Suzuki LT80L Quad Runner 1990 Workshop Service Manual

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UGS: 73729

Mots clés: 1990 Atv LT80L Quad Runner Misc Motorcycles Suzuki

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Description

The Suzuki LT80L Quad Runner, produced in 1990, is a robust and reliable entry-level youth ATV designed for recreational riding. This model features an automatic transmission with a continuously variable transmission (CVT), electric start, and a compact, lightweight chassis, making it ideal for younger riders. Its engineering quality is evident in its durable two-stroke, air-cooled engine and user-friendly operation, which established Suzuki's strong presence in the youth ATV market. The LT80L was a foundational model, known for its suitability for young enthusiasts and offering a dependable platform for outdoor adventures. This comprehensive workshop service manual provides essential information for the repair and maintenance of the 1990 Suzuki LT80L Quad Runner. Covering a wide range of topics, it details engine mechanical procedures, fuel and ignition systems, transmission and drivetrain, brakes, suspension, steering, electrical systems, and chassis components. The manual includes routine maintenance schedules, troubleshooting guides for common issues, detailed repair procedures, inspection checks, and critical technical specifications. Its purpose is to empower owners, mechanics, and technicians to effectively maintain and repair the vehicle, ensuring its longevity and optimal performance.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

LT80L Quad Runner

Year:

Product Type:

Workshop Service Manual

Product Format:

PDF Download

👋 Introduction

Market Position

Segment:

Entry-level youth ATV / Quad bike

Target Audience:

Enthusiasts, parents of young riders, and service technicians working on vintage recreational vehicles.

Competitive Analysis

Competitors 1990:

Yamaha YFM80 Badger, Honda TRX70/90, Kawasaki Mojave 80.

Key Features Vehicle

Features:

Automatic transmission (CVT), electric start, reliable two-stroke engine, compact and lightweight chassis.

Key Features Manual

Manual Value:

Essential for maintaining the longevity and performance of the LT80L Quad Runner, enabling DIY repairs and informed servicing.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair and Maintenance

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

Digital PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and assembly of engine components (cylinder, piston, crankshaft, connecting rod, lubrication system, cooling system).

Fuel System:

Carburetor inspection, cleaning, adjustment, and overhaul; fuel tank, fuel lines, and fuel pump.

Ignition System:

Spark plug specifications, ignition timing, CDI unit, and stator/rotor inspection.

Transmission Drivetrain:

Automatic transmission (CVT) overhaul, clutch operation, chain drive inspection and adjustment, rear axle service.

Brakes:

Brake caliper overhaul, brake pad replacement, brake fluid bleeding, brake shoe adjustment, parking brake operation.

Suspension Steering:

Front and rear suspension component inspection, shock absorber service, steering column and tie-rod end inspection/replacement, wheel bearing service.

Electrical System:

Wiring diagrams, lighting system, battery inspection and maintenance, starter motor, charging system (alternator/stator).

Frame Chassis:

Frame inspection for damage, front and rear bumper mounting, skid plates.

Bodywork:

Body panel removal and installation, fenders, seat, handle grips.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, lubrication points, chain adjustment, spark plug service, tire pressure checks.

Troubleshooting:

Diagnostic flowcharts for common starting, running, and electrical issues.

Repair Procedures:

Step-by-step instructions for engine rebuilds, transmission repairs, brake system overhauls, and suspension component replacement.

Inspection Checks:

Detailed inspection guidelines for critical components to identify wear, damage, or potential failures.

Specifications Settings:

Torque specifications for all fasteners, engine tuning parameters, electrical component resistance values.

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds.

📊 Manual Specifications

File Format

Format:

Print Quality

Quality:

High-resolution, clear text and diagrams, suitable for printing.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

Searchability

Text Search:

Likely text-searchable PDF for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Two-stroke, air-cooled

Displacement:

72 cc (4.4 cubic inches)

Bore X Stroke:

43.0 mm x 48.0 mm (1.69 in x 1.89 in)

Compression Ratio:

6.2:1

Carburetor:

Mikuni VM16SC (example, specific model may vary)

Performance

Horsepower Estimated:

Approximately 6-8 HP (specifications not always published for youth ATVs)

Torque Estimated:

Low to mid-range power delivery optimized for recreational riding.

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Mixture:

Pre-mix (e.g., 50:1 ratio of gasoline to 2-stroke oil, confirmed in manual).

Fuel Tank Capacity:

Approximately 2.0 Liters (0.5 US gal)

Lubrication

Oil Type:

API TC W II or TC W III compliant 2-stroke engine oil.

🔧 Transmission

Standard

Type:

Automatic (Continuously Variable Transmission - CVT)

Drive System:

Shaft drive (rear wheel)

Gear Reduction:

Single reduction, helical gears.

Features

Clutch:

Centrifugal clutch mechanism.

📐 Dimensions

Exterior

Length:

Approx. 1395 mm (55.0 in)

Width:

Approx. 770 mm (30.3 in)

Height:

Approx. 920 mm (36.2 in)

Wheelbase:

Approx. 955 mm (37.6 in)

Weights

Dry Weight:

Approx. 64 kg (141 lbs)

Tires

Front Tire Size:

AT16 x 6.5-7

Rear Tire Size:

AT18 x 9.5-8

Wheels

Bolt Pattern:

Not applicable, hub-mounted wheels.

🛡️ Safety Features

Ratings

Safety Standard:

Designed for youth rider supervision; always follow age recommendations and safety guidelines.

Active Features

Throttle Limiter:

Often includes a throttle limiter screw for controlled speed adjustment.

Parking Brake:

Standard rear brake lever lock.

Passive Features

Engine Guard:

Included for rider protection.

Footwells:

Integrated footboards for rider protection.

Recommended Usage

Rider Age:

Intended for younger riders (e.g., 12+ years), always check manufacturer recommendations and local laws.

💡 Technology Features

Infotainment

Features:

N/A (Utility/Recreational vehicle of its era)

Driver Assistance

Features:

N/A (Basic mechanical controls)

Connectivity

Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1000 km or 6 months, or as specified for severe use in the manual.

Air Filter Cleaning:

Inspect and clean every 500 km, replace as needed.

Spark Plug Inspection:

Every 1000 km.

Chain Adjustment:

Check and adjust every 500 km.

Fluid Specifications

Transmission Fluid:

Suzuki SHA or equivalent SAE 80 hypoid gear oil (confirm with manual for specific grade).

Brake Fluid:

DOT 3 or DOT 4 brake fluid (confirm with manual).

Grease Type:

Lithium-based multi-purpose grease (specific grades may be recommended in manual).

Known Issues

Common Wear Points:

Carburetor jets clogging, worn drive clutch weights, CDI ignition module failure, rear axle bearings.

Fuel Mixture Problems:

Incorrect 2-stroke oil to gas ratio leading to fouled spark plugs or engine damage.

Starting Difficulties:

Often related to carburetor issues, old fuel, or weak ignition.

📚 Vehicle History

Brand Heritage

Suzuki Atv Legacy:

Suzuki has a long history in motorsport and ATV development, known for robust and reliable recreational vehicles.

Model Evolution

Lt80 Lineage:

The LT80 Quad Runner was a foundational model for Suzuki in the youth ATV market, evolving into later models like the LT-Z50 and LT-80.

Production

Production Period:

The LT80 was produced for many years, with the 1990 model representing an early iteration of this popular youth quad.

🏆 Awards & Recognition

Recognitions

Market Recognition:

The LT80 Quad Runner was highly regarded for its durability and suitability for young riders, establishing Suzuki's presence in the youth ATV segment.