SERVICE DATA

Date: January 13, 1999

2 STROKE Model: LT80Y
CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT

Piston to cylinder clearance 0.080 – 0.090 0.120
(0.0031 – 0.0035) (0.0047)
Cylinder bore 50.000 – 50.015 50.050
(1.9685 – 1.9691) (1.9705)
Measure at 20 mm (0.8 in) from the top surface.
Piston diam. 49.915 – 49.930
49.880
(1.9652 – 1.9657) (1.9638)
Measure at 20 mm (0.8 in) from the skirt end.
Cylinder distortion ——— 0.05
(0.002)
Cylinder head distortion ——— 0.05
(0.002)
Piston ring free end gap 4.0 3.2
1st T Approx.(0.16) (0.13)
2nd T Approx. 4.0 3.2
(0.16) (0.13)
Piston ring end gap 0.15 – 0.35 0.80
(0.006 – 0.014) (0.031)
Piston ring to groove clearance 0.020 – 0.060
1st (0.0008 – 0.0024) ———
0.020 – 0.060
2nd ———
(0.0008 – 0.0024)
Piston pin bore 12.002 – 12.010 12.030
(0.4725 – 0.4728) (0.4736)
Piston pin O.D. 11.994 – 12.000 11.980
(0.4722 – 0.4724) (0.4717)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.000 – 16.008 16.040
(0.6299 – 0.6302) (0.6315)
Conrod deflection 3.0
———
(0.12)
Crank web to web width 38.0 ± 0.1
———
(1.50 ± 0.004)
Crankshaft runout 0.05
——— (0.002)

OIL PUMP
ITEM SPECIFICATION
Oil pump reduction ratio 6.500 (13/2)
Oil pump discharge rate 1.0 – 1.3 ml
(Full open) (0.03/0.04 – 0.04/0.05 US/lmp oz)
for 3 minutes at 3 000 r/min.

Model: LT80Y 1/4 P-01,02,03,28,94

CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Clutch wheel I.D. 110.00 – 110.15 110.50
(4.331 – 4.337) (4.350)
Clutch shoe thickness 4.0 2.5
(0.16) (0.10)
Clutch engagement 2 500 – 2 900 r/min. ———
Clutch lock-up 3 000 – 3 600 r/min. ———
Clutch spring free length 34.2
——— (1.35)

TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Final reduction ratio Gears 7.197 (33/12 × 27/14 × 19/14) ———
Chain 2.200 (22/10) ———
Gear ratios Variable, 2.341 – 0.851 ———
Drive belt width 17.6 – 18.6 16.7
(0.69 – 0.73) (0.66)
Driven face spring free length 107.5 102.1
(4.23) (4.02)
Drive chain Type RK520SMO ———
Links 36 ———

CARBURETOR
ITEM SPECIFICATION
Carburetor type MIKUNI VM16SH
Bore size 16 mm
I.D. No. 41B10
Idle r/min. 1 600 ± 150 r/min.
Float height 18.5 ± 1.0 mm
(0.73 ± 0.04 in)
Main jet (M.J.) #92.5
Jet needle (J.N.) 3J17-2nd
Needle jet (N.J) E-0
Pilot jet (P.J.) #20
Throttle cable play 1.0 – 3.0 mm
(0.04 – 0.12 in)

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Spark plug DENSO: W22FPR
Type
NGK: BPR7HS
0.60 – 0.80
Gap
(0.024 – 0.031)
Spark performance Over 8 (0.3) at 1 atm.
Ignition coil resistance Primary 0.01 – 1.0 Ω +Terminal – -Terminal
Secondary 10 – 20 kΩ Plug cap – - Terminal
Generator coil resistance Charging 0.5 – 0.8 Ω W/R – Ground
Primary 139 – 207 Ω B/R – Ground
Generator no-load voltage More than 28 V (AC) at 5 000 r/min.
Generator MAX. output 30 W at 5 000 r/min.

Model: LT80Y 2/4 P-01,01,03,28,94

 ITEM SPECIFICATION NOTE
Starter relay resistance 72 – 88 Ω
Battery Type designation YTX5L-BS
Capacity 12 V 14.4 kC (4 Ah)/10 HR
Fuse size 5A
Circuit breaker 30 A

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Rear brake pedal free travel 15 – 25
———
(0.59 – 0.98)
Rear brake pedal height 5
———
(0.2)
Brake drum I.D. 80.7
Front ——— (3.18)
130.7
Rear ———
(5.15)
Wheel axle runout 3.0
Rear ———
(0.12)
Wheel rim size Front & Rear 8 × 5.5 AT ———
Toe-in (with 60 kg load) 8 ———
(0.31)
Turning radius 2.1 m (6.89 ft) ———
Camber 1° ———
Kingpin inclination 15° ———
Caster 3° ———
Trail 11.6 ———
(0.46)
Steering angle Inside 35° ———
Outside 27° 30’ ———
Tire size Front AT 19 × 7.00 – 8 ———
Reat AT 19 × 7.00 – 8 ———
Tire tread depth 4.0
Front ——— (0.16)
4.0
Rear ———
(0.16)

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Front suspension stroke 31 ———
(1.22)
Front wheel travel 50 ———
(1.97)
Rear suspension stroke 55
———
(2.17)
Rear wheel travel 57.4
(2.26) ———

Model: LT80Y 3/4 P-01,02,03,28,94

TIRE PRESSURE
COLD INFLATION
kPa kgf/cm2 psi
TIRE PRESSURE
FRONT 15 0.15 2.2
REAR 20 0.20 2.9
VEHICLE LOAD CAPACITY : 132 lbs (60 kg)

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane ( R +2 M ) or 91 octane or higher rated by the
research method.
Gasoline containing MTBE (Methyl Tertiary Butyl P-03
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corro-
sion inhibitor is permissible.
Use only unleaded gasoline of at least 87 pump
octane ( R +2 M method) or 91 octane or higher rated P-28
by the research method.
Gasoline used should be graded 91 octane or For the others
higher. An unleaded gasoline is recommended.
Fuel tank including reserve 6.0 L (1.58/1.32 US/lmp gal)
reserve 2.0 L (0.53/0.44 US/lmp gal)
Engine oil type Use SUZUKI CCI SUPER 2-CYCLE MOTOR
LUBRICANT or an equivalent good quality syn- P-03
thetic based 2-stroke engine oil rated FC under
the JASO classification.
Use SUZUKI CCI SUPER OIL or an equivalent
good quality synthetic based 2-stroke oil rated FC For the others
under the JASO classification.
Engine oil tank capacity 1.2 L (1.27/1.06 US/lmp qt)
Transmission oil type SAE 10W/40
Transmission oil capacity Change 80 ml (2.7/2.8 US/lmp oz)
80 – 90 ml
Overhaul (2.7/2.8 – 3.0/3.2 US/lmp oz)

Model: LT80Y 4/4 P-01,01,03,28,94