Cut the shoe off 1/2 inch from the contact pad then drill to weight. I use a 1/2" dril bit.
I consider the LT80 a lil jerky starting out. these clutch mods smooths it out IMO. Works fine w/stock motor.
There are no aftermarket clutch stuff for a LT80 (except for belts).
Google cheap Suzuki parts and it won't take long to find the best prices.
Make sure you check the bearings in the rear clutch (put finger in them and turn).

 

Ok, great! I'll do the clutch mods for sure. I'll probably just get a set of new shoes if I'm going to spend the time modifying them. I'm sure the stock ones are probably worn.

So if I shave the head down .030, will that require using race gas due to the raised compression, or will 91octane work. Will the stock oil injection pump provide the right mixture? Will the carb jets need to be changed?

 

Your shoes are prolly fine. They wear forever. IMO, if there is any pad left it's worth modifying.
1) 91 octane will be fine.
2) the stock oil pump will work. Most ditch the pump and run pre-mix. The pumps run a long time, till they don't and you buy a top end kit.
3) stock jets will be fine.
FYI: to get the clutch pack off the post, the big nut is LEFT hand threads.

 

Ok, sounds good. I'll go ahead and mill the head down 30 thousands and take the clutch shoes down to 180 grams. Hopefully after rebuilding the carb (with new parts this time) and going through the front and back clutches, it starts running good again.

After this is running good, it's time to get my '83 ATC 250R running again. I've owned it since new, and its been sitting in my garage for the past 15 years without any use. Still looks great. Guess its time to get it going again.

Thanks again for everyone's help. I really appreciate it, and I'm sure my little boy will appreciate it too as soon as I can get this quad going for him!

 

Rescue ...how does it run with milled head and rear clutch fix?

 

All done with all the mods. Milled the head, lightened the clutch shoes, and cleaned out the carb one last time. The quad runs GREAT!! It made a great birthday present for my boy, and he loves it. Thanks for all the help.

 

Cool.