🏷️ Basic Information Identification Make: Suzuki Model: LT80L Quad Runner Year: 1990 Product Type: Workshop Service Manual Product Format: PDF Download 👋 Introduction Market Position Segment: Entry-level youth ATV / Quad bike Target Audience: Enthusiasts, parents of young riders, and service technicians working on vintage recreational vehicles. Competitive Analysis Competitors 1990: Yamaha YFM80 Badger, Honda TRX70/90, Kawasaki Mojave 80. Key Features Vehicle Features: Automatic transmission (CVT), electric start, reliable two-stroke engine, compact and lightweight chassis. Key Features Manual Manual Value: Essential for maintaining the longevity and performance of the LT80L Quad Runner, enabling DIY repairs and informed servicing. 📋 Manual Details Coverage Areas Primary Coverage: Repair and Maintenance Page Count Total Pages: 227 Manual Type Type: Workshop Service Manual Language Language: English Format Format: Digital PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, repair, and assembly of engine components (cylinder, piston, crankshaft, connecting rod, lubrication system, cooling system). Fuel System: Carburetor inspection, cleaning, adjustment, and overhaul; fuel tank, fuel lines, and fuel pump. Ignition System: Spark plug specifications, ignition timing, CDI unit, and stator/rotor inspection. Transmission Drivetrain: Automatic transmission (CVT) overhaul, clutch operation, chain drive inspection and adjustment, rear axle service. Brakes: Brake caliper overhaul, brake pad replacement, brake fluid bleeding, brake shoe adjustment, parking brake operation. Suspension Steering: Front and rear suspension component inspection, shock absorber service, steering column and tie-rod end inspection/replacement, wheel bearing service. Electrical System: Wiring diagrams, lighting system, battery inspection and maintenance, starter motor, charging system (alternator/stator). Frame Chassis: Frame inspection for damage, front and rear bumper mounting, skid plates. Bodywork: Body panel removal and installation, fenders, seat, handle grips. Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication points, chain adjustment, spark plug service, tire pressure checks. Troubleshooting: Diagnostic flowcharts for common starting, running, and electrical issues. Repair Procedures: Step-by-step instructions for engine rebuilds, transmission repairs, brake system overhauls, and suspension component replacement. Inspection Checks: Detailed inspection guidelines for critical components to identify wear, damage, or potential failures. Specifications Settings: Torque specifications for all fasteners, engine tuning parameters, electrical component resistance values. Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: High-resolution, clear text and diagrams, suitable for printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Searchability Text Search: Likely text-searchable PDF for quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, air-cooled Displacement: 72 cc (4.4 cubic inches) Bore X Stroke: 43.0 mm x 48.0 mm (1.69 in x 1.89 in) Compression Ratio: 6.2:1 Carburetor: Mikuni VM16SC (example, specific model may vary) Performance Horsepower Estimated: Approximately 6-8 HP (specifications not always published for youth ATVs) Torque Estimated: Low to mid-range power delivery optimized for recreational riding. Fuel System Fuel Type: Unleaded gasoline Fuel Mixture: Pre-mix (e.g., 50:1 ratio of gasoline to 2-stroke oil, confirmed in manual). Fuel Tank Capacity: Approximately 2.0 Liters (0.5 US gal) Lubrication Oil Type: API TC W II or TC W III compliant 2-stroke engine oil. 🔧 Transmission Standard Type: Automatic (Continuously Variable Transmission - CVT) Drive System: Shaft drive (rear wheel) Gear Reduction: Single reduction, helical gears. Features Clutch: Centrifugal clutch mechanism. 📐 Dimensions Exterior Length: Approx. 1395 mm (55.0 in) Width: Approx. 770 mm (30.3 in) Height: Approx. 920 mm (36.2 in) Wheelbase: Approx. 955 mm (37.6 in) Weights Dry Weight: Approx. 64 kg (141 lbs) Tires Front Tire Size: AT16 x 6.5-7 Rear Tire Size: AT18 x 9.5-8 Wheels Bolt Pattern: Not applicable, hub-mounted wheels. 🛡️ Safety Features Ratings Safety Standard: Designed for youth rider supervision; always follow age recommendations and safety guidelines. Active Features Throttle Limiter: Often includes a throttle limiter screw for controlled speed adjustment. Parking Brake: Standard rear brake lever lock. Passive Features Engine Guard: Included for rider protection. Footwells: Integrated footboards for rider protection. Recommended Usage Rider Age: Intended for younger riders (e.g., 12+ years), always check manufacturer recommendations and local laws. 💡 Technology Features Infotainment Features: N/A (Utility/Recreational vehicle of its era) Driver Assistance Features: N/A (Basic mechanical controls) Connectivity Features: N/A 🔧 Maintenance Service Intervals Engine Oil Change: Every 1000 km or 6 months, or as specified for severe use in the manual. Air Filter Cleaning: Inspect and clean every 500 km, replace as needed. Spark Plug Inspection: Every 1000 km. Chain Adjustment: Check and adjust every 500 km. Fluid Specifications Transmission Fluid: Suzuki SHA or equivalent SAE 80 hypoid gear oil (confirm with manual for specific grade). Brake Fluid: DOT 3 or DOT 4 brake fluid (confirm with manual). Grease Type: Lithium-based multi-purpose grease (specific grades may be recommended in manual). Known Issues Common Wear Points: Carburetor jets clogging, worn drive clutch weights, CDI ignition module failure, rear axle bearings. Fuel Mixture Problems: Incorrect 2-stroke oil to gas ratio leading to fouled spark plugs...