I recently picked up an 01 LT80. Great little machine to get my youngest used to riding. Of course the second I get it off the trailer, it won't run.

After playing around with it for a while I realize that the jets are clogged. No big deal, he wanted to ride it through the yard for a while, and it runs fine when choked for that. Now I am building a list of parts that need replaced, I look at the front knuckles and the bushings on both sides are shot. Wheel bearings seem fine, but the knuckles have a lot of play in them and the wheels are toed when someone sits on it.

I'm assuming all I need to buy (I live in the middle of nowhere, so running to the parts store over and over is out of the question) are the two bushings per side, the kingpin spacer and the dust covers. Are there any other parts I should replace since I'm going to tear it apart?

Also, the starter intermittently won't engage. A bit of googling showed that normally means a new starter. Not looking forward to prying that out.

 

Welcome to the forums.
Your correct on the front end parts.
Negative camber is something a single a-arm machine does.
You have to remove the motor pivot bolt and raise the motor out of the frame slightly for the starter to come out. It helps If you do that when you have the carb off to clean.
You should service the clutchs.

 

After adding up the parts from some online place, it would be cheaper for me to buy used pieces of this off ebay. I found both front knuckle/bearing/brake/hub assemblies used in what appears to be great shape for $80, vs $100+ just for the bushings/etc. Having never really worked on quads (Long history with motorcycles tho) would it be better to go the cheaper route?

Also, what all parts would I need to service the clutch?

 

I looked at the clutch diagram, I realize what you mean now by servicing it. I'm gonna have to open it up before I know what parts I need. FWIW, I found this in one of your other posts, so thanks for answering.

 

All you really need is 4 of #5
You can get #17 if you think your metal tubes are wore.
I see #4 at 11.48 each and #17 at 10.94 (motorsportssupercenter.com)
There is a site with even lower prices but I forget
Used knuckles may be good but what if they are just as wore?!

 

Did you get this finished and running again?

 

Hey guys,. I have scrubbed the site looking for some sort of discussion and haven't found any. Hoping either of you can help with this rather simple question. Rebuilding an LT80 and removed front shocks. The arms are rather hard to move up and down and seems like they are under tension load from the bushings. The farther you lift up or down, the tighter the suspension arm gets. Is this the case? I can make a video and post to YouTube. I know it is a random question, but since my other ATVs don't do this I'm reaching out.

Best regards
GT

 

They only need 2 inches of travel. I'd think tight is good.