Suzuki LT160E Service Manual
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Suzuki LT160E Service Manual

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  • Page 1 9 9 5 0 0 - 4 1 1 1 4 - 0 1 E...
  • Page 2 GROUP INDEX FOREWORD GENERAL INFORMATION The SUZUKI LT160E was designed to offer supe- rior performance through four stroke power, PERIODIC MAINTENANCE equipped with a reverse gear. The suspension sys- AND TUNE-UP PROCEDURES tem consists of “wishbone” for front and “swingarm”...
  • Page 220 LT-F160Y/K1/K2 ( ’ 00, ’ 01, ’ 02-MODELS) 14-8 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Front brake lever free travel ——— (1.2) Rear brake pedal free travel 20 – 30 ——— (0.8 – 1.2) Brake drum I.D. 120.7 Front ———...
  • Page 227 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) This section describes service data, service specifications and servicing procedures which differ from those of 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 (*).
  • Page 228 15-1 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) SPECIFICATIONS LT160 DIMENSIONS AND DRY MASS Overall length ............* 1 610 mm (63.4 in) Overall width ............985 mm (38.8 in) Overall height ............1 000 mm (39.4 in) Wheelbase ............1 070 mm (42.1 in) Ground clearance ..........
  • Page 229 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-2 CHASSIS Front suspension..........Independent, swing axle, coil spring, oil damped Rear suspension ..........Swinging arm, coil spring, oil damped Caster..............8° Trail..............31 mm (1.2 in) Toe-in ..............7 mm (0.28 in) Camber ...............
  • Page 230 15-3 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) LT-F160 DIMENSIONS AND DRY MASS Overall length ............1 670 mm (65.7 in) Overall width ............985 mm (38.8 in) Overall height ............1 000 mm (39.4 in) Wheelbase ............1 070 mm (42.1 in) Ground clearance ..........
  • Page 231 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-4 CHASSIS Front suspension..........Independent, swing axle, coil spring, oil damped Rear suspension ..........Swinging arm, coil spring, oil damped Caster..............8° Trail..............31 mm (1.2 in) Toe-in ..............7 mm (0.28 in) Camber ...............
  • Page 232 15-5 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) SERVICE DATA LT160 VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.1) — (1.0) Valve clearance (when cold) 0.03 – 0.08 — (0.001 – 0.003) 0.05 – 0.10 —...
  • Page 233 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-6 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.768 – 33.808 33.470 (1.3295 – 1.3310) (1.3177) P-03 33.390 – 33.430 33.090 (1.3146 – 1.3161) (1.3028) 33.490 – 33.530 33.190 (1.3185 –...
  • Page 234 15-7 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) ITEM STANDARD LIMIT Piston ring thickness 1.17 – 1.19 1st & 2nd — (0.046 – 0.047) Piston pin bore 14.002 – 14.008 14.030 (0.5513 – 0.5515) (0.5524) Piston pin O.D. 13.996 – 14.000 13.980 (0.5510 –...
  • Page 235 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-8 DRIVE TRAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.736 (71/19) — Final reduction ratio 3.545 (39/11) — Gear ratios 3.166 (38/12) — 2.142 (30/14) — 1.588 (27/17) —...
  • Page 236 15-9 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug NGK: DPR7EA-9 Type ND: X22EPR-U9 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 0.1 –...
  • Page 237 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-10 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Front brake lever free travel — (1.2) Rear brake pedal free travel 20 – 30 — (0.8 – 1.2) Brake drum I.D. 120.7 Front —...
  • Page 238 15-11 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible.
  • Page 239 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-12 LT-F160 VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.1) — (1.0) Valve clearance (when cold) 0.03 – 0.08 — (0.001 – 0.003) 0.05 – 0.10 — (0.002 – 0.004) Valve guide to valve stem 0.010 –...
  • Page 240 15-13 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.490 – 33.530 33.190 (1.3185 – 1.3201) (1.3067) 33.353 – 33.393 33.060 (1.3131 – 1.3147) (1.3016) Camshaft journal oil clearance 0.032 –...
  • Page 241 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-14 ITEM STANDARD LIMIT Piston ring thickness 1.17 – 1.19 1st & 2nd — (0.046 – 0.047) Piston pin bore 14.002 – 14.008 14.030 (0.5513 – 0.5515) (0.5524) Piston pin O.D. 13.996 – 14.000 13.980 (0.5510 –...
  • Page 242 15-15 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) DRIVE TRAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.736 (71/19) — Final reduction ratio P-51 *4.090 (45/11) — The others 3.545 (39/11) — Gear ratios 3.166 (38/12) —...
  • Page 243 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-16 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug NGK: DPR7EA-9 Type ND: X22EPR-U9 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 0.1 –...
  • Page 244 15-17 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Front brake lever free travel — (1.2) Rear brake pedal free travel 20 – 30 — (0.8 – 1.2) Brake drum I.D. 120.7 Front —...
  • Page 245 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-18 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl P-28 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-...
  • Page 246 15-19 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) WIRING DIAGRAM LT160 AND LT-F160...
  • Page 247 Prepared by 15th Ed. August, 2004 1st Ed. November, 1988 Part No. 99500-41114-01E Printed in Japan...
  • Page 248 Printed in Japan K L M N P R S T V W X Y K1 K2 K3 K4 K5...

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