1984-1987 Suzuki LT185 Service & Repair Manual

FOREWORD The SUZUKI L T185 was designed to offer superior performance through four stroke power (Twin Dome Combustion Chamber engine), equipped with wishbone type front suspension and baloon tires. This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service Suzuki Vehicles. Apprentice mechanics and udo it yourself" mechanics will also find this manual to be an extremely useful guide. Model L T185 manufactured to standard specifications is the main subject matter of this manual. However, the L T185 machines distributed in your country might differ in minor respects from the standard-specification L T185 and, if they do, it is because some minor modifications (which are of no consequence in most cases as far as servicing is concerned) had to be made to comply with the statutory requirements of your country. This manual contains up-to-date information at the time of its issue. Later made modifications and changes will be explained to each SUZUKI distributor in respective markets, to whom you are kindly requested to make query about updated infromation, if any. SUZUKI MOTOR CORPORATION Motorcycle Technical Service Department

VIEW OF SUZUKI LT185E ('84-MODEL) RIGHT SIDE LEFT SIDE

GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND ENGINE FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION . APPENDIX LT185FE ('84-MODEL) Except for LT185F ('85-MODEL) LT185G ('86-MODEL) LT185H ('87-MODEL)

GENERAL INFORMATION ~--------------CONTENTS----------------~ VIN AND SERIAL NUMBER LOCATIONS······························· ·1- 1 FUEL AND OIL RECOMMENDATIONS·································· ·1- 1 BREAICIN(;-IN I'ROCEDURE············································· ····1- 1 SI'ECIAL FEATURES························································· ·1- 2 I'RECAUTIONS AND (;ENERAL INSTRUCTIONS··················· ·1- 5 SI'ECIAL MA1nE:RIALS·············································· ···········1- E; SI'ECIFICATIONS········································ ·······················1- 8

1-1 GENERAL INFORMATION VIN AND SERIAL NUMBER LOCATIONS The VIN number CD is stamped on the left frame member as shown in photograph. The engine serial number ® is located on the crankcase. These numbers are required especially for register- ing the machine and ordering spare parts. FUEL AND OIL RECOMMENDATIONS FUEL For U.S. model Use only unleaded or low-lead type gasoline of at least 85 - 95 pump octane (R ; M method) or 89 octane or higher rated by the Research Method. For other models Gasoline used should be graded 85 - 95 octane or higher. An unleaded or low-lead type gasoline is recommended. ENGINE OIL Be sure that the engine oil you use comes under API classification of SE or SF and that its viscosity rating is SAE 10W-40. If SAE 10W-40 motor oil is not available, select the oil viscosity according to the following chart: SAE ( 40 ) 30 - 20W/50 I lOW/50 \ 10W/30 20W lOW - °c -20-10 0 10 20 30 40 J Temp. of 4 14 32 50 68 86 104 ( BREAKING-IN PROCEDURE During munufacture only the best possible ma- terials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to "BREAK-IN" before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows. 1. Keep to this break-in throttle position. Up to 10 hours Less than % throttle

SPECIAL FEATURES TWIN DOME COMBUSTION CHAMBER FEATURES OF L T185 ENGINE GENERAL INFORMATION 1-2 The Twin Dome Combustion Chamber is a new combustion chamber of the two-valve engine which has been newly developed by SUZUKI Motor Co., Ltd. This combustion chamber is the culmination of SUZUKI's research and development work for the ideal combustion chamber for two-valve engines. Any high-performance engine must meet the following requisites given below: • Good combustion efficiency • Satisfactory intake and charging efficiency It is possible to get a high-performance engine only when these two vital factors are combined ideally. The following is brief explanation on the configuration and features of the newly-developed combustion chamber which has made it possible to satisfy the above-described requisites in a two-valve engine. 1. Configuration of Combustion Chamber Fig. 1 shows a hemispheric type combustion chamber, a two-spherical type combustion chamber and a twin dome type combustion chamber, each having the identical valve arrangement and the same compression ratio. The twin dome configuration means such a shape which would be produced when an egg or a foot- ball is cut crosswise. The following is a comparison chart which indicates features of each type of combustion chambers. Squish areas: C> B> A Combustion chamber volume at cylinder head side: A> B> C Height of piston head: A > B > C B Squish area Fig. 1 A: Hemispheric type B: Two-spherical type C: Twin dome type C

1-3 GENERAL INFORMATION 2. Features of SUZUKI Twin Dome Combustion Chamber 1) Swirl The combustion chamber formed by two domes has been so designed that a swirl can be gen- erated readily because of the walls at both side surfaces, resulting in a very quick combustion speed. (See Fig. 2.) 2) Squish The mixture will be injected from the squish areas which are formed at both sides at the final stage of the compression stroke. Such squish effect will further accelerate the combustion speed. 3) Low piston head height As is described in Fig. 1, the twin dome type combustion chamber has the lowest piston head height. Consqeuently, such design feature can produce the following essential advantages. a. The swirl is hardly disturbed. Acceleration of combustion b. The heat-receiving area of the piston can be reduced. Improved durability and prevention of detonation. The foregoing explains how the newly-developed Twin Dome Combustion Chamber has made it possible to produce a remarkable combustion efficiency by combining the swirl and squish effects and low piston head height. Fig. 2 Twin Dome Combustion Chamber Squish area Squish area

GENERAL INFORMATION 1-4 3. Factors Which Enable Excellent Intake and Charging Efficiency Figs. 3 and 4 show the flow state of mixture and the change in cross section in a twin dome type combustion chamber and a hemispheric type combustion chamber, respectively. You will note that the passage area increases sharply at the time of the valve lifting in the case of the hemispheric type combustion chamber. As a result, flow separation will easily occur. Consequently, the pressure loss increases and the intake mixture volume descreases On the other hand, in the case of the twin dome type combustion chamber, the intake mixture volume can be increased by controlling the change in passage area at the time of the valve lifting. Valve area area Twin Dome Combustion Chamber Conventional Dome Type Fig. 3 area Twin Dome Combustion Chamber Conventional Dome Type Fig.4

1-5 GENERAL INFORMATION PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when disassembling and reassembling vehicles. • Be sure to replace packings, gaskets, circlips, O-rings and cotter pins with new ones. CAUTION: Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always insure that it is completely seated in its groove and securely fitted. • Tighten bolts and nuts from the ones of larger diameter to those of smaller diameter, and from inside to out-side diagonally, with specified tightening torque. • Use special tools where specified. • Use specified genuine parts and recommended oils. • When more than 2 persons perform work in cooperation, pay attention to the safety of each other. • After the reassembly, check parts for tightening condition and operation. • Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use gasoline as cleaning solvent. Warning, Caution and Note are included in this manual occasionally, describing the following contents. WARN I NG ........... Personal safety of the rider is involved, and disregard of the information could result in injury. CAUTION ............ For the protection of the vehicle, the instruction or rule must be strictly adhered to. NOTE ............... Advice calculated to facilitate the repair of the vehicle is given under this heading. USE OF SUZUKI GENUINE PARTS To replace any part of the machine, use a genuine SUZUKI replacement part. Imitation parts or parts supplied from any other source than SUZUKI, if used to replace SUZUKI parts, can reduce the machine's performance and, even worse, could induce costly mechanical troubles.

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1984-1987 Suzuki LT185 Service & Repair Manual

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