Suzuki LT160E, Service Manual

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Page 2: ... the main subject matter of this manual However the LT160E machines distributed in your country might differ in minor respects from the stan dard specification 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 require ments of your country This service manual has been produced...

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Page 220: ...75 kg 165 lbs 3 11 0 1 0 4 Caster 8 Trail 31 1 2 Wheel axle runout Rear 8 0 0 31 Wheel rim size Front 8 5 5 AT Rear 8 8 0 AT Tire size Front AT 20 7 8 Rear AT 22 10 8 Tire tread depth Front 4 0 0 16 Rear 4 0 0 16 SUSPENSION Unit mm in ITEM STANDARD LIMIT NOTE Rear shock absorber spring 2nd position setting Front wheel travel 80 3 1 Rear wheel travel 90 3 5 Swingarm pivot shaft runout 0 6 0 02 TIRE...

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Page 227: ...the LT F160K2 02 MODEL Any differences in sevice data and service specifications with those that apply to the LT160K3 K4 LT F160K3 K4 K5 models are clearly indicated with an asterisk Please refer to the sections 1 through 14 for details which are not given in this section SPECIFICATIONS 15 1 LT160 15 1 LT F160 15 3 SERVICE DATA 15 5 LT160 15 5 LT F160 15 12 WIRING DIAGRAM 15 19 ...

Page 228: ... in Displacement 158 cm3 9 6 cu in Compression ratio 9 2 1 Carburetor MIKUNI VM20SS single P 03 MIKUNI BS26SS single P 33 Air cleaner Polyurethane foam element Starter system Electric Lubrication system Wet sump Idle speed 1 500 100 r min DRIVE TRAIN Clutch Wet multi plate type automatic centrifugal type Transmission 5 forward constant mesh and 1 reverse Gearshift pattern forward All up foot lever...

Page 229: ... size AT22 10 8 ELECTRICAL Ignition type Electronic ignition CDI Ignition timing 10 B T D C at 1 500 rpm Spark plug NGK DPR7EA 9 or DENSO X22EPR U9 Battery 12V 32 4 kC 9 Ah 10HR Generator Three phase A C generator Fuse 15A Headlight 12V 45 45W Brake light Taillight 12V 21 5W Neutral indicator light 12V 3 4W Reverse indicator light 12V 3 4W CAPACITIES Fuel tank including reserve 8 5 L 2 2 1 9 US Im...

Page 230: ...58 cm3 9 6 cu in Compression ratio 9 2 1 Carburetor MIKUNI VM20SS single Air cleaner Polyurethane foam element Starter system Electric Lubrication system Wet sump Idle speed 1 500 100 r min DRIVE TRAIN Clutch Wet multi plate type automatic centrifugal type Transmission 5 forward constant mesh and 1 reverse Gearshift pattern forward All up foot lever operated Gearshift pattern reverse Hand lever op...

Page 231: ... size AT22 10 8 ELECTRICAL Ignition type Electronic ignition CDI Ignition timing 10 B T D C at 1 500 rpm Spark plug NGK DPR7EA 9 or DENSO X22EPR U9 Battery 12V 32 4 kC 9 Ah 10HR Generator Three phase A C generator Fuse 15A Headlight 12V 45 45W Brake light Taillight 12V 21 5W Neutral indicator light 12V 3 4W Reverse indicator light 12V 3 4W CAPACITIES Fuel tank including reserve 8 5 L 2 2 1 9 US Im...

Page 232: ...0 030 0 057 0 0012 0 0022 Valve stem deflection IN EX 0 35 0 014 Valve guide I D IN EX 5 500 5 512 0 2165 0 2170 Valve stem O D IN 5 475 5 490 0 2155 0 2161 EX 5 455 5 470 0 2148 0 2153 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem end length IN EX 2 5 0 10 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free len...

Page 233: ... 018 0 4724 0 4731 Rocker arm shaft O D IN EX 11 977 11 995 0 4715 0 4722 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 ITEM STANDARD LIMIT Compression pressure 1 000 1 400 kPa 10 14 kgf cm2 142 199 psi 800 kPa 8 kgf cm2 114 psi Piston to cylinder clearance 0 030 0 040 0 0012 0 0016 0 120 0 0047 Cylinder bore 58 000 58 015 2 2835 2 2841 58 100 2 2874 Piston diam 57 ...

Page 234: ...side clearance 0 10 0 45 0 0039 0 0177 1 00 0 039 Conrod big end width 15 95 16 00 0 628 0 630 Crank web to web width 53 0 0 1 2 087 0 004 Crankshaft runout 0 05 0 002 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 30 kPa 0 30 kgf cm2 4 3 psi Below 70 kPa 0 70 kgf cm2 10 0 psi at 3 000 r min ITEM STANDARD LIMIT Clutch release screw 0 1 8 turn back Drive plate thickness 2 7 2 9 0 106 0 114 2 ...

Page 235: ... 0 161 Shift fork thickness No 1 No 2 No 3 4 30 4 40 0 169 0 173 Reverse 3 80 3 90 0 150 0 154 Drive chain Type TAKASAGO RK520SM Links 84 20 pitch length 319 4 12 57 Drive chain slack 20 30 0 8 1 2 Gearshift lever height 10 0 4 ITEM SPECIFICATION P 03 P 33 Carburetor type MIKUNI VM20SS MIKUNI BS26SS Bore size 20 mm 26 mm I D No 02C02 02C1 Idle r min 1 500 100 r min Float height 25 8 1 0 mm 1 02 0 ...

Page 236: ...cap Ground Magneto coil resistance Pulser 380 600 Ω BI G Charging 0 5 1 2 Ω Y Y Generator no load voltage More than 55 V AC at 5 000 r min Generator Max output Approx 150 W at 5 000 r min Regulated voltage 13 5 15 5 V at 5 000 r min Starter relay resistance 3 7 Ω Battery Type designation YB9A A Capacity 12 V 32 4 kC 9 Ah 10 HR Standard electrolyte S G 1 28 at 20 C 68 F Fuse size 15 A ITEM SPECIFIC...

Page 237: ...utside 30 Turning radius 2 4 m 7 9 ft Toe in with 75 kg 165 lbs 3 11 0 1 0 4 Caster 8 Trail 31 1 2 Wheel axle runout Rear 8 0 0 31 Wheel rim size Front 8 5 5 AT Rear 8 8 0 AT Tire size Front AT 20 7 8 Rear AT 22 10 8 Tire tread depth Front 4 0 0 16 Rear 4 0 0 16 ITEM STANDARD LIMIT NOTE Rear shock absorber spring setting 2nd position Front wheel travel 80 3 1 Rear wheel travel 90 3 5 Swingarm pivo...

Page 238: ...asoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corro sion inhibitor is permissible Fuel tank including reserve 8 5 L 2 2 1 9 US lmp gal reserve 1 1 L 0 3 0 2 US lmp gal Engine oil type SAE 10W 40 API SF or SG Engine oil capacity Change 1 500 ml 1 6 1 3 US lmp qt Filter change 1 700 ml 1 8 1 5 US lmp qt Overhaul 1 900...

Page 239: ... 0 057 0 0012 0 0022 Valve stem deflection IN EX 0 35 0 014 Valve guide I D IN EX 5 500 5 512 0 2165 0 2170 Valve stem O D IN 5 475 5 490 0 2155 0 2161 EX 5 455 5 470 0 2148 0 2153 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem end length IN EX 2 5 0 10 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length I...

Page 240: ...77 11 995 0 4715 0 4722 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 ITEM STANDARD LIMIT Compression pressure 1 000 1 400 kPa 10 14 kgf cm2 142 199 psi 800 kPa 8 kgf cm2 114 psi Piston to cylinder clearance 0 030 0 040 0 0012 0 0016 0 120 0 0047 Cylinder bore 58 000 58 015 2 2835 2 2841 58 100 2 2874 Piston diam 57 965 57 980 2 2821 2 2827 Measure at 20 mm 0 8 in f...

Page 241: ...side clearance 0 10 0 45 0 0039 0 0177 1 00 0 039 Conrod big end width 15 95 16 00 0 628 0 630 Crank web to web width 53 0 0 1 2 087 0 004 Crankshaft runout 0 05 0 002 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 30 kPa 0 30 kgf cm2 4 3 psi Below 70 kPa 0 70 kgf cm2 10 0 psi at 3 000 r min ITEM STANDARD LIMIT Clutch release screw 0 1 8 turn back Drive plate thickness 2 7 2 9 0 106 0 114 2 ...

Page 242: ... 0 177 0 181 Reverse 4 00 4 10 0 157 0 161 Shift fork thickness No 1 No 2 No 3 4 30 4 40 0 169 0 173 Reverse 3 80 3 90 0 150 0 154 Drive chain Type TAKASAGO RK520SM Links P 51 88 The others 84 20 pitch length 319 4 12 57 Drive chain slack 20 30 0 8 1 2 Gearshift lever height 10 0 4 ITEM SPECIFICATION P 24 28 P 51 Carburetor type MIKUNI VM20SS Bore size 20 mm I D No 02C02 02C2 Idle r min 1 500 100 ...

Page 243: ... cap Ground Magneto coil resistance Pulser 380 600 Ω BI G Charging 0 5 1 2 Ω Y Y Generator no load voltage More than 55 V AC at 5 000 r min Generator Max output Approx 150 W at 5 000 r min Regulated voltage 13 5 15 5 V at 5 000 r min Starter relay resistance 3 7 Ω Battery Type designation YB9A A Capacity 12 V 32 4 kC 9 Ah 10 HR Standard electrolyte S G 1 28 at 20 C 68 F Fuse size 15 A ITEM SPECIFI...

Page 244: ...utside 30 Turning radius 2 4 m 7 9 ft Toe in with 75 kg 165 lbs 3 11 0 1 0 4 Caster 8 Trail 31 1 2 Wheel axle runout Rear 8 0 0 31 Wheel rim size Front 8 5 5 AT Rear 8 8 0 AT Tire size Front AT 20 7 8 Rear AT 22 10 8 Tire tread depth Front 4 0 0 16 Rear 4 0 0 16 ITEM STANDARD LIMIT NOTE Rear shock absorber spring setting 2nd position Front wheel travel 80 3 1 Rear wheel travel 90 3 5 Swingarm pivo...

Page 245: ...r less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corro sion inhibitor is permissible P 28 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended P 24 51 Fuel tank including reserve 8 5 L 2 2 1 9 US lmp gal reserve 1 1 L 0 3 0 2 US lmp gal Engine oil type SAE 10W 40 API SF or SG Engine oil capacity Change 1 500 ml 1 6 1 3 US lmp qt Filte...

Page 246: ...AL INDICATOR LIGHT RE REVERSE INDICATOR LIGHT REGULATOR RECTIFIER REVERSE SWITCH NEUTRAL SWITCH IGNITION SWITCH HEADLIGHT SPEEDOMETER OPTION INDICATOR LIGHT DIMMER SWITCH FRONT BRAKE SWITCH STARTER BUTTON ENGINE STOP SWITCH IGNITION COIL DIODE CDI UNIT NEUTRAL RELAY BRAKE LIGHT TAILLIGHT FUSE BOX BATTERY 12 V M STARTER MOTOR STARTER RELAY GENERATOR Y G B W Bl B O W O O O Gr Gr Gr B W Gr Y G Y B Y ...

Page 247: ...Prepared by 15th Ed August 2004 1st Ed November 1988 Part No 99500 41114 01E Printed in Japan 252 ...

Page 248: ...Printed in Japan K L M N P R S T V W X Y K1 K2 K3 K4 K5 ...