I just bought my second LT80. My boy has one and his sister is tired up trying to keep up on the 50. I got it pretty cheap and it runs OK but it makes an awful rumbling noise like a bad roller bearing or something. I can usually fake my way through stuff but I may need technical info on this one. Where can I get a manual to get me through a rebuild? It is a '95 so I am sure it is due. Also is there a big bore kit for or something these? Who would go through all of the work of a rebuild with out trying to sqeeze out a little more power, right? I don't want anything too radical, just shaving down the head a bit or something? What is the thing to do?

Thanks for any help.

 

I agree that the top end should be freshened up. Please use Suzuki parts (including the piston).
Don't ruin your cylinder by going to the big bore. It really don't add the power you'd think.
I think you should service the clutchs too.
Stock mods:: remove 2 rollers from the clutch and shave the head .030
We'll help you thru it all. [img]i/expressions/face-icon-small-smile.gif[/img]

 

Thanks for the advise LT80. I have heard that before I think (milling the head down and the clutch rollers). Sounds like a good way to go. I found a manual on Worldofpowersports.com. It was $70!!! I'll probably get some good milage out of it though. It looks like all of the moving parts are relatively cheap and the ones that dont move are the expensive ones.

 

$70!!!! Now I know why I don't have one. [img]i/expressions/face-icon-small-happy.gif[/img] [img]i/expressions/face-icon-small-happy.gif[/img]

 

<div class="FTQUOTE"><begin quote>Originally posted by: LT80

$70!!!! Now I know why I don't have one. [img][/img] [img][/img]</end quote></div>

LOL [img]i/expressions/face-icon-small-smile.gif[/img] I think LT80 could write one.

 

So, I haven't gotten my manual yet but I started taking it apart. The piston and cylinder walls are gouged....alot. The deepest are around .015" to .020" deep but there are alot of them. Anyway it is a '95 so I geuss I should expect that. The bearings, as far as I can tell, look to be in OK shape. I was going to replace the wrist pin and the piston bearing and all gaskets that I have remove too. Is there anything else that I should check out since I am in there? Can I get that cylinder machined out that much and get an oversized piston? Say .030" over? Is that getting too thin? A new cyinder seems to be about $150. Any idea how much machining will cost?

 

A new cylinder will come ready for the new piston.
You can bore yours. Bore sizes are 20-40-60-80. I'd say go for the 1.0 over ( .040) but it's hard to tell w/o seeing it. .5 (.020) usually cleanes em up....
The bore should be around $40 and the pistin kit around $45. Pin, brg, and cir clips $13.Base,head, and exhaust gaskets around $12-$15. All Zuki parts of course.
I have all this in the garage. [img]i/expressions/face-icon-small-smile.gif[/img]

 

LT80

I sent my cylinder off to the local machine shop for 1mm over. I am hesitant on the milling because .030 off of my head looks like it would take me into the dome, but just barely, is that right? Mabey somebody has already done this? How much of a lip is supposed to be there (I mean before machining).

Thanks

 

I also took my head in to be cut. I checked squash and I was at.057 and.049 and the guy said that .030 would take it down to the dome. this guy is a racer around here that opened a shop and he is doing very well has alot of bike small to big. he does all his own machining. ( in house). he is charging me$30 to cut head and $5 to ball hone, wash and oil cyl. for new piston. I cant wait!!!!!!

 

got it back in 6 hours. and only charged me 25.00 and looks nice. puting back together tonight