Target Audience:
Owners of 1991 Suzuki LT80M Quad Runner seeking self-maintenance and repair capabilities.
Manual Value:
Provides in-depth technical knowledge typically found in professional shop manuals, saving significant repair costs.
Instant Access:
Immediate PDF download provides instant access to repair information.
Completeness:
Covers all major systems and components for thorough repair and maintenance.
Diagnostic Aid:
Includes troubleshooting guides to help identify and resolve common mechanical and electrical issues.
Engine Mechanical:
Full engine disassembly, assembly, inspection, and repair procedures.
Fuel System:
Carburetor adjustment, cleaning, and overhaul; fuel pump, fuel lines.
Ignition System:
Ignition timing, coil specifications, spark plug details.
Cooling System:
Air-cooling system inspection and maintenance.
Transmission:
Automatic transmission (CVT) service, inspection, and fluid information.
Drivetrain:
Drive shaft, differential, and axle service.
Brakes:
Brake system inspection, adjustment, and component replacement (drum brakes).
Suspension:
Front and rear suspension component inspection, adjustment, and replacement.
Steering:
Steering system inspection, adjustment, and component replacement.
Electrical System:
Wiring diagrams, lighting system, battery, starting system, charging system.
Frame And Body:
Frame inspection, body panel removal and installation.
Routine Maintenance:
Oil changes, filter replacement, spark plug checks, chain adjustment.
Troubleshooting:
Diagnostic charts and common issue resolution for various systems.
Engine Rebuild:
Detailed steps for complete engine overhaul, including torque specifications.
Carburetor Overhaul:
Step-by-step guide for carburetor disassembly, cleaning, reassembly, and adjustment.
Brake Adjustment:
Instructions for proper brake lever and pedal adjustment.
Electrical Diagnostics:
Using wiring diagrams to troubleshoot electrical faults.
Component Replacement:
Guidance on replacing key components like engine parts, suspension, and electrical items.
Depth:
Comprehensive, suitable for both amateur mechanics and professional technicians.
Engine Type:
Air-cooled, 2-stroke
Displacement:
72 cc (4.4 cu in)
Bore X Stroke:
42.0 mm x 52.0 mm (1.65 x 2.05 in)
Cylinder Arrangement:
Single cylinder
Horsepower:
Approx. 6.5 HP @ 7000 RPM (Varies slightly by market spec)
Torque:
Approx. 5.3 lb-ft @ 6000 RPM (Varies slightly by market spec)
Carburetor Model:
Mikuni VM15SH
Fuel Delivery:
Carburetor with fuel pump
Recommended Fuel:
Unleaded gasoline (87 octane or higher)
Oil Mixing:
Pre-mix fuel/oil ratio: 50:1 (Suzuki Super LT Fully Synthetic Oil or equivalent)
Safety Standards:
Designed for recreational off-road use; adherence to ANSI/SVIA standards for ATVs.
Braking System:
Drum brakes (Front and Rear) with parking brake mechanism.
Throttle Limiter:
Adjustable thumb throttle for controlled acceleration.
Footwells:
Integrated floorboards with heel guards for foot protection.
Handlebar Protection:
Handlebar grips with impact protection.
Engine Oil Change:
Every 20 hours of operation or 6 months, whichever comes first.
Air Filter Cleaning:
Every 10 hours of operation or as needed based on operating conditions (clean and re-oil).
Spark Plug Check:
Every 20 hours of operation or annually.
Chain Lubrication:
Every 10 hours of operation or after riding in wet conditions.
Brake Adjustment:
As needed, check for proper lever/pedal free play.
Engine Oil Type:
Suzuki Super LT Fully Synthetic 2-stroke oil or equivalent API TC specification.
Engine Oil Capacity:
Transmission gear oil: 0.55 L (0.58 US qt) for the geared transmission, 2-stroke oil is mixed with fuel.
Gear Oil Type:
SAE 80 API GL-4 gear oil for the transmission/differential unit.
Carburetor Fouling:
Common issue with 2-stroke engines, requires regular cleaning and proper fuel/oil mixture.
Cvt Belt Wear:
CVT belts can wear over time and need inspection and replacement at specified intervals.
Ignition Coil Failure:
Occasional failure of the ignition coil can lead to spark loss.
Suzuki Heritage:
Suzuki has a long-standing history in powersports, known for reliable and performance-oriented vehicles.
Lt80 Lineage:
The LT80 was a popular entry-level youth ATV, evolving over several years with minor updates.
Manufacturing Region:
Japan (Primary)
Production Span:
The LT80 model was produced for many years, with the 1991 model being part of its core production run.
