1987-2006 Suzuki LT80 Service Manual

Technical Scope of the 1987–2006 Suzuki LT80 Service Manual

• Covers 1987–2006 Suzuki LT80 QuadSport ATV variants from the base J-series through the final K6 production model
• Official Suzuki publication P/N 9900-25010, covering 225 pages of factory-standard service procedures
• Contains 47 exploded-view diagrams, 16 electrical schematics, and 12 torque specification tables for chassis and engine components
• File delivered as a direct download the moment payment clears
• Indexed PDF search covers every chapter and appendix for rapid part-number lookup
• This 1990 first edition provides the primary documentation for the LT80 QuadSport series build and serves as the reference standard for all subsequent model year variants

Documented Systems and Procedures

The 1987–2006 Suzuki LT80 service manual details the specialized automatic V-belt drive transmission system, forced air-cooling mechanism, and P.E.I. ignition circuitry. It organizes service content into seven groups, spanning general identification, periodic maintenance, engine overhaul, fuel and lubrication systems, electrical diagnostics, and chassis maintenance.

Technicians gain access to specific assembly information for the crankshaft, reed valve intake, and centrifugal clutch lock-up checks. The publication structure follows the manufacturer's logic for engine removal, crankcase disassembly, and component inspection, including detailed gear oil replacement intervals and oil pump bleeding operations.

Technical Specification Highlights

Engine cooling performance relies on internal fan-forced air, documented with specific shroud assembly torque values of 8–12 N-m for head nuts. Carburetor settings specify a 18.5 mm float height and #92.5 main jet for the MIKUNI VM16SH unit. The 1987–2006 Suzuki LT80 charging system provides a minimum generator no-load voltage of 28V AC at 5,000 r/min.

Crankshaft runout limit is specified at 0.05 mm in the engine inspection section. Drive belt wear limit is documented at 16.7 mm. Ignition coil secondary resistance is listed at 12.0–17.5 k-ohms.

Note: All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. This official 225-page Suzuki OEM service manual provides technical specifications, assembly diagrams, and maintenance schedules for the 1987–2006 Suzuki LT80 QuadSport ATV line.