1987 Suzuki ATV Repair Manual

The 1987 Suzuki ATV Repair Manual provides comprehensive technical information for maintaining and repairing Suzuki all-terrain vehicles from the 1987 model year. This manual covers engine systems, transmission, electrical systems, brakes, suspension, steering, and routine maintenance procedures. Below are key sections for safety precautions, specifications, troubleshooting, and step-by-step repair instructions.

1. Safety Precautions 2. General Specifications 3. Engine Repair 4. Transmission & Drive System 5. Electrical System 6. Brake System 7. Suspension & Steering 8. Routine Maintenance 9. Troubleshooting Guide 10. Wiring Diagrams 11. Parts & Tools

Safety Precautions

Always follow safety procedures when working on your Suzuki ATV to prevent injury and damage.

Safety Area	Precaution
Work Area	Work in well-ventilated area away from flames and sparks
Battery	Disconnect negative terminal first; avoid short circuits
Fuel System	Drain fuel tank before repairs; no smoking in work area
Lifting	Use proper jack stands; never work under unsupported vehicle
Hot Components	Allow engine to cool before working on exhaust system
Electrical	Disconnect battery before electrical repairs
Tires	Deflate tires before removal; use tire irons carefully
Test Riding	Wear helmet and protective gear during test rides

General Specifications

Technical specifications for 1987 Suzuki ATV models.

Engine Type: 2-stroke/4-stroke air-cooled single cylinder
Displacement: 50cc to 250cc depending on model
Fuel System: Carburetor with manual choke
Ignition System: CDI electronic ignition
Transmission: 5-speed manual with reverse
Drive System: Chain drive with 2WD/4WD options
Brake System: Drum brakes front and rear
Suspension: Independent front, swingarm rear
Fuel Capacity: 2.5 to 4.0 gallons
Oil Capacity: 1.0 to 1.5 quarts

Engine Repair

Step-by-step engine repair procedures.

Engine Removal: Disconnect battery, drain fluids, remove mounting bolts
Cylinder Head: Remove in sequence; check for warpage
Piston & Rings: Measure clearance; replace if worn
Crankshaft: Check runout; replace bearings if damaged
Carburetor: Clean jets; adjust float level and mixture
Ignition Timing: Set according to specifications
Cooling System: Clean fins; check for obstructions

WARNING! Engine components are heavy; use proper lifting equipment.

Transmission & Drive System

Transmission and drive train maintenance.

Clutch Adjustment: Adjust cable free play to 10-15mm
Gear Shift Mechanism: Check shift drum and forks for wear
Chain Adjustment: Maintain 20-30mm free play
Sprocket Inspection: Replace if teeth are hooked or worn
Differential Service: Change gear oil every 100 hours
Drive Shaft: Lubricate universal joints regularly

CAUTION! Always support ATV securely when working underneath.

Electrical System

Electrical system diagnosis and repair.

Component	Testing Procedure	Specification
Battery	Load test at 1/2 CCA rating	12.6V minimum
Stator	Resistance between phases	0.1-1.0 ohms
CDI Unit	Continuity and resistance tests	Refer to chart
Spark Plug	Check gap and condition	0.6-0.7mm gap
Lighting	Voltage at bulb socket	12V ±10%

Brake System

Brake system maintenance and repair.

Brake Adjustment: Adjust lever free play to specifications
Brake Shoes: Replace if lining thickness below 1.0mm
Brake Drums: Measure diameter; replace if oversize
Cables: Lubricate and adjust for smooth operation
Parking Brake: Adjust for proper holding force

WARNING! Test brakes at low speed after repairs.

Suspension & Steering

Suspension and steering component service.

Front Suspension: Check A-arm bushings and ball joints
Shock Absorbers: Inspect for leaks and damage
Steering Stem: Adjust bearing preload
Wheel Bearings: Replace if rough or loose
Tire Pressure: Maintain 3-5 psi for off-road use

Routine Maintenance

Scheduled maintenance intervals and procedures.

Service	Interval	Procedure
Oil Change	Every 50 hours	Drain, replace filter, refill
Air Filter	Every 25 hours	Clean and oil foam element
Spark Plug	Every 100 hours	Clean and regap or replace
Chain Lubrication	Every 10 hours	Clean and lubricate chain
Brake Inspection	Every 50 hours	Check wear and adjustment
Wheel Nuts	Every ride	Check for proper torque

Troubleshooting Guide

Common problems and solutions for 1987 Suzuki ATVs.

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, or compression issue	Check fuel flow, spark plug, compression
Poor performance	Clogged carburetor, worn piston	Clean carburetor, check compression
Electrical failure	Bad battery, stator, or regulator	Test charging system components
Transmission problems	Worn gears or shift mechanism	Inspect transmission internals
Brake issues	Worn shoes, adjustment needed	Replace shoes, adjust cables
Steering difficulty	Bent components, bad bearings	Inspect and replace damaged parts

Wiring Diagrams

Complete electrical wiring diagrams for all 1987 Suzuki ATV models.

Color Codes: R=Red, B=Black, W=White, G=Green, Y=Yellow, L=Blue, Br=Brown

Main Circuits: Ignition, charging, lighting, starting, accessory

Connector Locations: Under seat, behind headlight, near CDI unit

Parts & Tools

Recommended tools and replacement parts.

Basic Tools: Socket set, wrenches, screwdrivers, pliers
Special Tools: Flywheel puller, clutch holder, bearing driver set
Common Replacement Parts: Spark plugs, air filters, brake shoes, chains
Lubricants: Engine oil, gear oil, chain lube, grease
Cleaning Supplies: Carburetor cleaner, degreaser, shop towels

Service Support: Contact Suzuki dealer for genuine parts and technical assistance.