This manual covers the Suzuki Quad Runner 80 (LT80) model, produced from 1987 through 2006. The Quad Runner 80 is a well-regarded, youth-oriented all-terrain vehicle known for its reliability and ease of use. Engineered in Japan, this two-stroke, air-cooled ATV features a 72.7 cc engine and an automatic Continuously Variable Transmission (CVT) drive system, making it an accessible option for younger riders. Its design prioritizes safety with features like an adjustable throttle limiter and integrated footwells, contributing to its enduring popularity in the entry-level ATV market. This comprehensive Service Repair Workshop Manual provides detailed guidance for owners, mechanics, and technicians. It encompasses all essential aspects of maintenance, repair, and troubleshooting for the Suzuki LT80. Coverage includes complete engine overhauls, transmission servicing, drivetrain and suspension maintenance, brake system repairs, and electrical system diagnostics. With step-by-step instructions, detailed diagrams, and specifications, this manual is an indispensable resource for keeping the Quad Runner 80 in optimal operating condition and ensuring its longevity. 🏷️ Basic Information Identification Make: Suzuki Model: Quad Runner 80 Model Designation: LT80 Product Type: Service Repair Workshop Manual 👋 Introduction Market Position Target Audience: Owners, independent repair shops, and mechanics working on Suzuki LT80 Quad Runner ATVs. Competitive Analysis Value Proposition: Provides essential information for maintaining and repairing a popular youth ATV, saving on dealership service costs and extending vehicle lifespan. Key Features Comprehensiveness: Covers a wide range of model years and all major mechanical and electrical systems. Detail Level: Includes detailed diagrams, torque specifications, and troubleshooting guides. 📋 Manual Details Coverage Areas Covered Years: 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Page Count Estimated Page Count: 300+ Manual Type Type: Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, inspection, tuning, carburetor, ignition system, cooling system (air-cooled), exhaust system. Transmission: Automatic transmission (CVT) service, clutch assembly, drive belt, gear reduction inspection and adjustment. Drivetrain: Front and rear axle service, differential inspection, drive shafts, wheel bearings, chain drive maintenance (if applicable for specific sub-models). Suspension: Front and rear suspension components, shock absorbers, A-arms, bushings, steering system components, linkage maintenance. Brakes: Front and rear brake systems (drum or disc depending on year/variant), brake shoe/pad replacement, hydraulic system bleeding, brake cable adjustment. Electrical: Ignition system, lighting, charging system (stator, regulator/rectifier), battery service, starter motor, wiring diagrams, component testing. Fuel System: Fuel tank, fuel lines, fuel filter replacement, carburetor disassembly, cleaning, adjustment, and troubleshooting. Frame And Body: Frame inspection, body panel removal/installation, fenders, handlebars, seat, plastic components, graphics. Procedures Included Maintenance: Routine maintenance checks, oil changes, filter replacements, spark plug service, chain lubrication and adjustment, battery maintenance, air filter cleaning/replacement. Troubleshooting: Diagnostic procedures for common starting, running, and performance issues. Fault finding based on symptoms. Repair: Step-by-step instructions for component removal, repair, and reinstallation for all major systems. Rebuilds: Complete engine and transmission rebuild procedures with detailed specifications. Adjustments: Carburetor adjustments, brake adjustments, clutch adjustments, chain tension adjustments. Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic information and specifications. 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF with clear diagrams and text. Print Quality Printability: Printable pages for easy workshop reference. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder Displacement: 72.7 cc Bore X Stroke: 43.0 mm x 50.0 mm Cooling System: Air-cooled Ignition System: CDI (Capacitor Discharge Ignition) Compression Ratio: 6.5 : 1 Starting System: Kick starter Performance Horsepower: Approximately 7-8 HP (Varies slightly by year and tuning) Torque: N/A (Specific figures often not published for this class of ATV) Fuel System Fuel Delivery: Mikuni VM14SC carburetor Fuel Type: Unleaded gasoline (87 octane recommended) Fuel Tank Capacity: 2.0 L (0.5 US gal) Oil Type: 2-stroke premix oil (typically 10W-30 or specific 2T oil) Oil Mixture Ratio: 50:1 (Gasoline to Oil) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Optional Optional Transmission: N/A Features Drive: Shaft drive (single speed forward, reverse) Clutch: Automatic centrifugal clutch Transmission Fluid: Typically Suzuki Gear Oil 80W API GL-3 (or equivalent, check manual for exact spec) 📐 Dimensions Exterior Overall Length: 1,455 mm (57.3 in) Overall Width: 760 mm (29.9 in) Overall Height: 930 mm (36.6 in) Wheelbase: 970 mm (38.2 in) Ground Clearance: 100 mm (3.9 in) Weights Dry Weight: 95 kg (209 lbs) Gross Vehicle Weight Rating: 230 kg (507 lbs) 🛡️ Safety Features Ratings Atv Safety Standards: Designed to meet American National Standards Institute (ANSI) standards for ATVs. Parental supervision and protective gear are always recommended. Active Features Throttle Limiter: Adjustable throttle limiter screw for speed control. Parking Brake: Hand-operated parking brake lever. Passive Features Footwells: Wide, integrated footwells with grip treads for...