Suzuki LT50 1985 1986 1987 - 1990 Workshop Manual

GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE SERVICING ENGINE ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION LT50F (85-MODEL) LT50G (86-MODEL) LT50H (87-MODEL) LT50J (88-MODEL) LT50K ('89-MODEL) LT50L ('90-MODEL) FUEL AND LUBRICATION SYSTEM - www.instant-manuals.com -

VIEW OF SUZUKI LT50 RIGHT SIDE - www.instant-manuals.com -

GENERAL INFORMATION -CONTENTS VIN AND SERIAL NUMBER LOCATIONS 1- 1 FUEL AND OIL RECOMMENDATIONS /- 1 SPECIFICATIONS 1- 2 PRECAUTIONS AND GENERAL INSTRUCTIONS 1-3 SPECIAL MATERIAL 1- 4 - www.instant-manuals.com -

1-1 GENERAL INFORMATION VIN AND SERIAL NUMBER LOCATIONS The V.I.N. (Vehicle Identification Number) (D is stamped on the steering head pipe. The engine serial number (2) is located on the crankcase. These numbers are required especially for reg- istering the machine and ordering spare parts. FUEL Use only unleaded or low-lead type gasoline of at least 85 - 95 pump octane ( R * M method), 89 octane or higher rated by the research method. ENGINE OIL Use SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRICANT or an equivalent good quality synthetic based 2-cycle oil. FUEL AND OIL RECOMMENDATIONS Be sure to use the specified fuel and oils. The following are the specifications. TRANSMISSION OIL A multi-grade motor oil with SAE 20W/40 vis- cosity rating is specified. - www.instant-manuals.com -

GENERAL INFORMATION 1-2 SPECIFICATIONS DIMENSIONS AND MASS Overall length 1 045 mm (41.1 in) Overall width 640 mm (25.2 in) Overall height 680 mm (26.8 in) Wheelbase 765 mm (30.1 in) Ground clearance 75 mm ( 3.0 in) Rear track 500 mm (19.7 in) Dry mass 48 kg (106 lbs) ENGINE Type Two-stroke, air-cooled Intake system Piston valve Number of cylinders 1 Bore x Stroke 41.0 mm (1.614 in) x 37.8 mm (1.488 in) Piston displacement 49 cm' (3.0 cu. in) Corrected compression ratio 5.9 : 1 Carburetor MIKUNI VM12SC, single Air cleaner Polyurethane foam element Starter system Recoil starter Lubrication system SUZUKI "CCI" TRANSMISSION Clutch Wet shoe, automatic, centrifugal type Primary reduction 2.650 (53/20) Final reduction 3.364 (37/11) Transmission 2.416 (29/12), 1 -speed Drive chain DAIDO D.I.D. 420 or TAKASAGO RK420, 64 links CHASSIS Steering angle Inside 35° Outside 21.5° Trail 10 mm Turning radius 2 mm Toe-in 4.0 ±1.5 mm Camber angle 1 ° Caster angle 3°30' King pin angle 10° Rear brake Internal expanding Front tire size 145/70-6 x 2 Rear tire size 145/70-6 x 2 ELECTRICAL Ignition type SUZUKI "PEI" Ignition timing 24" B.T.D.C. at 3 000 r/min Spark plug NGK BP4H or NIPPON DENSO W14FP NGK BPR4H or NIPPON DENSO W14FPR . . . CAPACITIES only for Canada Fuel tank 1 -5 L (0.4/0.3 US/Imp gal) Engine oil tank 0.5 L (0.53/0.45 US/Imp qt) Transmission oil 500 ml (0.53/0.45 US/Imp qt) These specifications are subject to change without notice. - www.instant-manuals.com -

1-3 GENERAL INFORMATION PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when disassembling and reassembling vehicles. D Be sure to replace packings, gaskets, circlips, 0 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 cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter, and from inside to outside diagonally, to the specified tightening torque. □ Use special tools where specified. □ Use SUZUKI Genuine Parts and recommended oils. D When 2 or more persons work together, pay attention to the safety of each other. □ After the reassembly, check parts for tightness and operation. D Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use gasoline as cleaning solvent. WARNING The personal safety of the rider or bystanders may be involved. Disregarding this information could result in personal injury. CAUTION These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine. NOTE This provides special information to make maintenance easier or important instructions clearer. REPLACEMENT PARTS When you replace any parts, use only genuine SUZUKI replacement parts, or their equivalent. Genuine SUZUKI parts are high quality parts which are designed and built specifically for SUZUKI vehicles. CAUTION: Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems and damage. - www.instant-manuals.com -

GENERAL INFORMATION 14 SPECIAL MATERIAL The materials shown are required for maintenance work on the Model LT50, and should be kept on hand for ready use. In addition, such standard materials as cleaning fluids, lubricants, etc., should also be available, Methods of use are discussed in the text of this manual on later pages. Material SUZUKI SUPER GREASE"A" 99000-25030 SUZUKI BOND No. 1207B 99104-31140 SUZUKI THREAD LOCK "1342" 99000-32050 Use Oil seal. Throttle grip lever. Rear axle bearing. Wheel bearing. Brake cam- Steering stem bearing. Recoil starter spring. Rachet return spring. Steering shaft. Knuckle arm. Crankcase mating surface Bearing retainer/oil guide plate screw. Magneto coil screw. Material THREAD LOCK CEMENT 99000-32040 THREAD LOCK SUPER "1333B" 99000-32020 Use Crankshaft oil seal outer surface. Recoil starter lever nut. Magneto rotor nut. - www.instant-manuals.com -

CONTENTS PERIODIC MAINTENANCE SCHEDULE 2- 1 MAINTENANCE AND TUNE-UP PROCEDURES 2-3 AIR CLEANER 2-3 CYLINDER HEAD NUTS 2- 4 CYLINDER HEAD AND CYLINDER 2- 4 SPARK PLUG 2- 5 CARBURETOR 2- 6 FUEL LINE 2- 6 TRANSMISSION OIL 2- 7 BRAKES 2- 7 DRIVE CHAIN 2- 8 TIRE 2-9 STEERING 2-10 CHASSIS BOLTS AND NUTS 2-11 - www.instant-manuals.com -

2 1 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy. Mileages are expressed in terms of months. NOTE: More frequent servicing may be performed on vehicles that are used under severe conditions. PERIODIC MAINTENANCE CHART ENGINE Interval Initial Item 1 month Air cleaner Cylinder head nuts Cylinder head and cylinder Spark plug Carburetor Fuel line Transmission oil Drive chain Every Every 3 months 6 months Every 12 months Clean monthly or more frequently Inspect — Inspect Inspect Inspect — Inspect — — Remove carbon Replace Inspect — — — Overhaul Replace every 4 years Change — Change — Adjust and lubricate every month Page 2-3 24 2-4 25 26 2-6 27 2-8 CHASSIS Interval Item Brakes Tire Steering Chassis bolts and nuts Initial 1 month Every 3 months Inspect Inspect Inspect Inspect Every 12 months — — Check pressure each time you ride. Inspect Inspect Inspect Inspect — — ■ Page 2-7 2-9 2 10 2-11 - www.instant-manuals.com -

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-2 LUBRICATION CHART The maintenance schedule, which follows, is based on this philosophy. It is timed by month and is calcu- lated to achieve the ultimate goal of the vehicle maintenance in the most economical manner. Interval Item Throttle cable Throttle lever Brake cable Brake cam shaft Drive chain Steering stem bearings Recoil starter spring Steering shaft Knuckle arm Initial and Every 6 months Motor oil — Motor oil — Every 12 months — Grease — Grease Lubricate every month with motor oil Grease every 2 years Grease every 2 years Grease every 2 years Grease every 2 years WARNING: Be careful not to apply too much grease to the brake cam shaft. If grease gets on the linings, brake slippage will result. Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the vehicle has been operated under wet or rainy conditions. Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. - www.instant-manuals.com -

Suzuki LT50 1985 1986 1987 - 1990 Workshop Manual

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