SUZUKI LT50 Service Repair Workshop Manual 1985 Onwards

FOREWORD This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service Suzuki Motorcycles. Apprentice mechanics and "do it yourself" mechanics will also find this manual to be an extremely useful guide. Model L T50 manufactured to standard specifications is the main subject matter of this manual. However, the L T50 machines distributed in your country might differ in minor respects from the standard-specification and, if they do, it is because some minor modifica- tions (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. Latermade modifi- cations and changes will be explained to each SUZUKI distributor in respective markets, to whom you are kindly requested to make query about updated information, if any.

GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE SERVICING ENGINE FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION LT50F ('85-MODEL) LT50G ('86-MODEL) LT50H ('87-MODEL) LT50J ('88-MODEL) L T50K ('89-MODEL) L T50L ('90-MODEL) LT50x/yIK1('99, 'OO,'01-MODELS)

VIEW OF SUZUKI LT50 RIGHT SIDE LEFT SIDE

GENERAL INFORMATION ~--------------CONTENTS----------------~ VIN AND SERIAL NUMBER LOCATIONS······························· ·1- 1 FUEL AND OIL RECOMMENDATIONS·································· ·1- 1 SPECiFiCATIONS·················· ............................................ ·1- 2 PRECAUTIONS AND GENERAL INSTRUCTIONS··················· ·1- 3 SPECIAL MATERIAL·························································· ·1- 4

1-1 GENERAL INFORMATION VIN AND SERIAL NUMBER LOCATIONS The V.I.N. (Vehicle Identification Number) CD is stamped on the steering head pipe. The engine serial number ell is located on the crankcase. These numbers are required especially for reg- istering the machine and ordering spare parts. FUEL AND OIL' RECOMMENDATIONS Be sure to use the specified fuel and oils. The following are the specifications. 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 LUBR ICANT or an equivalent good quality synthetic based 2-cycle oil. TRANSMISSION OIL A multi-grade motor oil with SAE 20W/40 vis- cosity rating is specified.

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) Drymass ..................... ...... ... 48kg (106Ibs) ENGINE Type .................................. Two-stroke, air-cooled Intake system ........................... Piston valve Number of cylinders ...................... 1 GENERAL INFORMATION 1-2 Bore x Stroke ........................... 41.0 mm (1.614 in) x 37.8 mm (1.488 in) Piston displacement ...................... 49 cm 3 (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 ............................. OAIOO 0.1.0.420 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 ti re 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.

1-3 GENERAL INFORMATION PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when disassembling and reassembling vehicles. o 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. o 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. o Use special tools where specified. o Use SUZUKI Genuine Parts and recommended oils. o When 2 or more persons work together, pay attention to the safety of each other. o After the reassembly, check parts for tightness and operation. o 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.

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 "13338" 99000-32020 GENERAL IN FORMATION 1-4 Use • Crankshaft oil seal outer surface. • Recoil starter lever nut. • Magneto rotor nut.

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SUZUKI LT50 Service Repair Workshop Manual 1985 Onwards

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