1987-1989 Suzuki LT300E LT F300 QuadRunner ATV Repair

VIEW OF SUZUKI L T300E LEFT SIDE RIGHT SIDE

GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES ENGINE FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION LT-F300 L T300EJ ('88 MODEL) L T-F300 ('88 MODEL) L T300EK ('89 MODEL) L T-F300 ('89 MODEL)

GENERAL INFORMATION ~---------------CONTENTS----------------~ ,,/~ ~~£) ~f:fl/~L. ~LI~lJf:fl L.()~~;r/()~~··································1-1 FLlf:L. ~~£) ()/L. flf:~()~~f:~£)~;rJ()~~ .................................... ·1-1 lJflf:~I{/~~-/~ "fl()~f:£)Llflf:···················································1-1 ~"f:~/~L. M~;rf:fl/~L.~·························································· ·1-2 "flf:~~LI;rJ()~~ ~~£) ~f:~f:fl~L. /~~;rflLl~;rJ()~~······················ ·1-5 ~"f:~/F/~~;r/()~~· ............................................................... ·1-6

1-1 GENERAL INFORMATION VIN AND SERIAL NUMBER LOCATIONS The VIN number CD is stamped on the left frame pipe. 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 chart right. BRAKE FLUID Specification and classification: 99000-23021 WARNING: DOT 3 or DOT 4 For U.S. model SAE J1703, DOT 3 or DOT 4 For other models SUZUKI BRAKE FLUID Not available in U.S.A. * Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix differ- ent types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. * Do not use any brake fluid taken from old or used or unsealed containers. * Never re-use brake fluid left over from the previous servicing and stored for a long period. MULTIGRADE TEMP. BRAKING-IN PROCEDURE During the manufacture only the best possible materials 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 engi,ne depends on the care and restraint exercised during its early life. The general rules are as follows. • Keep to this break-in throttle position. Up to 10 hours Less than 1/2 throttle • Do not maintain constant engine speed for an extended time period during any portion of the break-in. Try to vary the throttle position.

GENERAL INFORMATION 1·2 SPECIAL MATERIALS The materials listed below are needed for maintenance work on the LT300E and should be kept on hand for ready use. These items supplement such standard materials as cleaning fluids, lubricants, emery cloth and the like. How to use them and where to use them are described in the text of this manual. For U.S. model SUZUKI SUPER GREASE "A" 99000-25030 SUZUKI MOLY PASTE 99000-25140 SUZUKI BOND No. 1207B 99104-31140 Material For other models SUZUKI SUPER GREASE "A" 99000-2501 0 SUZUKI MOLY PASTE 99000-25140 SUZUKI BOND No. 1207B 99000-31140 Part Page • Throttle lever 2-21 • Speedometer cable 2-21 • Brake pedal shaft and rod link 2-21 • Gearshift lever 2·21 • Crankcase oil seal 3-49 • Recoil starter spiral spring, shaft and ratchet 3-77 • Starter motor armature bearing 5-10 • Starter motor oil seal 5·11 • Front wheel hub bearing 6-3 • Front wheel hub dust seal 6-4 • Front brake 6-10 • Steering shaft 6-21 • Steering shaft holder and dust seal 6-22 6-25 • Rear brake camshaft a-ring 6-33 • Rear brake camshaft and pin 6-34 • Rear axle housing dust seal 6-34 6-40 • Rear axle shaft 6-34 • Speedometer gear 6-39 • Rear axle housing spacer 6-39 • Rear axle housing bearing 6-40 • Rear swingarm dust seal 6-46 • Rear shock absorber bearing 6-46 • Valve stem 3-33 • Piston pin 3-69 • Camshaft journal 3-73 • Rocker arm shaft 3-73 • De-compression shaft 3-74 • Armature end 5-10 • Front brake backing plate 6-9 6-10 • Knuckle arm 6-11

1·3 GENERAL INFORMATION Material For U.S. model ~.~ ~ ~~ SUZUKI BOND No. 1207B 99104·31140 WATER RESISTANT GREASE 99000-25160 99000-25170 SUZUKI SILICONE GREASE 99000·25100 Not available THREAD LOCK SUPER "1303" 99000·32030 For other models SUZUKI BOND No. 1215 99000-3111 0 WATER RESISTANT GREASE 99000-25160 99000-25170 SUZUKI SILICONE GREASE 99000-25100 SUZUKI BRAKE FLUID 99000-23021 (0.5L) THREAD LOCK SUPER "1303" 99000·32030 Part • Cylinder head cover • Magneto lead wire grommet • Mating surfaces of left and right crankcase • Rear brake drum dust seal • Front brake • Brake fluid (Front) Page 2-4 3-74 3-44 3·58 6-35 6-10 1-1 2-11 • Starter clutch bolts 3-43 • Oil pump case securing screw 3-44 • Cam sprocket bolts 3-72

Material For U.S. model THREAD LOCK SUPER "1303" 99000·32030 THREAD LOCK SUPER "1303" 99000-32030 THREAD LOCK SUPER "1303" 99000-32030 For other models THREAD LOCK SUPER "1305" 99000-32100 THREAD LOCK SUPER "1322" 99000-32110 THREAD LOCK SUPER "1324" 99000-32120 THREAD LOCK SUPER "13338" THREAD LOCK SUPER "13338" 99000-32020 99000-32020 THREAD LOCK "1342" 99000-32050 THREAD LOCK "1342" 99000-32050 GENERAL INFORMATION 1·4 Part • Magneto rotor nut • Knuckle arm bolt Page 3-67 6-23 6-25 • Knuckle arm lower bolt 6-23 6-25 • Reverse lever screw • Rear axle inner and outer 6-34 lock nut • 2nd drive gear 3-52 • Stator mounting bolts 3-44 5-2 • Gearshift cam retainer screws 3-59 • Oil pump mounting screws 3-61 • Starter motor housing screws 5-11

1·5 GENERAL INFORMATION PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when servicing, disassembling and reassembling motorcycles. o Do not run engine indoors with little or no ventilation. o 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 fined. o Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter, and from inside to out-side diagonally, to the specified tightening torque. o Use special tools where specified. o Use genuine parts and recommended oils. o When 2 or more persons work together, pay attention to the safety of each other. o After a reassembly, check parts for tightness and operation. o Treat gasoline, whkh 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. WARNING ............. .when personal safety of the rider is involved, disregard of the information could result in injury. CAUTION ............... For the protection of the motorcycle, the instruction or rule must be strictly adhered to. NOTE .................. Advice calculated to facilitate the use of the motorcycle is given under this heading. USE OF GENUINE SUZUKI PARTS To replace any part of the machine, use genuine SUZUK I replacement parts. 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.

SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............................. 1,860 mm (73.2 in) Overall width .............................. 1,110 mm (43.7 in) Overall height ............................. 1,120 mm (44.1 in) Wheelbase ................................ 1,170 mm (46.1 in) Front track ............................... 810 mm (31.9 in) Rear track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 820 mm (32.3 in) Ground clearance. . . . . . . . . . . . . . . . . . . . . . . . .. 140 mm ( 5.5 in) Seat height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 770 mm (30.3 in) Dry mass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 203 kg (447 Ibs) ENGINE GENERAL INFORMATION 1·6 Type ................................... .4-stroke, air-cooled, OHC, TSCC Number of cylinders ........................ 1 Bore .................................... 72.0 mm (2.835 in) Stroke ................................... 72.0 mm (2.835 in) Piston displacement ......................... 293 cm 3 (17.9 cu. in) Compression ratio .......................... 8.5 : 1 Carburetor ................................ M I KUN I VM26SS, single Air cleaner ................................ Polyurethane foam element Starter system (U.S A.l ...................... Electric starter (Others) ...................... Electric and recoil starter Lubrication system ........................ .wet sump TRANSMISSION Clutch ................................... Wet multi-plate, automatic, centrifugal type Transmission .............................. 5-forward constant mesh, 1-reverse Gearshift pattern, Forward ................... AII up, foot lever operated Reverse .................... Hand knob operated Primary reduction .......................... 3.500 (63/18) Final reduction ............................ 3.727 (41/11) Gear ratios, Low ........................... 3.272 (36/11) 2nd ........................... 2.000 (28/14) 3rd ........................... 1.388 (25/18) 4th ........................... 1.120 (28/25) Top ........................... 0.958 (23/24) Reverse ........................ 2.545 (29/11 x 28129) Drive chain ........ , ...................... DAIDO 0.1.0. 520V 3 orTAKASAGO RK520SMOZ 2, 92 links

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1987-1989 Suzuki LT300E LT F300 QuadRunner ATV Repair

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