1987 Suzuki LT80 Repair Manual

The 1987 Suzuki LT80 is a youth ATV featuring a 79cc 2-stroke air-cooled engine, automatic transmission with high/low range, shaft drive, front and rear suspension, and electric start. This repair manual covers maintenance, troubleshooting, and repair procedures for engine, transmission, electrical system, chassis, and all major components. Below are key sections for specifications, maintenance, troubleshooting, and repair procedures.

1. Specifications 2. Maintenance Schedule 3. Engine Repair 4. Transmission & Drive System 5. Electrical System 6. Chassis & Suspension 7. Brake System 8. Fuel System 9. Troubleshooting Guide 10. Safety Precautions 11. Parts & Tools

Specifications

Technical specifications for the 1987 Suzuki LT80 ATV.

Component	Specification
Engine Type	79cc 2-stroke, air-cooled, single cylinder
Bore x Stroke	47.0mm x 45.6mm
Compression Ratio	6.6:1
Transmission	Automatic CVT with high/low range
Drive System	Shaft drive
Fuel Capacity	1.6 gallons (6.0 liters)
Oil Capacity	0.63 quarts (0.6 liters)
Front Suspension	Double A-arm
Rear Suspension	Swingarm
Brakes	Front and rear drum brakes
Wheelbase	39.4 inches (1000mm)
Dry Weight	187 lbs (85 kg)

Maintenance Schedule

Regular maintenance intervals for optimal performance and longevity.

Engine oil change: Every 6 months or 500 miles
Air filter cleaning: Every 3 months or 250 miles
Spark plug replacement: Every 12 months or 1000 miles
Brake inspection: Every 6 months
Drive shaft lubrication: Every 12 months
Wheel bearing inspection: Every 12 months

WARNING! Always perform maintenance on level ground with engine off and cool. Use proper safety equipment.

Engine Repair

Procedures for engine disassembly, inspection, and reassembly.

Cylinder head removal: Remove cooling shroud, disconnect spark plug wire, remove head bolts
Cylinder and piston: Inspect cylinder walls for scoring, check piston ring gap
Crankcase splitting: Drain oil, remove all external components, separate case halves
Crankshaft inspection: Check for wear on connecting rod and main bearings
Reed valve inspection: Check for cracks or improper sealing

CAUTION! Mark all components during disassembly for proper reassembly. Use torque wrench for all fasteners.

Transmission & Drive System

CVT transmission service and shaft drive maintenance.

CVT Belt Inspection: Check for cracks, glazing, or excessive wear
Drive Shaft: Inspect universal joints for play, lubricate splines
Gear Oil Change: Drain and refill with recommended 80W-90 gear oil
High/Low Range Selector: Adjust linkage if shifting is difficult
Clutch Inspection: Check centrifugal clutch shoes for wear

Electrical System

Troubleshooting and repair of electrical components.

Battery: 12V 4Ah, check voltage and specific gravity. Starter: Test draw current, inspect brushes. Charging System: Check stator output, regulator/rectifier function. Ignition: Test CDI unit, spark plug cap resistance.

Component	Test Procedure	Specification
Battery Voltage	Measure with multimeter	12.6V minimum
Stator Output	AC voltage at specified RPM	20V AC minimum
Spark Plug Gap	Adjust with feeler gauge	0.024-0.028 inches

Chassis & Suspension

Frame, suspension, and steering component service.

Front suspension: Check A-arm bushings, ball joints, and shock absorbers
Rear suspension: Inspect swingarm pivot bearings, shock mounting
Steering stem: Check for play, lubricate bearings
Wheel alignment: Adjust toe-in as specified
Tire pressure: Maintain 3.5 PSI front, 3.0 PSI rear

Tip: Use thread locker on all critical suspension fasteners.

Brake System

Drum brake inspection, adjustment, and repair.

Brake adjustment: Turn adjuster on brake lever/ pedal
Brake shoe replacement: Remove wheel, disassemble brake assembly
Cable lubrication: Lubricate brake cables regularly
Drum inspection: Check for scoring or excessive wear

WARNING! Test brakes after adjustment before riding. Replace worn components immediately.

Fuel System

Carburetor service and fuel system maintenance.

Carburetor: Clean jets and passages, adjust float level, set air/fuel mixture. Fuel tank: Inspect for rust, clean sediment. Fuel lines: Replace if cracked or hardened. Fuel filter: Replace annually.

Troubleshooting Guide

Common problems and solutions for the LT80.

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, or compression issue	Check spark plug, fuel flow, compression test
Poor performance	Clogged carburetor, worn piston	Clean carburetor, inspect top end
Transmission slipping	Worn CVT belt, clutch issues	Replace belt, inspect clutch components
Electrical failure	Battery, stator, or wiring	Test charging system, check connections
Brakes dragging	Cable adjustment, stuck mechanism	Adjust cables, clean brake assembly

Safety Precautions

Important safety information for repair and operation.

Always work in well-ventilated area. Use jack stands when lifting ATV. Disconnect battery before electrical work. Wear safety glasses. Keep fire extinguisher nearby. Follow all torque specifications.

CAUTION! Gasoline is highly flammable - no smoking or open flames during fuel system work.

Parts & Tools

Recommended tools and replacement parts information.

Basic Tools: Metric socket set, torque wrench, screwdrivers, pliers
Special Tools: Flywheel puller, clutch holding tool, case splitter
Common Parts: Spark plug BR8ES, oil filter, air filter, drive belt
Fluids: 2-stroke oil, gear oil, brake fluid
Sources: Suzuki dealerships, online parts suppliers

Service: Contact authorized Suzuki service centers for complex repairs.