🏷️ 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 comes first. Air Filter Cleaning: Every 10 hours of operation or as needed based on operating conditions (clean and re-oil). Spark Plug Check: Every 20 hours of operation or annually. Chain Lubrication: Every 10 hours of operation or after riding in wet conditions. Brake Adjustment: As needed, check for proper lever/pedal free play. Fluid Specifications Engine Oil Type: Suzuki Super LT Fully Synthetic 2-stroke oil or equivalent API TC specification. Engine Oil Capacity: Transmission gear oil: 0.55 L (0.58 US qt) for the geared transmission, 2-stroke oil is mixed with fuel. Gear Oil Type: SAE 80 API GL-4 gear oil for the transmission/differential unit. Known Issues Carburetor Fouling: Common issue with 2-stroke engines, requires regular cleaning and proper fuel/oil mixture. Cvt Belt Wear: CVT belts can wear over time and need inspection and replacement at specified intervals. Ignition Coil Failure: Occasional failure of the ignition coil can lead to spark loss. 📚 Vehicle History Brand Heritage Suzuki Heritage: Suzuki has a long-standing history in powersports, known for reliable and performance-oriented vehicles. Model Evolution Lt80 Lineage: The LT80 was a popular...