Suzuki LT160E Manuals

Manuals and User Guides for Suzuki LT160E. We have 1 Suzuki LT160E manual available for free PDF download: Service Manual

Suzuki LT160E Service Manual (249 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 58.85 MB

Group Index
2
Product View
3
General Information Contents
4
Vin and Serial Number Location
5
Fuel and Oil Recommendations
5
Breaking-In Procedure
6
Special Materials
7
Precautions and General Instructions
10
Replacement Parts
10
Specifications
11
Periodic Maintenance and Tune-Up Procedures Contents
12
Periodic Maintenance Schedule
13
Battery
14
Maintenance Procedures
14
Engine Nuts and Bolt
15
Cylinder Head Nuts
15
Cylinder Base Nuts
15
Exhaust Pipe Nuts and Muffler Bolt
15
Valve Clearance
16
Camshaft Drive Chain Tensioner
17
Spark Plug
17
Engine Idle Speed
18
Idling Adjustment
18
Throttle Cable Play
18
Choke Cable Play
18
Engine Oil and Oil Filter
19
Spark Arrester
19
Fuel Line
19
Air Cleaner
21
Clutch
22
Drive Chain
22
Checking
22
Cleaning and Lubricating
23
Adjusting
23
Sprockets
24
Tires
24
Standard Tire Pressure
24
Front Brake Adjustment
25
Rear Brake Adjustment
25
Brake Lining Wear Limit
25
Suspension
26
Toe-In
26
Steering
26
Chassis Nuts and Bolts
27
General Lubrications
29
Engine Contents
30
Compression Pressure
31
Initial Engagement and Clutch Lock-Up Inspection
31
Initial Engagement Inspection
32
Clutch Lock-Up Inspection
32
Engine Components Removable with the Engine in Place
33
Engine Removal
34
Engine Remounting
36
Engine Disassembly
38
Rocker Arm ID
45
Engine Components Inspection and Servicing
45
Cylinder Head Cover Distortion
45
Cylinder Head Cover Servicing
45
Reassembly
46
Cylinder Head Servicing
46
Cylinder Head Distortion
47
Valve Face Wear
47
Valve Stem Runout
47
Valve Guide-Valve Stem Clearance
47
Valve Head Radial Runout
48
Valve Stem Wear
48
Valve Guide Servicing
48
Valve and Seat Condition
49
Valve Seat Width
49
Valve Seat Servicing
50
Valve Stem End Condition
51
Valve Springs
51
Camshaft
52
Camshaft Cam Wear
53
Camshaft Journal Wear
53
Camshaft Runout
54
Cam Chain 20-Pitch Length
54
Cylinder Distortion/Bore
54
Piston Diameter
54
Piston-Cylinder Clearance
55
Piston Ring-Groove Clearance
55
Piston Ring Free End Gap and Piston Ring End Gap
55
Oversize Rings
56
Piston Pin Bore and Pin
56
Conrod Small End ID
57
Conrod Deflection and Conrod Big End Side Clearance
57
Crankshaft Runout
57
Clutch Drive Plate
58
Clutch Driven Plate
58
Clutch Spring Free Length
58
Clutch Shoe
58
Clutch Wheel
59
One-Way Clutch
59
Clutch Cover and Clutch Adjuster
59
Clutch Release Ball
60
Starter Clutch
61
Magneto
62
Oil Pump
62
Transmission
62
Gearshift Fork and Gear
63
Crankcase Bearing
65
Mounting the 2Nd Drive Gear
65
Mounting the Driven Gear Bushing
65
Engine Reassembly
66
Oil Seals
66
Crankshaft
66
Gearshift Cam and Fork
67
Crankcase
68
Gearshift Shaft
69
Cam Driven Gear
69
Neutral Indicator Switch
73
Starter Clutch and Magneto Cover
73
Oil Ring and Piston Ring
74
Piston
75
Cylinder
75
Cylinder Head
76
Cylinder Head Cover
78
Cam Chain Tensioner
79
Magneto Cover
79
Fuel and Lubrication System Contents
80
Fuel Cock
81
Cleaning
81
Carburetor
82
Slow System
83
Main System
83
Starter System with Limiter
84
Float System
84
Removal and Disassembly
85
Inspection
86
Needle Valve
86
Float Height Adjustment
86
Reassembly and Remounting
86
Lubrication System
87
Oil Pressure
87
Lubrication System Chart
88
Electrical System Contents
89
Ignition System Description
90
Magneto Coil
90
Ignition Coil
91
CDI Unit
91
Charging System
92
Function of Regulator
92
Charging Output Check
94
AC Generator No-Load Performance
94
AC Generator Continuity Check
94
Reegulator/Rectifier
94
Starter System
95
Starter Motor Removal and Disassembly
96
Armature Coil
97
Commutator
97
Carbon Brushes
97
Starter Motor Inspection
97
Starter Motor Reassembly
98
Starter Relay Inspection
98
Armature and Bearing
98
Housing End and Housing Cover
98
Lamps
99
Neutral Relay Inspection
99
Switches Inspection
100
Battery Specification
101
Initial Charging
101
Servicing
101
Filling Electrolyte
101
Recharging Operation Based on SG Reading
102
Service Life
103
Chassis Contents
104
Front and Rear Fenders
105
Rear Fender
107
Remounting
107
Front Wheel and Brake
108
Inspection and Disassembly
110
Wheel Hub Bearing
110
Brake Drum
110
Brake Shoe
111
Tire Replacement
112
Steering and Front Suspension
114
Tie-Rod
117
Dust Seal
117
Steering Shaft and Holder
118
Shock Absorber
118
Steering Bushing
118
Steering Shaft Dust Seal
118
Toe-In Adjustment
119
Handlebar
119
Reassembling Information
120
Rear Wheel
121
Rear Brake
122
Rear Axle Housing and Axle Shaft
124
Axle Housing Bearing
125
Rear Sprocket
126
Rear Axle Shaft
126
Rear Swigarm and Shock Absorber
128
Bearing
129
Swingarm Pivot Shaft
129
Swinging Bearing
130
Servicing Information Contents
131
Troubleshooting
132
Wiring Diagram
139
Wire Routing
140
Cable Routing
141
Hose Routing
142
Special Tools
143
Tigtening Torque
145
Tightening Torque Chart
147
Service Data
148
LT160EL Contents
155
LT-F160L/M Contents
165
LT160EM/N Contents
175
LT-F160N/P Contents
185
LT-F160R/S/T/V Contents
194
LT-F160W/X Contents
203
LT-F160Y/K1/K2 Contents
212
Ignition System
225
Table of Contents
227
LT160K3/K4 and LT-F160K3/K4/K5 Contents
227
Specifications
228
- Lt160
  228
- Lt-F160
  230
Service Data
232
- Lt160
  232
- Lt-F160
  239
Wiring Diagram
246

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