1987 Suzuki LT80 Service Manual

The 1987 Suzuki LT80 is a youth ATV featuring a 79cc 2-stroke air-cooled engine, automatic transmission with reverse, shaft drive, front and rear suspension, electric start, and safety features. This manual covers maintenance, troubleshooting, repair procedures, and specifications for proper operation and longevity.

1. General Information 2. Periodic Maintenance 3. Engine Service 4. Fuel System 5. Electrical System 6. Transmission & Drive 7. Chassis & Suspension 8. Brake System 9. Troubleshooting 10. Specifications 11. Wiring Diagrams

General Information

Introduction to the Suzuki LT80 ATV, including model identification, safety precautions, and tool requirements.

Component	Description
Model Identification	LT80K7 (1987 model year)
Engine Type	2-stroke, single cylinder, air-cooled
Displacement	79cc
Starting System	Electric start with auxiliary pull start
Transmission	Automatic CVT with reverse
Drive System	Shaft drive
Fuel Capacity	1.7 gallons (6.5 liters)
Oil Capacity	0.63 qt (0.6L) engine oil
Weight	187 lbs (85 kg)
Load Capacity	130 lbs (59 kg)

Periodic Maintenance

Regular maintenance schedule and procedures to ensure optimal performance and safety.

Pre-ride inspection: Check tires, brakes, controls, and fluid levels.
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 1,000 miles.
Drive chain adjustment: Check every ride, adjust as needed.

WARNING! Always perform maintenance in well-ventilated area. Use proper safety equipment.

Engine Service

Complete engine disassembly, inspection, and reassembly procedures.

Cylinder head removal: Remove cooling shrouds, disconnect spark plug wire.
Cylinder and piston: Inspect for wear, measure cylinder bore.
Crankcase splitting: Remove engine from frame, separate cases.
Crankshaft inspection: Check runout and bearing condition.
Reed valve: Inspect for damage or wear.

CAUTION! Tag and organize all parts during disassembly. Use torque wrench for reassembly.

Fuel System

Carburetor: Mikuni VM16SS, main jet #92.5, pilot jet #25
Fuel Mix: 32:1 (gasoline to 2-stroke oil) for break-in, 40:1 thereafter
Fuel Filter: Inline type, replace annually
Fuel Tank: Plastic, 1.7 gallon capacity
Carb Adjustment: Air screw 1-1/2 turns out, idle speed 1,800 RPM

Electrical System

Battery, charging system, ignition, and lighting circuit maintenance.

Battery: 12V 4Ah, maintain fluid level, specific gravity 1.280

Charging System: AC magneto, output 65W @ 5,000 RPM. Ignition: CDI type, spark plug NGK BR8ES gap 0.024-0.028 in. Lighting: Headlight 25W/25W, taillight 5W. Fuses: Main 10A, spare included.

Transmission & Drive

CVT transmission service and shaft drive maintenance.

CVT belt inspection: Check for cracks, wear, replace if damaged.
Drive shaft: Lubricate splines every 100 hours.
Gear oil: SAE 80W-90, change annually.
Reverse operation: Engine must be at idle to engage.

Tip: Always check transmission fluid level when engine is warm.

Chassis & Suspension

Frame, wheels, tires, and suspension component service.

Front suspension: Oil-filled forks, check for leaks.
Rear suspension: Swingarm with single shock, preload adjustable.
Tire pressure: Front 3.6 psi, rear 3.6 psi (cold).
Wheel bearings: Inspect annually, repack with grease.
Steering stem: Check for play, adjust as needed.

WARNING! Always support ATV securely when working underneath.

Brake System

Drum brake adjustment and maintenance procedures.

Front brakes: Mechanical drum, adjust via cable. Rear brakes: Mechanical drum, self-adjusting. Brake shoes: Replace when worn to 0.08 in (2mm). Brake cables: Lubricate monthly with cable lube.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel flow, spark plug, compression (120 psi min)
Poor performance	Clogged air filter, carb issues	Clean air filter, check carburetor jets
Transmission slipping	Worn belt, low fluid	Inspect CVT belt, check transmission fluid
Electrical failure	Battery, fuse, connections	Test battery, check fuses, clean connections
Overheating	Cooling fins, fuel mix	Clean cooling fins, check fuel mixture ratio

Specifications

Engine: 79cc 2-stroke, air-cooled
Bore x Stroke: 47.0 x 45.6 mm
Compression Ratio: 6.7:1
Carburetor: Mikuni VM16SS
Ignition: CDI electronic
Transmission: Automatic CVT with reverse
Final Drive: Shaft
Suspension Travel: Front 3.1 in, Rear 3.0 in
Brakes: Drum front and rear
Tires: Front 19x7-8, Rear 18x9.5-8

Wiring Diagrams

Complete electrical schematics for the 1987 Suzuki LT80, including color codes and connector locations.

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

Main Harness: Follows frame from headlight to taillight with branches to engine components.

Service: Contact Suzuki dealer or visit www.suzukicycles.com for technical support.