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    Suzuki LTF160 Service Manual[1

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    96 views14 pages

    Suzuki LTF160 Service Manual (1

    Uploaded by

    Jor GE

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    SUZUKI LT160F 230 SUZUKI LT160F NOTE: Metric fasteners are used throughout vehicle. CONDENSED SERVICE DATA MODEL LT160F General Engine Make Suzuki Engine Type. + Four-Strake; Air-Caoled Number of Cylinders... 1 Bore ae aa 58.9 mm (2.283 in.) Stroke. 60.0 mm (2.282 in.) Displacement. 158 o¢ (9.6cu. in) Compression Ratio 92:1 Fuel Recommended. Unleaded or Low-Lead Pump Octane Ratng 85.95 Engine Lubrication sae Wet Sump; Pump Engine/Transmisson Gil Recommencation SAE 10-40 Forward Speeds. 5 : * 1 5 : 207.008 Rear... 22x 11.00-8 Tite Pressures (cod): POR sors a cree temic 17.5 kPa (24s) Alla sa 15kPa (22psi) Dry Weight. . 152 kg (334 Ibs.) Tune-Up Engine Idle Speed. ..... 1450-1550 1pm Spark Plug, NGK. D7EA ‘Champion fete ABYC Electrode Gap : 06-07 mm (0.024-0.028 in lgnition: Type ee Breakerlass Timing ‘ 10° BTOG @ 1000 pm Carburetor Make . Mikuni Model uae ae vzoss Float Height... ee 24.8-26.8 mm (0.98-1.06 in.) Jet Needle ‘SFU ‘Tune-Up (Cont.) Carburetor: (Cort,) Clip Position. Throttle Cutaway Pilot Jet é Needle Jet... Main Jet Throttle Cable Free Piay .. Sizes-Clearences \Vaive Clearance (cold) Intake... Exhaust Valve Face Ange Valve Seat Ange Valve Seat Widh ..... Valve Stem Diameter: Intake Exhaust .. Valve Guide Bae Diameter: Intake & Exhaust .. Valve Sterr-to-Guide Clearance: Intake Fe Exhaust Velve Spring Free Length (Min.) . Rocker Arm Bere Diameter: Intake & Exhaust Rocker Shaft Ciameter: Intake & Exhaust... 2.22... Camshatt Lobe Height: Intake. Wear Limit. Exhaust ee Wear Limit... Camshaft Journal Diameter. . . Camshaft Journal Clearance. . Wear Limit ‘Camshaft Runout (Max.) . SUZUKI LT160 3rd Groove From Top 25 #75 oF #825 0.5-1.0 mm (0.02-004 in) 0.08-0.08 mm (0.001-0.008 in.) 0.08-0.13 mm (0.003-0.005 in.) 45 15° 8 45° 09-11 mm (0.035-0.043 in.) 5.475-5.490 mm (0.2156-0.2161 in) 5.455-5.470 mm (0.2148-0.2183 in) 5.500-5512mm (02165-02170 in) 0.010:0,037 mm (0,0004-0.00°5 in.) 0.080 0.067 mm (0.0012-0,0022 in.) 39.5 mm (1.56 in.) 12,000-12.013 mm. (0.4724-0.4731 in.) 11.977-11.995 mm (0.4715-0.4722 in.) 33.768-33.808 mm (1.3296-1.33'0 in) 33.470 mm (1.397 in) 33.390-33.430 mn (1.3146-1.3161 in) 3.090 ren (1.3028 in.) 21.959-21.960 mm (0.8645-0.8854 in, 0.032-0.066 mm {0.0013-0.0026 in.) 0.450 mm (0.0059 in.) 0.10 mm (0.008 in) 231 SUZUKI LT160F ‘Sizes-Clearances (Cont.) Cylinder Head Cover Distortion (Max.) Cylinder Head Distortion (Max) Piston-to-Cylinder Wall Clearance... . Cylinder Bore Diameter .......- Wear Limit... Cylinger Bore Distortion (Max.) Piston Diametar: Monsured 16m (0.50 0) from Skint Bottom Wear Limit... Piston Pin Bore Diameter in Piston Wear Limit ..... Piston Pin Diameter Wear Limit Piston Ring End Gap in Standard Bore. Wear Limit...... Piston Ring Side Claaranra in Pitan (Maw ) Top. Second, Connecting Flod Small End Bore Diameter Wear Limit Connecting Rod Small End Sie Shake (Max.) Crankshaft Runout at Main Be sled (Max: Neo Capacities Fuel Tank . Engine/Transmission Oil Tightening Torques Camshaft Sprocket Bolt Clutch Hub Nut . Cylinder Base Nut Cylinder Head Cover Bolt... . 0.05 mm (0.002 in.) 0.05 mm, (0.002 in.) 0.030-0.040 mn (0.0012.0.0016 n,) 58.000-58.015 nm (2.2835-2.2840 n.) 58.100 mm (2.2874 in.) 0.05 (0.002 in.) 57.965-57.980 im (2,2821-2.2807 in.) 57.880 mm (2.2787 in.) 14.002-14.008 nm (0.5513-0.5514 in.) 14.030 mm (0.5524 in.) 13.995-14.000 nm (0.5510-0.5512 1.) 13.980 mm (0.5504 in.) 0.10-0.25 mm (0.004-0.010 in) 0.70 mm (0.028 in.) 0.160 mm (9.0071 in.) 0.150 mm (0.0069 in.) 14.004-14.012 nm (0.5513-0.5516 in) 14.040 mm (0.5828 in.) 3.0mm (0.12 in) 0.05 mm (0.002 in.) B5L (2.2gal) ‘See Text 10-12Nem (88-106 in.-Its.) 60-80 Nm (4459 ft-lbs.) 71 Nm (62.97 in.-Ibs.) 911 Nem (80-97 in.-bs.) x) Tightening Torques (Cont.) Cylinder Head Nut .. Engine Mounting Nut Engne Sprooke: Nut Flywheel Nut Front Axle Nut Rear Axle Nut Wheel Retaining Nuts: Front Rear: Standard Screws: ‘Unmarked or Marked “4 4mm 5mm 6mm amm. 10mm 12mm 14mm 16mm 18mm Marked °7" 4mm 5mm 6mm... 10mm. 12mm... 14mm 16mm... 18mm ‘SUZUKI LT160F 21-25 Ne (15-18 th-lbs) 60-72 Ne (4453 tllos.) 80-100 Nem (59-73 ft-lbs.) 145-175 Non (107-129 1.-bs.) 50-80 Nn (37-59 ft-tbs.) 85-115 Nem (63-83 ft-lbs.) 20-31 Nem (15:23 fos) 44-66 Nem (82.48 ft-lbs.) 1.0-2.0 Nem (8.9.18 in.-lts.) 2.0-4.0 Nem (18.36 ints.) 4.0-7.0 Nem (36-62 in.-ts.) 10-16Nn (885-142 in.tbs.) 22-35 Non (16-26 tts.) 95-55 N.n (26-40 tt-lts.) 50-80 Nen (37-59 ft-its.) 80-130 Nn (59-96 ft-ts.) 130-190 Nm (06-140 ft-bs.) 15-30 Nm (18-27 in-bs.) 30-60 Nm (27-53 in.-bs.) 80-120 (71-108 in.-bs.) 18-28 Nin (13-21 f-bs.) 40-60 Nan (29-44 ft-tbs.) 70-100 Nm (92-/4 1-105.) 110-160 Nem (81-118 ft.-bs) 470-250 Nam (125-184 ft-1bs.) 200-280 N.m (147-206 tts.) 233 SUZUKI LT160F LUBRICATION ENGINE AND TRANSMISSION. The engine and transmission have a common sump and a’e lubricated by a crankshaft driven oll pump, Recommended oil is a multigrade SAE 10W-40 motor oil with an API classifi- cation of SE or SF The sump is filed through filer plug opering (F—Fig. '$3-1). Oil level should be maintained at level indicated On sight glass (G), Oil is drained by removing piug in underside of crankcase. Dry capacity of crankcase is 1.8 (20 qt) atter an engine or transmission overhaul Reliling after changing oi and oil fiter requres only 1.7 L (1.8 qt) as some ol will be retained in crankcase castings Manufacturer recommends oil and sil fiter be hanged after the first month of operation and every three months thereater The ail filter may be renewed after removng fiter cap (C). Insart new fiter with closed end towaid fier cap. Renew fiter cap °O" ring and ensure filter retaining spring is properly located when installing cap DRIVE CHAIN. The final drive chain should be lubri: ‘cated with a suitable chain lube or SAE 90 coar oil prior to each operating interval. Select chain lute designed for use on °O" ring-type drive chains; incerrect chain lubricating of may cause damage to “0 ring seals. Aftor avery month af operation, the chais should be thoroughly washed in kerosene then lubicated with SAE 90 gear oll, The use of any cleaning solstions other than kerosene may result in “O" ring seal damage Adjust orive chain as outined in DRIVE CHAIN AND SPROCKETS section Fig, S-1—Engine/transmission sump is filled through {illee plug opening (F). Oil level should be maintained at Jevel on sight glass (G). Oil filter is located behind site cover (0). 234 CABLES, LEVERS AND SHAFTS. The brake, choke and throttle cables should be lubricated with motor cil every three months. Brake pedal chat, thrattle lever rear axle housing, front wheel bearings, king pins and steering shaft should be greased every 2000 km (1200 mites), AIR CLEANER ELEMENT The air cleaner element shoud be removed and leaned every three months. To remove air cleaner element, frst remove seat ane element cover, Remove element retaining pin and withdraw element. Carefully ‘Separate foam element from frame, Thoroughly clean element na suitable nonflammable solvent. Compress element between hands to remove solvent. Saturate element in clean motor of. Compress. element to remove excess ol. Reinstall element by reversing removal procedure. FUEL SYSTEM CARBURETOR. All models are equipped with a Mikuni VM20SS carburetor. Refer to CONDENSED ‘SERVICE DATA for carburetor specications. Before performing carburetor adustments, the throt- tle cable should be adjusted to provide 0.5-1.0 mm (0.02-0.04 in.) free play at idle position. To adjust, push bback dust boat on throttle cable, loosen locknut (L—Fig. S3-2) and rotate adjuster (A) a5 required. Initial setting ot idle mixture screw (18—Fig. S3-3) is two tums out from a lightly seated position. Rotating idle mixture screw counterclockwise will richen mixture While clockwise rotation will ean mixture. Final adjust ment should be made with engine at normal operating temperature and running. Adjust ide speed screw (17) so engine idles at 1450-1850 mpm. Adiust idle mixture screw so highest idle is achisved and readjust idle ‘speed screw to recommended ipm. After adjusting car- CY Fig. $$2—Measure throttie cable tree play (F) at cable guide s shown. Loosen focknut (L) and turn adjuster (A) to sdjust free play. buretor, check throttle cable adjustment as previously descibed. When servicing carburetor, observe he following: Clip (6—Fig, S3-4) should be in third groore from top of jet needle (9). Float height should be 24.8-26.8 mm (0.96-1.06 in). To check float height, remove float bow! and invert carburetor. Measure the distance (A—Fig $3-5) between bottom of float and gasket surface on carburetor body. Adjust float by bending foat arm tang. FUEL STRAINER. All models are equippadwith afuel strainer located in each fuel tank outlet. The strainer should be removed and cleaned periodically. IGNITION AND ELECTRICAL SPARK PLUG. Standard recommended spark plug is NGK D7EA or Nippon Denso X22ES.J. Spark plug electrode gan should be 0.6-0.7 mm (0.024-0.028 in.) Spark plug should be removed, cleaned and elec trode gap set every three months and renewed annually IGNITION. All models are equipped wth a capacitor discharge, pointless electronic ignition system. The ig- nition system consists of the flywheel, a magneio coll located underneath flywheel, an exterrally mounted pickup coil, a CO! module attached t» front frame bracket, an ignition coll located on front ame brackel, @ spark plug and an engine stop switch. Ignition timing should occur at 10° BTOC with engine operating a 1000 pm andbelow and at 30° BTOC at 5000 rpm and above. Ignition lining is fixed ard not adjustable. The flywheel has a single mark ‘T° (Fg. $3-6) to indicate Top Dead Center and which is used dunng valve clearance adjust- iment or when setting camshaft timing. {t ignition malfunction occurs, check condition of spark plug, all wires and connections before trou- bleshoating ignition circuit. Using Suzuk pocket tester (09900-25002 ora suitable ahmmeter, refer to the follow- ing test specifications and procedures to aid trou- bleshooting ‘To check condition of CDI module, firs: remove mod- ule from vehicle. Use tester or ohmmeter in conjunction Fig, S3-3—View of carburetor showing location of idle ‘speed screw (17) and idle mixture screw (16) ‘SUZUKI LT160F with test chart shown in Fig. 53-7, Flenew CDI module it required, To check condition of magneto coil and pickup coil, remove rear fender and discannect leads to CDI mod: Ule. To check pickup coil, attath one tester lead to pickup coil end of blue wire and remaining tester lead to green wire. Resistance reading shauld be approximately 200- 400 ohms. Attach one tester lead to magneto coil end of blackwhile wire and remeining tester lead to brown wire, Resistance reading shauld be approximately 350 550 ohms. Fig. S3-4—Expioded view cf Mikuni VM20SS carbure- tor. 1 17. ie speed screw 2 Ie mocure screw 3 Prot 2 Noel jat 5 Nozzle 7 Fuel inet seat 8 Fuetiniat va 9. Inlet sat retainer 10, Theale side Bats piste 1, Cable quae Screw 12) Washer Flos! pn 3 Float 1 Stator vata Gastot 45. Starter inter Drain screw $8. “O"7ing Fu bow! 235 ‘SUZUKI LT160F Fig. $3-5—Fleat level (A) should be 24.8-26.8 mm (0.98- 1.96 In.) Bend float arm tang to adjust float level, “et PK Fig. $9-6—View of top dead center mark (T) on tlywheel and reference mark (M) on crankcase. ‘Testor Lead Geen | Bue | Whia’| Black’ | Bact’ | Brown Bue | Bue | Yolow | alo] Fig, 99-7—Use chart shown above and vaiues iisted below to test condition of CD ignition module. All val- ves are approximations. A. bine resistance F 20h-ddk ome B. 1 5kskonns G. 254 50k ohms © Get ohm Hi. a0K-100% one D. 6-16 ohms “S 80k 250k obms E1025 ohms K 1004-6004 she Tocheck condition of ignition coil, separate white/blue wire connector from col to COX module and remove high tension wire from spark plug. Attach one tester lead to white/blue wire and remaininy lead to coil ground. Pri- mary coil resistance reading should be approximately 0.1-1.0 ohms. Attach one tester lead to high tension wire {and remining lead to coil ground. Secondary col resis- tance reading should be approximately 10-25 ohms. CHARGING CIRCUIT. A charging circuit which con- sists of an AC generator located undemaath the fly- wheel, a regulator/rectitier and a battery is used. Standard battery is YB9A-A wth 9 ampere hour, 12-volt rating. Under load. the AC ganerator should produce 13.5-15.5 volts DC at 5000 rpm. No-lood voltage of AC generator should be 55 volts AC at §000 rpm. The battery should be checked and filed to maximum ‘eval with distlled water, frequired, ater the frst morth and every three months thervafter. During periods of vohice storage, the battery should be charged once a month to reduce sulfation and prolong battery life. When charging battery, always discoinect battery from charg- ing crcutt to prevent damage to regulaloritectfier or ‘other components. Do not exceed maximum charging rate of 0.9 amperes. The AC generator can be statically checked using ‘Suzuki pocket tester 09900-25002 or a suitable ohmmo- ter. Separate wire connector bbck fram AC generator io regulator/tecttier and attach tester leads between each yellow stator lead. Tester reading should indicate cont- fully hetueen each load Aach one toster lead 10 ground and remaining tester bad to each yellow wire individually. Tester reading shuld indicate infinite resis- tance at each lead. ‘An operational check can be performed using Suzuki pocket tester 09900-25002 or a suitable voltmeter as follows: Set lighting switch to on position and dimmer ‘switch ta high beam position. Remove tront fender cover and attach voltmeter leads to battery noting correct polariy, Start and run engine at 5000 rpm. With a fully chargad battery, AC generater and regulator/rectifier may be considered satislactery it voltage reading is within the limits of 13.5-15.5 vots. Ifvoltage is not within required limits the AC generator may be eliminated as cause of difficulty by performingano-load test. Separate ‘AC generator io regulator/rectiter wire connector block. Start and run engine at 5000 rpn. Attach voltmeterleads between each yellow siatorlead. The AC generator may 'be oonsiderod satistactory if load voltage is nt less than £5 volts AC. STARTER. An electric starter is used. Startor should ‘draw 30 amperes at ongine starting speed. Removal and disassembly of starter is evident after inspection of unit. Starter brushes should be renewed if worn to § mm (04 in) orless. WIRING. Itwiring requires repair, always use replace- ment wire of the same gauge. Wires should be routed away trom areas of extreme heat or sharp edges. Plastic te straps should be used to retain wires it their original positions to prevent short citcuiting. Refer to Fig $3-9 for schamatic wiring diagram. FASTENERS Atier the first montn ot operation and every three months thereafter the cylinder head, cyinder, exhaust system, engine mounts and all chassis nuts or bolts, should be retightened. Refer to TIGHTENING TORQUES seviion uf CONDENSED SERVICE DATA {or torque specifications. VALVE SYSTEM clearance should be adjusted with engine cold. The valves are actuated via rocker arms by a single ovethead camshaft. Camshatt is timed and driven by a roller drive chain trom lett end of cratkshatt. Valve clearance should be adjusted after the first month of operation and every three months therealter. Valve ‘SUZUKI LT160F ‘To adust vaive clearance, frst drain engine oil then fender, spark plug. valve adjustment ccaps and lel side cover. Rotate crankshaft until"T" mark (TDC—Fig. $3-8) on flywhzel aligns with stationary ‘mark (M) on crankcase and piston is on compression stroke. To ensure piston is on compression stroxe, rotate crankshaft '% tun past TDC while observing intake valve. It valve movement is indicated, rotate crankshaft one full reveluticn and align timing marks again. Clearance between rock arm adjusting screw and valve stem should be 0.03-.08 mm (0.001-0.003 in.) for intake vaive and 0.08-0.13 mm (0.003-0.005 in.) for exhaust valve. Adjust clearance by loosening locknut (Fig, $3-13) and turning serew (A). Ba sute to re- check adjustment aiter lockruts have been tightened. CAM CHAIN ‘Cam chain should be adjusted atter the first month of ‘operation and every three months thereafter. Cam chain tension is adjusted with piston at TOC on compression stroke. Align timing marks as previously described in VALVE SYSTEM section toset piston at TDC on com- pression stroke; however fo" cam chain tension agjust- Fig, $3:9—Wiring diagram for Model LT106F ‘SUZUKI LT160F Fig. $2-13--Measure valve clearance with eer gauge (rf Loosen oennur ix) ana Tetate screw (A) fo asus Fig. $3-15—Following procedure outiired In text, loosen locknut (L) and sel screw (S) to adjust cam chain tension, ment, make sure flywheel is rctated in normal operation Girection (counterclockwise) only. Loosen beknut (_— Fig. 53-15) and back out set scrow (S) ono complete revolution to release tensioner push rod. Saring in ten- sioner mechanism automatically adjusts can chain ten- sion, Tighten sot screw and secure with locknut. Cam chain noise alter adjustment may bs caused by a stuck tensioner push rod. Remove tensiover retaining ‘cam screws (C) and withdraw the unit. Loosen set screw and clean tensioner with a suitable solvert. Lubricate tensioner push rod with clean motor oil. Actuale push ‘od several times to ensure smooth movement. Rein- stall tensioner and acjust as previously described. CLUTCH All models are equipped with two types of automat- ically actuated clutches. One type is a throe-shoe oen- trifugal clutch attached to right end of craskshatt and actuated by engine rpm. The other type is anultiple-disc clutch attached to right end of transmission countershatt and actuated by the gear shift lever. Ouringgear selec- tion, a lever attached to end of gear shift shaft simulta- neously disengages the multiple-dise clutch to permit ‘smooth transmission operation. The clutch should be adjusted after the first month of operatian and every six months thereafter. To adjust clutch, drain engine’transmission sump and remove the three screws securing engine/transmission sump sight ‘glass cover and withdraw cover. Loosen locknut (L— 238 Fig. $3-17—To adjust clutch, loosen focknut (L) and ‘rotate screw (S) as outlined in text. Ng. 09-17), turn eujustiny sew () clockwise one-hall tum, then rotate screw (S) ccunterclockwise stopping just ‘as internal resistance is felt. Rotate screw (S) clockwise “turn and retain adjusting screw position while tightening locknut (U) To check clutch operation, trst adjust clutch as pre viously described, Ensure oll vel is correct and engine ‘sat operation temperature. Atach a suitable tachome. ter. Select low gear and slowly accelerate engine while ‘observing meter. Initial engagement should begin at 2000-2400 rom. Next, with trarsmission stil in low gear, lack up brakes and momentaily open the throttle. Da pot maintain open throttle Icnger than 10 seconds. Engine speed should be held to 3250-3750 mpm. Any results other than specified may indicate disassembly and repair of clutch urit is required. FRONT BRAKE BRAKE LEVER ADJUSTMENT. Adjust each brake: cable adjuster (J—Fig. S3-19) untl equalizer lever (E) 's parallel with Cable bracket (B). Raise the front wheels off the ground and slowly rotata each front wheel while lightly applying thebrake lever. An evenamountof brake {drag should be noted on each wheel. If nat, loosen the ‘appropriate cable locknut (N) and rotate adjuster (A) Until equal brake drag is felt. Note that no brake drag ‘should be felt whien brake lever is released OVERHAUL. Brake lining thickness may be deter- ‘mined externally by actuating brake and noting position of pointer (P—Fig. S3-20) on brake camshatt. I pointer falls within limit mark (L) on backing plate, then lining thickness is acceptable and brake shoes do not require renewal WANING: Inhaling asbestos brake dusts injuri- ‘ous te human health. Approved OSHA respiration wipment must be worn when working on or arourd brake components. DO NOT use com- pressed air to clean brake drums, shoes or nearby components as brake dust will be blown into air. Only vacuum equipment designed to pick up brake dust should be used. Fig. $9-19—Braking action at the two font brakes is ‘equalized by adjusting front brake cables. Refer lo text tor procedure. Fig. $3-20—It pointer (P) does not pass line (L), brab wear limit, tached to brake camshaft ining thictness /s within ‘The front brake assemblyis accessibleatter removing brake drum and hub assembly (14—Fig. 53-21). Renew the brake shoes if shoe lining thickness s less than 1.5, mm (0.06 in.) or any otner damage is noted. Renew the brake drum assembly ithe inside diameter is more than 20.7 mm (4.75 in.). During reaazembly rete thet morte (M—Fig, $3-22) on lever (1) and pointer (2) must align with groove (G) in camshatt (7) FRONT AXLE ASSEMBLY R&A AND OVERHAUL. Refer to Fig. S3-21 for an oxploded view of front axle assembly. To remove either SUZUKI LT160F wheet hub (14), remove front wheel and axle nut (20), Pull wheel hub trom spindle Do not lose spacer (17). Drive seals (10 and 16), bearings (11 and 15) and spacer (12) rom hub it necessary To reassemble, reverse disassembly procedure while noting the following: Install the inner bearing (11) into hub first. Seals (10 and 16) are installed with open sides toward bearings. Tighten axle nut (20) to 60-80 Nun (37-58 ft-lbs.) torque. Tighten wheel retaining ruts to 20-31 Nam (15-22 ft-lbs). STEERING ADJUSTMENT. The toe-n should be checked and adjusted after the first month of operation and every three months thereatter. Prior to toe-in adjustment, in- spect sleering assembly for damaged or excessively wom components. If service to steering assembly is required, reler to R&R AND OVERHAUL section Ta check tocin, inflate tires to recommended pres- sure in CONDENSED SERVICE DATA. Position vehicle on a flat smooth surface and set handlebars straight forward. Using a suitable tape measure, measure the distance between right and ett tre centerlines on back side of res (B—Fig. S3-23) and rocord measurement. Locate the same tie centerine points on front side of tiros (F) and record measurement, The front measure ment should be 3-11 mm (0.1-0.4 in.) less than rear measurement. Note thal the distance from a projected veticie centerline toleft(L) and right (R) te centerlines should also be equal. To adjust toe-in, loosen tie rod locknuts (17 and 19—Fig. S3-24) on both lett and right tie rods. Inner tie rod encs (16) and locknuts 17) are color coded yellow and have left-hand threads. Rotate tie rods (18) in equal increments to maintain equal vehice centerline to left and right tire centerline distances. Tighten te rod locknuts to 22-35 Nam (16-25 ft-Ibs,) torque, R&R AND OVERHAUL. Refer to Fig. S3-24 for an exploded view of steering assembly. Removal and dis- assembly of steering components is evident after in- sSpection of unit and referral to exploded view. During reassembly, renew all cotter pins, Lubrcate all fricton points with a good quality graase. Tighten steering shalt ‘clamp cap screws to 18-28 Nam (13-20 t-Ibs.). Tighien steering shatt lower nut and tie fod retaining nuts to 22.35 Nem (16.25 ft-lbs). Tighten king pin bot to 40-60 Nem (30-44 fs.) SUSPENSION The vehicle is equipped with a single wishbone-type front suspension and oil dampened shock absorbers. ‘Shock absorher load setting is not adjustable, Reter to Fig. $3-24 for an exploded view of suspension compo- nents. The suspension components shoud be peri- ‘odcally inspected for excessive wear or damage. 239 ‘SUZUKI LT160F c e Fig. $3-21—Exploded view of tron brake and hub assembly. 1. Brake lever 17. Spacer 2) Branton 7 Ganshat 12 Spa 18. Washer 3. Spring 8. Braw ses 13, Sea 18. Washor 4 -OnMng 9. Spree 14 Brake orm 2. Ni 5. -O'Nng 10. Ses 15. Bearing 21. Cotter pin Backing plate 11, Being 16, Seal 2 Cap it T Bet mteuwnniraccamnam — -——i1——| @ ‘on lever (1) and pointer (2) are aligned with groove (G) Fig. $+-23—Toe-in should be 3-11 mm (0.1-04 in). Re- im ond of comanst (2 eee avaa itt he macomrang ptssodere! Tighten control arm retaining bolts to 55-77 Nem (40-56 ft-lbs.). Tighten shock absorber retaining cap screws to oe 60 Nem (20-44 ft-lbs.) REAR BRAKE ADJUSTMENT, All models are equipped with a two- shoo internal expanding drum brake mounted on rear axle and actuated by the brake pedal, Thebrake should bbe checked and adjusted atter the first month and every three months thereafter, To properly check and adjust brake system, first ac tunta brake pedal and maasure free travel at and ot pedal. Free travel should be 20-30 mm (03-1.2 in.) and ‘SUZUKI LT160F is adiusted by rotating brake cable adjuster nut (A—Fig. 83-25) at rear brake actuating lover. OVERHAUL. Brake lining thickness may be deter- mined externally by actuatingbrake and noting position of pointer (P—Fig. S3-25) onbrako camshaft. I poinior falls within limit mark (L) on backing plate, then lining thickness is acceptable and brake shoes do not require renewal WARNING: Innaling asbestos brake dust is injurl- ous to human health. Approved OSHA respiration equipment must be wort when working on or around brake componen's. DO NOT use com- Fig. $2-24—Exploded view of steer- ng and suspension components. Steerirg shat Pate Camp al Samp all ‘Snap tig Beal “Orne Packing Washer Leckwesher 1 Nut 42. Aight otrotarm 13. Behn Hh. Shock ibsorber $5 Uotteoua am 16 Irner be tod end 17. Looked (CH) 18 Tierod 18. Locked 2a ‘SUZUKI LT160F pressed air to clean brake drums, shors or nearby ‘components as brake dust will be blewn into ai. ‘Only vacuum equipment designed to pick up brake dust should be used. ‘To remove rear brake shoes for inspactien orrenewal, first support rear of vehicle and remove rght rear axle ah Fig. $3-25—Rotate adjuster nut (A) to adjust brake pedal tree travel. If pointer (P) attached to brake com- Shaft does not pass line (L), brake lining thickness is vwetthin wear limit Fig. $3-20—Expiodea View of rear Brake and ante housing assembly. a 2 Spacer 5 an i Sal 5 Gover : 5 Gackot Brake crum Brake shone Springs Seal 1h Bearing 12. Spacer 13. Atle housing 34. Camshat 15. “Oring 18. Spring 17. Pointer 8 242 ‘ut. Pull tre, wheel and hub off axle as an assembly. Unscraw drum rataining nuts (1—Fig. S326), Unbolt and withdraw brake crum cover (5). Remove “O" ring (2) then slice brake drum (7) off axle, Carefully extract brake shoes (8) and springs @) from backing plate. Brake shoes should be ren2wed if linings are worn to 1.5mm (0.06in. ) orless. Braks drum shouldbe renewed it inside diameter exceeds (150.7 mm (5.83 in.) Reinstall brake shoes by ‘eversing removal proce:

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