wow, i think that's a lot for the year, especially if you had to spend anything on it afterwards, and it's still not running right. i'd try the other pipe on it. i'm guessing maybe you have a partial blockage in there. also, make sure restrictors are removed in the exhaust, carb, and that your throttle/governor is adjusted all the way out.

do you need a manual? I may have a factory Suzuki manual I'll sell (shipped to your door) for $25.

 

Ok I got all the parts today, but something's wrong. When I go to put the front clutch on, there's not enough room for the outer sheave when the belt is on. I tried compressing the spring on the rear clutch to give it some more stack, but still couldn't get it to work. I think the part I got may be the wrong one, but I thought all years had the same clutch system. I ordered I '92 part b/c the guy I bought it from said that was the year, but the cap that screws on doesn't seem to fit right. Even worse, I tossed the old parts, so I don't even have anything to compare with. Any suggestions? TIA

 

Wow that sucks I am not sure about them being the wrong parts for sure but I would give lt 80 a pm and ask him.

 

i remember having the exact same problem, and it was me..... i didn't have someting lined up quite right or pushed in all the way. try re-aligning and wiggling. my belt rode up a little on a thrust washer between sheaves. also, the center bushing is snug, but pushes inward, exposing more shaft to get the nut on. i had to push, grunt, compress the spring (by pushing) and then i JUST got the nut started. do you have a schematic diagram?

I'm guessing the parts are correct. do you have a manual? If you're interested, i have a factory Suzuki repair manual that I'll sell for $25 (US), and I'll ship it by regular mail. PM me if you're interested.

 

I figured it out. I was trying to put the screws through the plastic tab instead of sliding the tabs over the metal fingers. Whew! Sorry to bother you guys with my ignorance and lack of a manual. Luckily I looked closely at the picture in a clutch tuning article here:
http://www.off-road.com/atv/kidskorner/clutching3.html

 

Be sure to let us know how it turns out.

 

Turned out great! Once I got the assembly correct, I tightened everything up with the impact wrench, and she runs like a dream. The final test will come this weekend on the logging roads in vt, but I don' t think Katey will do too much damage. here's a link to her first run:

katey

 

My daughter has a 1988 LT80 that is very hard to start when cold. It seems to flooded and I've been reading up and it appears the problem may be in the petcock. Are they rebuildable? Does it make any sense that this could cause such a problem? If so, how?
I also saw the entry below indicating the Banshee petcock would work. Any idea what year or part number will work on a 1988 LT80?
Thank you
Don

 

Bail the oil injection system. Pre mix yourself! Im sure that causing some of your grief. good luck!