Just wandering if anyone can help shed some light on my lt80 problem. The story goes like this Once upon a time, last week infact in my infinate wisdom I decided to buy a dead lt80, I was told by the previous owner that the only fault was it needed a rebore & piston which on inspection was shot but not bad enough in my opinion to stop it dead. After getting it home & inspecting closer the big end has lots of play so to confirm my diagnosis and to see if anything else wanted replacing I rebuilt the top end & after a bit of messing it started. The mains have obviously been u/s for some time as it rumbles like a concrete mixer full of bricks.
What I need to know is as the lt80 engine is obviously based on a scooter type engine/transmission does anyone know of an engine that will fit as lt80 bits are scarce over here & to rebuild the engine is going to cost a fortune.
Any info would be greatly appreciated. Thanks Desmo.

 

Hello Mr.Desmo,
Welcome to the forums. [img]i/expressions/face-icon-small-smile.gif[/img]
The LT80 mains seem to run forever even tho they rumble. Obviously they should be replaced. More important is any play in the connecting rod.
If you are able to do the labor yourself, I don't think it would be very expensive to put new bearings and seals in it.
The crank is $165.00 US but after that (and only if it's needed)::
Aftermarket bearings $20.00 US.
Suzuki Seals $20-$30.00 US(I forget exactly)
You allready have the top end gaskets.
Even shipped overseas, I'd still think it wouldn't be too expensive.
I could guide you thru all the case splitting if needed.

I would advise to give the carb a good cleaning and service the clutchs.
You'll be brand new. [img]i/expressions/face-icon-small-smile.gif[/img]

FYI:: There is no other motor to replace it.[img]i/expressions/face-icon-small-sad.gif[/img]

 

Now thats what I call a lightening response Thanks LT80.
Yes the conrod has loads of play it looks a though the rollers have brocken up on the big end, I am, mechanicaly competent so this should not be too difficult but one never knows, as I've always said you never stop learning in this game so yes I'm sure I'll be taking up your offer of advise. As I say over here in the Uk Second hand parts seem to be quite rare & looking on the net there doesdn't seem to be an awfull lot of choice for new parts either.
I Suppose my first starting point should be to establish the year of manufacture as I have no Idea. Can you help? also any info on where to get parts at a reasonable price. If I have to get them shiped from the U/S then I will, I must say that before I found this forum I was feeling pretty hacked off & ready to scrap it but I now feel a sence of enthusiasm
Thanks again

 

Don't worry about the year, there are only 2 differences:
1) older machines have a long front clutch bushing. The newer has a shorter bushing and a big washer to make the belt ride higher.
2) sprocket sizes.
Any year 87-05 parts will work.

 

Hi LT80, I will start stripping the engine out some time this week. I have found a company on the web called Alpha Sports at http://www.alpha-sports.com/suzuki_atv_parts.htm
Alpha Sports Center
77 Sokokis Trail So.
Limerick, Me. 04048
They seem to stock qiute a lot for the Lt's, Has anyone had any dealings with this company? Are they us based? Cheers

 

Hi there LT80,
Well the engine is out & stripped, the bits are ordered from my local Suzuki Dealer & the barrel is at the machine shop waiting for a rebore ( if it can be done as its already 1.0mm over size) what a simple unit to strip. you mentioned that the sprocket sizes vary on the years so what would you recommend to fit or do I just stick with the stock sizes.
Thanks Dave

 

Stock sprockets are the easiest. You can use a bigger front but you will need to research on these forums for the "LT80 chain adjuster" thread. It will guide you to cheap and easy ways to adjust your chain of neccessary.