Suzuki LT160E - User Manual

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99500-41114-01E

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Group Index2
Product View3
General Information Contents4
Vin and Serial Number Location5
Fuel and Oil Recommendations5
Breaking-In Procedure6
Special Materials7
Precautions and General Instructions10
Replacement Parts10
Specifications11
Periodic Maintenance and Tune-Up Procedures Contents12
Periodic Maintenance Schedule13
Battery14
Maintenance Procedures14
Engine Nuts and Bolt15
Cylinder Head Nuts15
Cylinder Base Nuts15
Exhaust Pipe Nuts and Muffler Bolt15
Valve Clearance16
Camshaft Drive Chain Tensioner17
Spark Plug17
Engine Idle Speed18
Idling Adjustment18
Throttle Cable Play18
Choke Cable Play18
Engine Oil and Oil Filter19
Spark Arrester19
Fuel Line19
Air Cleaner21
Clutch22
Drive Chain22
Checking22
Cleaning and Lubricating23
Adjusting23
Sprockets24
Tires24
Standard Tire Pressure24
Front Brake Adjustment25
Rear Brake Adjustment25
Brake Lining Wear Limit25
Suspension26
Toe-In26
Steering26
Chassis Nuts and Bolts27
General Lubrications29
Engine Contents30
Compression Pressure31
Initial Engagement and Clutch Lock-Up Inspection31
Initial Engagement Inspection32
Clutch Lock-Up Inspection32
Engine Components Removable with the Engine in Place33
Engine Removal34
Engine Remounting36
Engine Disassembly38
Rocker Arm ID45
Engine Components Inspection and Servicing45
Cylinder Head Cover Distortion45
Cylinder Head Cover Servicing45
Reassembly46
Cylinder Head Servicing46
Cylinder Head Distortion47
Valve Face Wear47
Valve Stem Runout47
Valve Guide-Valve Stem Clearance47
Valve Head Radial Runout48
Valve Stem Wear48
Valve Guide Servicing48
Valve and Seat Condition49
Valve Seat Width49
Valve Seat Servicing50
Valve Stem End Condition51
Valve Springs51
Camshaft52
Camshaft Cam Wear53
Camshaft Journal Wear53
Camshaft Runout54
Cam Chain 20-Pitch Length54
Cylinder Distortion/Bore54
Piston Diameter54
Piston-Cylinder Clearance55
Piston Ring-Groove Clearance55
Piston Ring Free End Gap and Piston Ring End Gap55
Oversize Rings56
Piston Pin Bore and Pin56
Conrod Small End ID57
Conrod Deflection and Conrod Big End Side Clearance57
Crankshaft Runout57
Clutch Drive Plate58
Clutch Driven Plate58
Clutch Spring Free Length58
Clutch Shoe58
Clutch Wheel59
One-Way Clutch59
Clutch Cover and Clutch Adjuster59
Clutch Release Ball60
Starter Clutch61
Magneto62
Oil Pump62
Transmission62
Gearshift Fork and Gear63
Crankcase Bearing65
Mounting the 2Nd Drive Gear65
Mounting the Driven Gear Bushing65
Engine Reassembly66
Oil Seals66
Crankshaft66
Gearshift Cam and Fork67
Crankcase68
Gearshift Shaft69
Cam Driven Gear69
Neutral Indicator Switch73
Starter Clutch and Magneto Cover73
Oil Ring and Piston Ring74
Piston75
Cylinder75
Cylinder Head76
Cylinder Head Cover78
Cam Chain Tensioner79
Magneto Cover79
Fuel and Lubrication System Contents80
Fuel Cock81
Cleaning81
Carburetor82
Slow System83
Main System83
Starter System with Limiter84
Float System84
Removal and Disassembly85
Inspection86
Needle Valve86
Float Height Adjustment86
Reassembly and Remounting86
Lubrication System87
Oil Pressure87
Lubrication System Chart88
Electrical System Contents89
Ignition System Description90
Magneto Coil90
Ignition Coil91
CDI Unit91
Charging System92
Function of Regulator92
Charging Output Check94
AC Generator No-Load Performance94
AC Generator Continuity Check94
Reegulator/Rectifier94
Starter System95
Starter Motor Removal and Disassembly96
Armature Coil97
Commutator97
Carbon Brushes97
Starter Motor Inspection97
Starter Motor Reassembly98
Starter Relay Inspection98
Armature and Bearing98
Housing End and Housing Cover98
Lamps99
Neutral Relay Inspection99
Switches Inspection100
Battery Specification101
Initial Charging101
Servicing101
Filling Electrolyte101
Recharging Operation Based on SG Reading102
Service Life103
Chassis Contents104
Front and Rear Fenders105
Rear Fender107
Remounting107
Front Wheel and Brake108
Inspection and Disassembly110
Wheel Hub Bearing110
Brake Drum110
Brake Shoe111
Tire Replacement112
Steering and Front Suspension114
Tie-Rod117
Dust Seal117
Steering Shaft and Holder118
Shock Absorber118
Steering Bushing118
Steering Shaft Dust Seal118
Toe-In Adjustment119
Handlebar119
Reassembling Information120
Rear Wheel121
Rear Brake122
Rear Axle Housing and Axle Shaft124
Axle Housing Bearing125
Rear Sprocket126
Rear Axle Shaft126
Rear Swigarm and Shock Absorber128
Bearing129
Swingarm Pivot Shaft129
Swinging Bearing130
Servicing Information Contents131
Troubleshooting132
Wiring Diagram139
Wire Routing140
Cable Routing141
Hose Routing142
Special Tools143
Tigtening Torque145
Tightening Torque Chart147
Service Data148
LT160EL Contents155
LT-F160L/M Contents165
LT160EM/N Contents175
LT-F160N/P Contents185
LT-F160R/S/T/V Contents194
LT-F160W/X Contents203
LT-F160Y/K1/K2 Contents212
Ignition System225
Table of Contents227
LT160K3/K4 and LT-F160K3/K4/K5 Contents227
Specifications228
- Lt160228
- Lt-F160230
Service Data232
- Lt160232
- Lt-F160239
Wiring Diagram246

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Suzuki LT160E Specifications

General

Brand	Suzuki
Model	LT160E
Category	Offroad Vehicle
Language	English

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