First off thanks to everyone who posts on this site it helped me a lot. Just wanted to let you know of a few things (for little money), that seems to boost the power and gets this LT moving. I recently purched a stock 2002 LT80 for my Daughter we ride mostly on old logging roads the LT seems OK for that but I was worried about when we go to the Oregon dunes. After reading a LOT of posts this is what I did to the LT.
1. Drilled 4 1 inch holes in air box -- Free
2. Boyesen reeds -- $19.
3. Jetting I live and tested this at 3200 ft this past couple of weeks air temp about 40 to 50 deg It would not run full throttle with the stock main at 92.5 I ended up with a 97.5 and plug color looks good. -- $5
4. 428 chain and sprockets 26 stock steal rear sprocket and a 13 front and a chain roller on a long bolt with washers for spacers -- $50
5. Removed the oil injection system ( A LOT less smoke) -- Free
6. Shaved the head .022 -- $30
7. Clutch work which took me the longest time to figure out because I weight 225 and my Daughter 48 lb. But this is where it’s at for now I cross drill all 6 rollers with a ¼ in bit. Then cut the rear shoes down to 180 grams each and it seems to launch her off the line real fast. -- Free

For stability I added the JL front end extender kit and a set of Turff Tamer tires 18*9.5*8 on the rear and I like this setup a lot. I also purchased a set of Gliders 18*8.5*8 for the dunes. My next trip to the dunes is in June so I’ll let you all know how this setup works on the sand when we get back. Again THANKS to every one and hope this helps someone like me.

Ron
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Hey did you do a block off kit or did you just remove the gear that drives the pump and put the top back on? That seems like a really big main jet for that high of elevation. I think I've got a 87.5 in mine and I'm at 2600. Sounds like you got it figured out.[img]i/expressions/face-icon-small-smile.gif[/img]

 

I removed the little plastic piece on the inside of the case that turns the pump gear when I did the clutch work. Then I pulled the oil pump feed line and plugged it and took a little piece of rubber hose plugged it and put on the pump inlet. That way if I want to hook it back up it will be easy I also left some oil in the tank just for a emergency. I was a little confused about the jet also when I did the reeds and put the holes in the air box I also went with a 90 main jet but the thing would not run at full throttle at all. I keep going up till 97.5 and the thing runs great now and the plug is tan. Do you have any holes in the air box I noticed a difference with just that.

 

When you had the reeds out, did you notice how it tapers down instead of staying the same size? Many years ago, my son drove an old 87 LT80, and I went through a few mods, clutch,reeds, etc, and was told by a forum user to grind out the reed cage to take out the taper, really opens up the flow, and lets it wind on the top end, I ended up with a 105 main jet with no holes in the air box !! but it ran great, and would launch and wind out like a real racer, had a DG pipe on it ( junk, rivets all rattled out, ended up bolting it together) and it sounded like a motocross bike when you revved it . With all your mods, that extra flow might give that top end a boost and keep it climbing on those dunes !!

 

I did not notice that but next time I have the carb off I’ll pull the reed cage and take a look at it and see what I can do. But I’ve read here that you don’t need to modify the reed cage but if it tapers why not try it.

 

No I don't have any airbox mods. That's probably why I'm not that high on the main jet. Where do you drill the holes at? In the top of the airbox? Thanks.

 

I put 2 in the top haft 1 on right side just below the tank and 1 in the right side under the fender well. The other 2 I put in the bottom haft towards the back of the LT.

 

Sounds like you got 'er running good.
I'm aslo doing, and have done, some cheep stuff that seems to work well.
I'm gonna look for a used LT now to build up for racing [img]i/expressions/face-icon-small-happy.gif[/img][img]i/expressions/face-icon-small-happy.gif[/img]

Where did you get your sprockets from?
I'm also going to do that......

Thanks and good luck [img]i/expressions/face-icon-small-happy.gif[/img][img]i/expressions/face-icon-small-happy.gif[/img]

 

Hey guys,
I just had some motor / clutch work done on the lt80. There is now 3 rollers in the front clutch instead of 6. I took the bike out for the first time and it seems like the bike really needs to rev all the way out before the bike takes off. I e-mailed the person who built the motor for me, he says to add another roller and see what happens. Will one roller make that much of a difference? Do I just buy the rollers from a dealership? When you say cross drill the rollers with 1/4 bit can you explain how this is done? Is it simple?? Thanks everyone!!

 

Try 4 rollers you feel a difference for sure. To cross drill them you need to heat them up in some hot water then push out the steal part then drill it, clean up the edges reheat and press it back in. My 6 drilled is real close to just running 4. I got my sprockets from my local Suzuki shop they them order up for me $ 40 for sprockets and chain.