Suzuki LT160E Service Manual
Suzuki LT160E is a four-stroke ATV designed for superior performance, equipped with a reverse gear. It features a wishbone front suspension and a swingarm rear suspension for a smooth ride on various terrains. Its 158 cc engine delivers ample power for a variety of tasks, from recreational riding to light-duty hauling. The LT160E also boasts a 5-forward and 1-reverse constant mesh transmission for easy gear shifting and a wet multi-plate clutch for smooth power transfer.
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9 9 5 0 0 - 4 1 1 1 4 - 0 1 E
FOREWORD
The SUZUKI LT160E was designed to offer superior performance through four stroke power, equipped with a reverse gear. The suspension system consists of “wishbone” for front and “swingarm” for rear.
This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service SUZUKI vehicles. Apprentice mechanics and “do it yourself” mechanics will also find this manual to be an extremely useful guide.
The LT160E, manufactured to standard specifications, is the main subject matter of this manual.
However, the LT160E machines distributed in your country might differ in minor respects from the standard-specification and, if they do, it is because some minor modifications (which are of no consequence in most cases as far as servicing is concerned) had to be made to comply with the statutory requirements of your country.
This manual contains up-to-date information at the time of its issue. Later made modifications and changes will be explained to each SUZUKI distributor in respective markets, to whom you are kindly requested to make query about updated information, if any.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
AND TUNE-UP PROCEDURES
ENGINE
FUEL AND LUBRICATION SYSTEM
ELECTRICAL SYSTEM
CHASSIS
SERVICING INFORMATION
LT-F160EL (’90-MODEL)
LT-F160L/M (’90, ’91-MODELS)
LT160EM/N (’91, ’92-MODELS)
LT-F160N/P (’92, ’93-MODELS)
LT-F160R/S/T/V
(1994 to 1997-MODELS)
LT-F160W/X (’98, ’99-MODELS)
LT-F160Y/K1/K2 (’00, ’01, ’02-MODELS)
LT160K3/K4
(’03, ’04-MODELS)
LT-F160K3/K4/K5
(’03, ’04 ’05-MODELS)
12
13
14
15
7
8
9
10
11
4
5
6
1
2
3
c
COPYRIGHT SUZUKI MOTOR CORPORATION 1990
BRAKE + WHEEL
ITEM
Front brake lever free travel
Rear brake pedal free travel
Brake drum I.D.
Brake lining thickness
Steering angle
Turning radius
Toe-in (with 75 kg, 165 lbs)
Caster
Trail
Wheel axle runout
Wheel rim size
Tire size
Tire tread depth
SUSPENSION
ITEM
Rear shock absorber spring setting
Front wheel travel
Rear wheel travel
Swingarm pivot shaft runout
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR kPa
25
20
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Inside
Outside
STANDARD
2nd position
80
(3.1)
90
(3.5)
———
STANDARD
30
(1.2)
20 – 30
(0.8 – 1.2)
———
———
———
41°
30°
2.4 m (7.9 ft)
3 – 11 (0.1 – 0.4)
8°
31 (1.2)
———
8 × 5.5 AT
8 × 8.0 AT
AT 20 × 7-8
AT 22 × 10-8
4.0
(0.16)
4.0
(0.16)
LT-F160Y/K1/K2 (
’
00,
’
01,
’
02-MODELS) 14-8
Unit: mm (in)
LIMIT
———
———
120.7
(4.75)
150.7
(5.93)
1.5
(0.06)
———
———
———
———
———
———
8.0
(0.31)
———
———
———
———
———
———
Unit: mm (in)
NOTE LIMIT
———
———
———
0.6
(0.02)
LOAD CAPACITY
130 kg (285 lbs) kg/cm
2
0.25
0.20
psi
3.6
2.9
LT160K3/K4 (’03, ’04-MODELS)
LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS)
This section describes service data, service specifications and servicing procedures which differ from those of the LT-F160K2 (’02-MODEL).
•
Any differences in sevice data and service specifications with those that apply to the
LT160K3/K4, LT-F160K3/K4/K5 models are clearly indicated with an asterisk (*).
•
Please refer to the sections 1 through 14 for details which are not given in this section.
CONTENTS
SPECIFICATIONS ............................................................................15- 1
LT160 .........................................................................................15- 1
LT-F160 ......................................................................................15- 3
SERVICE DATA ................................................................................15- 5
LT160 .........................................................................................15- 5
LT-F160 ......................................................................................15-12
WIRING DIAGRAM ...........................................................................15-19
15
15-1 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS)
SPECIFICATIONS
LT160
DIMENSIONS AND DRY MASS
Overall length ....................................................... * 1 610 mm (63.4 in)
Overall width ........................................................ 985 mm (38.8 in)
Overall height ....................................................... 1 000 mm (39.4 in)
Wheelbase ........................................................... 1 070 mm (42.1 in)
Ground clearance ................................................ 135 mm ( 5.3 in)
Front track ............................................................ 730 mm (28.7 in)
Rear track ............................................................ 730 mm (28.7 in)
Seat height........................................................... 725 mm (28.5 in)
Dry mass.............................................................. * 155 kg (341 lbs)
ENGINE
Type ..................................................................... Four-stroke, air-cooled, OHC
Number of cylinders ............................................. 1
Bore ..................................................................... 58.0 mm (2.283 in)
Stroke................................................................... 60.0 mm (2.362 in)
Displacement ....................................................... 158 cm
3
(9.6 cu. in)
Compression ratio ................................................ 9.2 : 1
Carburetor............................................................ MIKUNI VM20SS, single.......... P-03
* MIKUNI BS26SS, single .......... P-33
Air cleaner............................................................ Polyurethane foam element
Starter system...................................................... Electric
Lubrication system ............................................... Wet sump
Idle speed ............................................................ 1 500 ± 100 r/min
DRIVE TRAIN
Clutch................................................................... Wet multi-plate type, automatic, centrifugal type
Transmission ........................................................ 5-forward constant mesh and 1-reverse
Gearshift pattern, forward .................................... All up, foot lever operated
Gearshift pattern, reverse .................................... Hand lever operated
Primary reduction ratio......................................... 3.736 (71/19)
Gear ratios, Low .................................................. 3.166 (38/12)
2nd ................................................... 2.142 (30/14)
3rd.................................................... 1.588 (27/17)
4th .................................................... 1.200 (24/20)
Top ................................................... 0.950 (19/20)
Reverse ............................................ 2.833 (34/12)
Final reduction ratio ............................................. 3.545 (39/11)
Drive chain ........................................................... RK520SM, 84 links
LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-2
CHASSIS
Front suspension .................................................
Independent, swing axle, coil spring, oil damped
Rear suspension .................................................
Swinging arm, coil spring, oil damped
Caster..................................................................
8°
Trail......................................................................
31 mm (1.2 in)
Toe-in ..................................................................
7 mm (0.28 in)
Camber ...............................................................
1° 40’
Steering angle .....................................................
42°
Turning radius......................................................
2.4 m (7.9 ft)
Front brake ..........................................................
Drum brake
Rear brake...........................................................
Drum brake
Front tire size.......................................................
AT20 × 7-8
★
Rear tire size .......................................................
AT22 × 10-8
★
ELECTRICAL
Ignition type .........................................................
Electronic ignition (CDI)
Ignition timing ......................................................
10° B.T.D.C. at 1 500 rpm
Spark plug ...........................................................
NGK DPR7EA-9 or DENSO X22EPR-U9
Battery.................................................................
12V 32.4 kC (9 Ah)/10HR
Generator ............................................................
Three-phase A.C. generator
Fuse ....................................................................
15A
Headlight .............................................................
12V 45/45W
Brake light/Taillight .............................................. * 12V 21/5W
Neutral indicator light ..........................................
12V 3.4W
Reverse indicator light .........................................
12V 3.4W
CAPACITIES
Fuel tank, including reserve ...............................
8.5 L (2.2/1.9 US/Imp gal) reserve ..............................................
1.1 L (0.3/0.2 US/Imp gal)
Engine oil, oil change .........................................
1 500 ml (1.6/1.3 US/Imp qt) with filter change...............................
1 700 ml (1.8/1.5 US/Imp qt)
Over haul ..........................................
1 800 ml (1.9/1.6 US/Imp qt)
15-3 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS)
LT-F160
DIMENSIONS AND DRY MASS
Overall length ....................................................... 1 670 mm (65.7 in)
Overall width ........................................................ 985 mm (38.8 in)
Overall height ....................................................... 1 000 mm (39.4 in)
Wheelbase ........................................................... 1 070 mm (42.1 in)
Ground clearance ................................................ 135 mm ( 5.3 in)
Front track ............................................................ 730 mm (28.7 in)
Rear track ............................................................ 730 mm (28.7 in)
Seat height........................................................... 725 mm (28.5 in)
Dry mass.............................................................. 162 kg (357 lbs)
ENGINE
Type ..................................................................... Four-stroke, air-cooled, OHC
Number of cylinders ............................................. 1
Bore ..................................................................... 58.0 mm (2.283 in)
Stroke................................................................... 60.0 mm (2.362 in)
Displacement ....................................................... 158 cm 3 (9.6 cu. in)
Compression ratio ................................................ 9.2 : 1
Carburetor............................................................ MIKUNI VM20SS, single
Air cleaner............................................................ Polyurethane foam element
Starter system...................................................... Electric
Lubrication system ............................................... Wet sump
Idle speed ............................................................ 1 500 ± 100 r/min
DRIVE TRAIN
Clutch................................................................... Wet multi-plate type, automatic, centrifugal type
Transmission ........................................................ 5-forward constant mesh and 1-reverse
Gearshift pattern, forward .................................... All up, foot lever operated
Gearshift pattern, reverse .................................... Hand lever operated
Primary reduction ratio......................................... 3.736 (71/19)
Gear ratios, Low .................................................. 3.166 (38/12)
2nd ................................................... 2.142 (30/14)
3rd.................................................... 1.588 (27/17)
4th .................................................... 1.200 (24/20)
Top ................................................... 0.950 (19/20)
Reverse ............................................ 2.833 (34/12)
Final reduction ratio .............................................* 4.090 (45/11) ….. P-51
3.545 (39/11) ….. Others
Drive chain ........................................................... * RK520SM, 88 links ….. P-51
RK520SM, 84 links ….. Others
LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-4
CHASSIS
Front suspension .................................................
Independent, swing axle, coil spring, oil damped
Rear suspension .................................................
Swinging arm, coil spring, oil damped
Caster..................................................................
8°
Trail......................................................................
31 mm (1.2 in)
Toe-in ..................................................................
7 mm (0.28 in)
Camber ...............................................................
1° 40’
Steering angle .....................................................
42°
Turning radius......................................................
2.4 m (7.9 ft)
Front brake ..........................................................
Drum brake
Rear brake...........................................................
Drum brake
Front tire size.......................................................
AT20 × 7-8
★
Rear tire size .......................................................
AT22 × 10-8
★
ELECTRICAL
Ignition type .........................................................
Electronic ignition (CDI)
Ignition timing ......................................................
10° B.T.D.C. at 1 500 rpm
Spark plug ...........................................................
NGK DPR7EA-9 or DENSO X22EPR-U9
Battery.................................................................
12V 32.4 kC (9 Ah)/10HR
Generator ............................................................
Three-phase A.C. generator
Fuse ....................................................................
15A
Headlight .............................................................
12V 45/45W
Brake light/Taillight .............................................. * 12V 21/5W
Neutral indicator light ..........................................
12V 3.4W
Reverse indicator light .........................................
12V 3.4W
CAPACITIES
Fuel tank, including reserve ...............................
8.5 L (2.2/1.9 US/Imp gal) reserve ..............................................
1.1 L (0.3/0.2 US/Imp gal)
Engine oil, oil change .........................................
1 500 ml (1.6/1.3 US/Imp qt) with filter change...............................
1 700 ml (1.8/1.5 US/Imp qt)
Over haul ..........................................
1 800 ml (1.9/1.6 US/Imp qt)
15-5 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS)
SERVICE DATA
LT160
VALVE + GUIDE
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
EX.
STANDARD
28
(1.1)
25
(1.0)
0.03 – 0.08
(0.001 – 0.003)
0.05 – 0.10
(0.002 – 0.004)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
—
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2155 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2153)
—
—
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length (IN. & EX.)
Valve spring tension (IN. & EX.)
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
—
0.9 – 1.1
(0.035 – 0.043)
—
—
18.4 – 21.6 kg
(40.6 – 47.6 lbs) at length 36.8 mm (1.45 in)
Unit: mm (in)
LIMIT
—
—
—
—
—
—
0.35
(0.014)
—
—
—
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
—
0.03
(0.001)
39.5
(1.56)
—
LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-6
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
P-03
P-33
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Rocker arm I.D.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX
IN. & EX
IN. & EX
STANDARD
33.768 – 33.808
(1.3295 – 1.3310)
33.390 – 33.430
(1.3146 – 1.3161)
33.490 – 33.530
(1.3185 – 1.3201)
33.353 – 33.393
(1.3131 – 1.3147)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
—
12.000 – 12.018
(0.4724 – 0.4731)
11.977 – 11.995
(0.4715 – 0.4722)
—
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
Piston to cylinder clearance
STANDARD
1 000 – 1 400 kPa
(10 – 14 kgf/cm 2 , 142 – 199 psi)
0.030 – 0.040
(0.0012 – 0.0016)
Cylinder bore
Piston diam.
58.000-58.015
(2.2835 – 2.2841)
57.965 – 57.980
(2.2821 – 2.2827)
Measure at 20 mm (0.8 in) from the skirt end.
Cylinder distortion
—
Piston ring free end gap
1st R Approx. 5.8 (0.23)
Piston ring end gap
Piston ring to groove clearance
2nd R
1st & 2nd
1st
Approx. 7.4 (0.29)
0.010 – 0.025
(0.004 – 0.010)
—
Piston ring groove width
2nd
1st & 2nd
Oil
—
1.21 – 1.23
(0.0476 – 0.0484)
2.51 – 2.53
(0.0988 – 0.0996)
Unit: mm (in)
LIMIT
33.470
(1.3177)
33.090
(1.3028)
33.190
(1.3067)
33.060
(1.3016)
0.150
(0.0059)
—
—
0.10
(0.004)
—
—
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
LIMIT
800 kPa
(8 kgf/cm 2 , 114 psi)
0.120
(0.0047)
58.100
(2.2874)
57.880
(2.2787)
0.05
(0.002)
4.7
(0.19)
6.0
(0.24)
0.70
(0.028)
0.180
(0.0071)
0.150
(0.0059)
—
—
15-7 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS)
ITEM
Piston ring thickness
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
1st & 2nd
STANDARD
1.17 – 1.19
(0.046 – 0.047)
14.002 – 14.008
(0.5513 – 0.5515)
13.996 – 14.000
(0.5510 – 0.5512)
STANDARD
14.004 – 14.012
(0.5513 – 0.5517)
—
0.10 – 0.45
(0.0039 – 0.0177)
15.95 – 16.00
(0.628 – 0.630)
53.0 ± 0.1
(2.087 ± 0.004)
—
STANDARD
Above 30 kPa (0.30 kgf/cm 2 , 4.3 psi)
Below 70 kPa (0.70 kgf/cm 2 at 3 000 r/min.
, 10.0 psi)
CLUTCH
ITEM
Clutch release screw
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
Clutch shoe
Clutch engagement
Clutch lock-up
STANDARD
0 – 1/8 turn back
2.7 – 2.9
(0.106 – 0.114)
11.8 – 12.0
(0.46 – 0.47)
—
—
—
2 200 ± 200 r/min.
3 500 ± 250 r/min.
LIMIT
—
Unit: mm (in)
LIMIT
—
2.4
(0.094)
11.0
(0.43)
0.10
(0.004)
27.6
(1.09)
No groove at any parts
—
—
LIMIT
—
14.030
(0.5524)
13.980
(0.5504)
Unit: mm (in)
LIMIT
14.040
(0.5528)
3.0
(0.12)
1.00
(0.039)
—
—
0.05
(0.002)
LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-8
DRIVE TRAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios Low
2nd
3rd
4th
Top
Reverse
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
Drive chain slack
Gearshift lever height
No.1, No.2
& No.3
Reverse
No.1, No.2
& No.3
Reverse
Type
Links
20-pitch length
STANDARD
3.736 (71/19)
3.545 (39/11)
3.166 (38/12)
2.142 (30/14)
1.588 (27/17)
1.200 (24/20)
0.950 (19/20)
2.833 (29/12 × 34/29)
0.10 – 0.30
(0.004 – 0.012)
4.50 – 4.60
(0.177 – 0.181)
4.00 – 4.10
(0.157 – 0.161)
4.30 – 4.40
(0.169 – 0.173)
3.80 – 3.90
(0.150 – 0.154)
TAKASAGO: RK520SM
84
—
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
—
—
319.4
(12.57)
20 – 30
(0.8 – 1.2)
10
(0.4)
—
—
CARBRETOR
ITEM
Carburetor type
Bore size
I.D. No
.
Idle r/min.
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Starter jet
Pilot screw
Throttle cable play
Starter cable play
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(G.S.)
(P.S.)
P-03
MIKUNI VM20SS
20 mm
02C02
1 500 ± 100 r/min.
25.8 ± 1.0 mm
(1.02 ± 0.04 in)
SPECIFICATION
P-33
MIKUNI BS26SS
26 mm
02C1
←
21.4 ± 1.0 mm
(0.84 ± 0.04 in)
#
4DN13-1st
#87.5
5FU96-3rd
O-1
#22.5
#22.5
1
!
turns back
3 – 5 mm
(0.12 – 0.20 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
#
#20
PRE-SET
←
←
15-9 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS)
ELECTRICAL
Spark plug
ITEM
Spark performance
Ignition coil resistance
Magneto coil resistance
Generator no-load voltage
Generator Max. output
Regulated voltage
Starter relay resistance
Battery Type designation
Capacity
Standard electrolyte S.G.
Fuse size
WATTAGE
ITEM
Headlight HI
LO
Brake light/Taillight
Reverse indicator light
Neutral indicator light
Type
Gap
Primary
SPECIFICATION
NGK: DPR7EA-9
ND: X22EPR-U9
0.8 – 0.9
(0.031 – 0.035)
Over 8 (0.3) at 1 atm.
0.1 – 1.0
Ω
Secondary 10 – 25 k
Ω
Pulser
Charging
380 – 600
Ω
0.5 – 1.2
Ω
More than 55 V (AC) at 5 000 r/min.
Approx. 150 W at 5 000 r/min.
13.5 – 15.5 V at 5 000 r/min.
3 – 7
Ω
YB9A-A
12 V 32.4 kC (9 Ah)/10 HR
1.28 at 20°C (68°F)
15 A
SPECIFICATION
45
45
*21/5
3.4
3.4
Unit: mm (in)
NOTE
Terminal –
Ground
Plug cap –
Ground
BI – G
Y – Y
Unit: W
BRAKE + WHEEL
ITEM
Front brake lever free travel
Rear brake pedal free travel
Brake drum I.D.
Brake lining thickness
Steering angle
Turning radius
Toe-in (with 75 kg, 165 lbs)
Caster
Trail
Wheel axle runout
Wheel rim size
Tire size
Tire tread depth
SUSPENSION
ITEM
Rear shock absorber spring setting
Front wheel travel
Rear wheel travel
Swingarm pivot shaft runout
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-10
Front
STANDARD/SPECIFICATION
30
(1.2)
20 – 30
(0.8 – 1.2)
—
Rear
Inside
Outside
Rear
Front
Rear
Front
Rear
Front
Rear
STANDARD
2nd position
80
(3.1)
90
(3.5)
— kPa
25
20
—
—
41°
30°
2.4 m (7.9 ft)
3 – 11 (0.1 – 0.4)
8°
31 (1.2)
—
8 × 5.5 AT
8 × 8.0 AT
AT 20 × 7-8
✩
AT 22 × 10-8
✩
4.0
(0.16)
4.0
(0.16)
LIMIT
—
—
—
0.6
(0.02)
LOAD CAPACITY
130 kg (285 lbs) kgf/cm 2
0.25
0.20
Unit: mm (in)
LIMIT
—
—
—
—
8.0
(0.31)
—
—
—
—
120.7
(4.75)
150.7
(5.93)
1.5
(0.06)
—
—
—
—
—
—
NOTE
psi
3.6
2.9
15-11 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS)
FUEL + OIL
ITEM
Fuel type
Fuel tank including reserve reserve
Engine oil type
Engine oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.
8.5 L
(2.2/1.9 US/lmp gal)
Change
Overhaul
1.1 L
(0.3/0.2 US/lmp gal)
SAE 10W/40, API, SF or SG
Filter change
1 500 ml
(1.6/1.3 US/lmp qt)
1 700 ml
(1.8/1.5 US/lmp qt)
1 900 ml
(2.0/1.8 US/lmp qt)
NOTE
LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-12
LT-F160
VALVE + GUIDE
Valve diam.
ITEM
Valve clearance (when cold)
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
EX.
STANDARD
28
(1.1)
25
(1.0)
0.03 – 0.08
(0.001 – 0.003)
0.05 – 0.10
(0.002 – 0.004)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
—
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2155 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2153)
—
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length (IN. & EX.)
Valve spring tension (IN. & EX.)
IN. & EX.
IN. & EX.
—
IN. & EX.
IN. & EX.
IN. & EX.
—
0.9 – 1.1
(0.035 – 0.043)
—
—
18.4 – 21.6 kg
(40.6 – 47.6 lbs) at length 36.8 mm (1.45 in)
Unit: mm (in)
LIMIT
—
—
—
—
—
—
0.35
(0.014)
—
—
—
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
—
0.03
(0.001)
39.5
(1.56)
—
15-13 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS)
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
IN. & EX.
IN. & EX.
Camshaft runout
Rocker arm I.D.
IN. & EX.
IN. & EX
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
IN. & EX
IN. & EX
STANDARD
33.490 – 33.530
(1.3185 – 1.3201)
33.353 – 33.393
(1.3131 – 1.3147)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
—
12.000 – 12.018
(0.4724 – 0.4731)
11.977 – 11.995
(0.4715 – 0.4722)
—
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
Piston to cylinder clearance
STANDARD
1 000 – 1 400 kPa
(10 – 14 kgf/cm 2 , 142 – 199 psi)
0.030 – 0.040
(0.0012 – 0.0016)
Cylinder bore
Piston diam.
58.000-58.015
(2.2835 – 2.2841)
57.965 – 57.980
(2.2821 – 2.2827)
Measure at 20 mm (0.8 in) from the skirt end.
Cylinder distortion
—
Piston ring free end gap
1st R Approx. 5.8 (0.23)
Piston ring end gap
Piston ring to groove clearance
2nd R
1st & 2nd
1st
Approx. 7.4 (0.29)
0.010 – 0.025
(0.004 – 0.010)
—
Piston ring groove width
2nd
1st & 2nd
Oil
—
1.21 – 1.23
(0.0476 – 0.0484)
2.51 – 2.53
(0.0988 – 0.0996)
Unit: mm (in)
LIMIT
33.190
(1.3067)
33.060
(1.3016)
0.150
(0.0059)
—
—
0.10
(0.004)
—
—
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
LIMIT
800 kPa
(8 kgf/cm 2 , 114 psi)
0.120
(0.0047)
58.100
(2.2874)
57.880
(2.2787)
0.05
(0.002)
4.7
(0.19)
6.0
(0.24)
0.70
(0.028)
0.180
(0.0071)
0.150
(0.0059)
—
—
ITEM
Piston ring thickness
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
CLUTCH
ITEM
Clutch release screw
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
Clutch shoe
Clutch engagement
Clutch lock-up
LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-14
1st & 2nd
STANDARD
1.17 – 1.19
(0.046 – 0.047)
14.002 – 14.008
(0.5513 – 0.5515)
13.996 – 14.000
(0.5510 – 0.5512)
STANDARD
14.004 – 14.012
(0.5513 – 0.5517)
—
0.10 – 0.45
(0.0039 – 0.0177)
15.95 – 16.00
(0.628 – 0.630)
53.0 ± 0.1
(2.087 ± 0.004)
—
STANDARD
Above 30 kPa (0.30 kgf/cm 2 , 4.3 psi)
Below 70 kPa (0.70 kgf/cm 2 , 10.0 psi) at 3 000 r/min.
STANDARD
0 – 1/8 turn back
2.7 – 2.9
(0.106 – 0.114)
11.8 – 12.0
(0.46 – 0.47)
—
—
—
2 200 ± 200 r/min.
3 500 ± 250 r/min.
LIMIT
—
Unit: mm (in)
LIMIT
—
2.4
(0.094)
11.0
(0.43)
0.10
(0.004)
27.6
(1.09)
No groove at any parts
—
—
LIMIT
—
14.030
(0.5524)
13.980
(0.5504)
Unit: mm (in)
LIMIT
14.040
(0.5528)
3.0
(0.12)
1.00
(0.039)
—
—
0.05
(0.002)
15-15 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS)
DRIVE TRAIN
ITEM
Primary reduction ratio
Final reduction ratio P-51
The others
Gear ratios Low
2nd
3rd
4th
Top
Reverse
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
Drive chain slack
Gearshift lever height
No.1, No.2
& No.3
Reverse
No.1, No.2
& No.3
Reverse
Type
Links
20-pitch length
STANDARD
3.736 (71/19)
*4.090 (45/11)
3.545 (39/11)
3.166 (38/12)
2.142 (30/14)
1.588 (27/17)
1.200 (24/20)
0.950 (19/20)
2.833 (29/12 × 34/29)
0.10 – 0.30
(0.004 – 0.012)
4.50 – 4.60
(0.177 – 0.181)
4.00 – 4.10
(0.157 – 0.161)
4.30 – 4.40
(0.169 – 0.173)
3.80 – 3.90
(0.150 – 0.154)
TAKASAGO: RK520SM
P-51
The others
*88
84
—
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
—
—
—
319.4
(12.57)
20 – 30
(0.8 – 1.2)
10
(0.4)
—
—
CARBRETOR
Carburetor type
Bore size
I.D. No
.
Idle r/min.
Float height
ITEM
Main jet
Jet needle
Needle jet
Pilot jet
Starter jet
Pilot screw
Throttle cable play
Starter cable play
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(G.S.)
(P.S.)
P-24, 28
MIKUNI VM20SS
20 mm
SPECIFICATION
02C02
1 500 ± 100 r/min.
25.8 ± 1.0 mm
(1.02 ± 0.04 in)
#87.5
5FU96-3rd
O-1
#22.5
#22.5
1
!
turns back
3 – 5 mm
(0.12 – 0.20 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
←
←
←
←
←
←
←
←
P-51
←
←
02C2
←
←
LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-16
ELECTRICAL
Spark plug
ITEM
Spark performance
Ignition coil resistance
Magneto coil resistance
Generator no-load voltage
Generator Max. output
Regulated voltage
Starter relay resistance
Battery Type designation
Capacity
Standard electrolyte S.G.
Fuse size
WATTAGE
ITEM
Headlight HI
LO
Brake light/Taillight
Reverse indicator light
Neutral indicator light
Type
Gap
Primary
SPECIFICATION
NGK: DPR7EA-9
ND: X22EPR-U9
0.8 – 0.9
(0.031 – 0.035)
Over 8 (0.3) at 1 atm.
0.1 – 1.0
Ω
Secondary 10 – 25 k
Ω
Pulser
Charging
380 – 600
Ω
0.5 – 1.2
Ω
More than 55 V (AC) at 5 000 r/min.
Approx. 150 W at 5 000 r/min.
13.5 – 15.5 V at 5 000 r/min.
3 – 7
Ω
YB9A-A
12 V 32.4 kC (9 Ah)/10 HR
1.28 at 20°C (68°F)
15 A
SPECIFICATION
45
45
*21/5
3.4
3.4
Unit: mm (in)
NOTE
Terminal –
Ground
Plug cap –
Ground
BI – G
Y – Y
Unit: W
15-17 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS)
BRAKE + WHEEL
ITEM
Front brake lever free travel
Rear brake pedal free travel
Brake drum I.D.
Brake lining thickness
Steering angle
Turning radius
Toe-in (with 75 kg, 165 lbs)
Caster
Trail
Wheel axle runout
Wheel rim size
Tire size
Tire tread depth
SUSPENSION
ITEM
Rear shock absorber spring setting
Front wheel travel
Rear wheel travel
Swingarm pivot shaft runout
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
Rear
Front
Rear
Front
Rear
Front
Rear
Front
STANDARD/SPECIFICATION
30
(1.2)
20 – 30
(0.8 – 1.2)
—
Rear —
Inside
Outside
—
41°
30°
2.4 m (7.9 ft)
3 – 11 (0.1 – 0.4)
8°
31 (1.2)
—
8 × 5.5 AT
8 × 8.0 AT
AT 20 × 7-8
✩
AT 22 × 10-8
✩
4.0
(0.16)
4.0
(0.16)
STANDARD
2nd position
80
(3.1)
90
(3.5)
—
LIMIT
—
—
—
0.6
(0.02) kPa
25
20
LOAD CAPACITY
130 kg (285 lbs) kgf/cm 2
0.25
0.20
Unit: mm (in)
LIMIT
—
—
—
—
8.0
(0.31)
—
—
—
—
120.7
(4.75)
150.7
(5.93)
1.5
(0.06)
—
—
—
—
—
—
NOTE
psi
3.6
2.9
LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS) 15-18
FUEL + OIL
Fuel type
ITEM
Fuel tank including reserve reserve
Engine oil type
Engine oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended.
8.5 L
(2.2/1.9 US/lmp gal)
Change
Overhaul
1.1 L
(0.3/0.2 US/lmp gal)
SAE 10W/40, API, SF or SG
Filter change
1 500 ml
(1.6/1.3 US/lmp qt)
1 700 ml
(1.8/1.5 US/lmp qt)
1 900 ml
(2.0/1.8 US/lmp qt)
NOTE
P-28
P-24, 51
15-19 LT160K3/K4 (’03, ’04-MODELS) LT-F160K3/K4/K5 (’03, ’04, ’05-MODELS)
WIRING DIAGRAM
LT160 AND LT-F160
O
W/B
W
Y
B/W
O
W/B
O/B
O
Bl/B
Bl/R
Gr
B/W
O
W/B
O
O/B
W/Bl
G
Bl
B/W
Bl/B
O/B
Y/B
O
Bl/B
Y/G
B/W
W/Bl
Y/G
O
Gr
B/W
O/W
O
W/B
Y/G
O
Gr
B/W
O/B
Gr
B/W
O/B
O
Bl/B
Bl/R
B/W
R
R
R
R
B/W
B/W
R
Y
Y
Y
R
Bl/B
Bl
Bl/R
Y
Y
Y
G
Bl
Bl
B/W
Y/B
O
R
Gr
Bl/B
Bl/R
Y
Y
Y
G
Bl
B/W
R
Y
Y
Y
O
R
Gr
B/W
B/Y
Bl
Prepared by
15th Ed. August, 2004
1st Ed. November, 1988
Part No. 99500-41114-01E
Printed in Japan
252
Printed in Japan
K L M N P R S T V W X Y K1 K2 K3 K4 K5
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