The 1991 Suzuki LT80M Quad Runner is a capable and reliable entry-level all-terrain vehicle, renowned for its user-friendly design and durable construction. Engineered for recreational off-road use, this model features an air-cooled, 2-stroke engine, providing accessible power for younger riders. Its robust chassis and thoughtful safety features, including integrated floorboards with heel guards and an adjustable throttle limiter, contribute to a secure riding experience. Suzuki's long heritage in powersports is evident in the LT80M's dependable performance and straightforward operation, making it a popular choice for families and young enthusiasts. This comprehensive Workshop Service Manual offers detailed repair and service information for the 1991 Suzuki LT80M Quad Runner. Spanning 227 pages, it covers all essential systems, including the engine mechanicals, fuel system, ignition, cooling, transmission, drivetrain, brakes, suspension, steering, and electrical system. The manual provides step-by-step procedures for routine maintenance, engine rebuilds, carburetor overhauls, and component replacements, along with troubleshooting guides and wiring diagrams. This resource is designed to empower owners, mechanics, and technicians with the knowledge needed to maintain and repair the vehicle effectively, ensuring its longevity and optimal performance. 🏷️ Basic Information Identification Make: Suzuki Model: LT80M Quad Runner Year: 1991 Codes Chassis Code: LT80M 👋 Introduction Market Position Target Audience: Owners of 1991 Suzuki LT80M Quad Runner seeking self-maintenance and repair capabilities. Competitive Analysis Manual Value: Provides in-depth technical knowledge typically found in professional shop manuals, saving significant repair costs. Key Features Instant Access: Immediate PDF download provides instant access to repair information. Completeness: Covers all major systems and components for thorough repair and maintenance. Diagnostic Aid: Includes troubleshooting guides to help identify and resolve common mechanical and electrical issues. 📋 Manual Details Coverage Areas General Coverage: Comprehensive repair and service information for the Suzuki LT80M Quad Runner. Page Count Total Pages: 227 Manual Type Type: Workshop Service Manual Language Primary Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine disassembly, assembly, inspection, and repair procedures. Fuel System: Carburetor adjustment, cleaning, and overhaul; fuel pump, fuel lines. Ignition System: Ignition timing, coil specifications, spark plug details. Cooling System: Air-cooling system inspection and maintenance. Transmission: Automatic transmission (CVT) service, inspection, and fluid information. Drivetrain: Drive shaft, differential, and axle service. Brakes: Brake system inspection, adjustment, and component replacement (drum brakes). Suspension: Front and rear suspension component inspection, adjustment, and replacement. Steering: Steering system inspection, adjustment, and component replacement. Electrical System: Wiring diagrams, lighting system, battery, starting system, charging system. Frame And Body: Frame inspection, body panel removal and installation. Procedures Included Routine Maintenance: Oil changes, filter replacement, spark plug checks, chain adjustment. Troubleshooting: Diagnostic charts and common issue resolution for various systems. Engine Rebuild: Detailed steps for complete engine overhaul, including torque specifications. Carburetor Overhaul: Step-by-step guide for carburetor disassembly, cleaning, reassembly, and adjustment. Brake Adjustment: Instructions for proper brake lever and pedal adjustment. Electrical Diagnostics: Using wiring diagrams to troubleshoot electrical faults. Component Replacement: Guidance on replacing key components like engine parts, suspension, and electrical items. Technical Depth Depth: Comprehensive, suitable for both amateur mechanics and professional technicians. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Clarity: High-resolution, clear text and diagrams for readability. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Simulation: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, 2-stroke Displacement: 72 cc (4.4 cu in) Bore X Stroke: 42.0 mm x 52.0 mm (1.65 x 2.05 in) Compression Ratio: 6.7:1 Cylinder Arrangement: Single cylinder Performance Horsepower: Approx. 6.5 HP @ 7000 RPM (Varies slightly by market spec) Torque: Approx. 5.3 lb-ft @ 6000 RPM (Varies slightly by market spec) Fuel System Carburetor Model: Mikuni VM15SH Fuel Delivery: Carburetor with fuel pump Recommended Fuel: Unleaded gasoline (87 octane or higher) Oil Mixing: Pre-mix fuel/oil ratio: 50:1 (Suzuki Super LT Fully Synthetic Oil or equivalent) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Features Drive System: 2WD (Rear Wheel Drive) Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: 1455 mm (57.3 in) Width: 920 mm (36.2 in) Height: 930 mm (36.6 in) Wheelbase: 1030 mm (40.6 in) Ground Clearance: 100 mm (3.9 in) Weights Dry Weight: 70 kg (154 lbs) Fuel Tank Capacity: 2.8 L (0.7 US gal) 🛡️ Safety Features Ratings Safety Standards: Designed for recreational off-road use; adherence to ANSI/SVIA standards for ATVs. Active Features Braking System: Drum brakes (Front and Rear) with parking brake mechanism. Throttle Limiter: Adjustable thumb throttle for controlled acceleration. Passive Features Footwells: Integrated floorboards with heel guards for foot protection. Handlebar Protection: Handlebar grips with impact protection. 💡 Technology Features Infotainment Features: N/A (Basic recreational ATV, no complex infotainment systems). Driver Assistance Features: N/A (No electronic driver assistance features). Connectivity Features: N/A (No connectivity features). 🔧 Maintenance Service Intervals Engine Oil Change: Every 20 hours of operation or 6 months, whichever...