Suzuki Gear Oil 80W (API GL-3) or equivalent.

Brake Fluid:

DOT 3 or DOT 4 (check master cylinder cap for specific type).

Known Issues

Carburetor Clogging:

Common issue due to fuel sitting, requiring regular cleaning and proper fuel storage.

Drive Belt Wear:

CVT drive belt can wear over time, leading to slipping and reduced performance. Regular inspection and replacement are recommended.

Carburetor Pilot Jet:

Pilot jet can be prone to clogging, affecting idle and low-speed performance.

Ignition Coil Failure:

Ignition coil can fail over time, leading to no spark.

Starter Clutch Wear:

The starter clutch mechanism can wear, causing the starter to engage or disengage improperly.

Exhaust Leak:

Exhaust gasket leaks can occur, affecting engine performance and sound.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Japan

Model Evolution

Development Focus:

The LT80 was developed as an entry-level, youth-oriented ATV, emphasizing ease of use, reliability, and safety for younger riders.

Production

Production Period:

1987 - 2006 (Discontinued in North America, continued in other markets for a period).

Key Markets:

North America, Europe, Australia.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Not typically awarded in a formal capacity, but recognized for its longevity and popularity in the youth ATV market.

Ratings

Consumer Satisfaction:

Generally high consumer satisfaction due to its durability and suitability for its intended purpose.

Certifications

Safety Certifications:

Meets relevant safety standards for ATVs for its production era.