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Suzuki LT160E Service Manual

Summary of LT160E

  • Page 1

    9 9 5 0 0 - 4 1 1 1 4 - 0 1 e.

  • Page 2: Foreword

    Foreword the suzuki lt160e was designed to offer supe- rior performance through four stroke power, equipped with a reverse gear. The suspension sys- tem consists of “wishbone” for front and “swingarm” for rear. 1 lt-f160el (’90-model) c copyright suzuki motor corporation 1990 group index general inf...

  • Page 220

    Lt-f160y/k1/k2 ( ’00, ’01, ’02-models) 14-8 brake + wheel unit: mm (in) item standard limit front brake lever free travel 30 (1.2) ——— rear brake pedal free travel 20 – 30 (0.8 – 1.2) ——— brake drum i.D. Front ——— 120.7 (4.75) rear ——— 150.7 (5.93) brake lining thickness ——— 1.5 (0.06) steering angl...

  • Page 227

    15 contents 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...

  • Page 228: Specifications

    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) ov...

  • Page 229

    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...

  • Page 230

    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 .....

  • Page 231

    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...

  • Page 232: Service Data

    15-5 lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) service data lt160 valve + guide unit: mm (in) item standard limit valve diam. In. 28 (1.1) — ex. 25 (1.0) — valve clearance (when cold) in. 0.03 – 0.08 (0.001 – 0.003) — ex. 0.05 – 0.10 (0.002 – 0.004) — valve guide to valve s...

  • Page 233

    Lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) 15-6 camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height p-03 in. 33.768 – 33.808 (1.3295 – 1.3310) 33.470 (1.3177) ex. 33.390 – 33.430 (1.3146 – 1.3161) 33.090 (1.3028...

  • Page 234

    15-7 lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit piston ring thickness 1st & 2nd 1.17 – 1.19 (0.046 – 0.047) — piston pin bore 14.002 – 14.008 (0.5513 – 0.5515) 14.030 (0.5524) piston pin o.D....

  • Page 235

    Lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) 15-8 drive train unit: mm (in) except ratio carbretor item standard limit primary reduction ratio 3.736 (71/19) — final reduction ratio 3.545 (39/11) — gear ratios low 3.166 (38/12) — 2nd 2.142 (30/14) — 3rd 1.588 (27/17) — 4th 1.20...

  • Page 236

    15-9 lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) electrical unit: mm (in) wattage unit: w item specification note spark plug type ngk: dpr7ea-9 nd: x22epr-u9 gap 0.8 – 0.9 (0.031 – 0.035) spark performance over 8 (0.3) at 1 atm. Ignition coil resistance primary 0.1 – 1.0 Ω te...

  • Page 237

    Lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) 15-10 brake + wheel unit: mm (in) suspension tire pressure item standard/specification limit front brake lever free travel 30 (1.2) — rear brake pedal free travel 20 – 30 (0.8 – 1.2) — brake drum i.D. Front — 120.7 (4.75) rear — 150...

  • Page 238

    15-11 lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) fuel + oil item specification note fuel type 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 t...

  • Page 239

    Lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) 15-12 lt-f160 valve + guide unit: mm (in) item standard limit valve diam. In. 28 (1.1) — ex. 25 (1.0) — valve clearance (when cold) in. 0.03 – 0.08 (0.001 – 0.003) — ex. 0.05 – 0.10 (0.002 – 0.004) — valve guide to valve stem cleara...

  • Page 240

    15-13 lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 33.490 – 33.530 (1.3185 – 1.3201) 33.190 (1.3067) ex. 33.353 – 33.393 (1.3131 – 1.3147) 33.060 (1.3016) ca...

  • Page 241

    Lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) 15-14 conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit piston ring thickness 1st & 2nd 1.17 – 1.19 (0.046 – 0.047) — piston pin bore 14.002 – 14.008 (0.5513 – 0.5515) 14.030 (0.5524) piston pin o.D...

  • Page 242

    15-15 lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) drive train unit: mm (in) except ratio carbretor item standard limit primary reduction ratio 3.736 (71/19) — final reduction ratio p-51 *4.090 (45/11) — the others 3.545 (39/11) — gear ratios low 3.166 (38/12) — 2nd 2.142 (30/...

  • Page 243

    Lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) 15-16 electrical unit: mm (in) wattage unit: w item specification note spark plug type ngk: dpr7ea-9 nd: x22epr-u9 gap 0.8 – 0.9 (0.031 – 0.035) spark performance over 8 (0.3) at 1 atm. Ignition coil resistance primary 0.1 – 1.0 Ω t...

  • Page 244

    15-17 lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) brake + wheel unit: mm (in) suspension tire pressure item standard/specification limit front brake lever free travel 30 (1.2) — rear brake pedal free travel 20 – 30 (0.8 – 1.2) — brake drum i.D. Front — 120.7 (4.75) rear — 150...

  • Page 245

    Lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) 15-18 fuel + oil item specification note fuel type 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 t...

  • Page 246: Wiring Diagram

    15-19 lt160k3/k4 (’03, ’04-models) lt-f160k3/k4/k5 (’03, ’04, ’05-models) wiring diagram lt160 and lt-f160 1 free push off on lights on off hi • push off run off on lo bl g gr o r w y b/w b/y bl/b bl/r o/b w/b w/bl y/b y/g wire colors blue green gray orange red white yellow black with white tracer b...

  • Page 247

    Prepared by 15th ed. August, 2004 1st ed. November, 1988 part no. 99500-41114-01e printed in japan 252.

  • Page 248

    Printed in japan k l m n p r s t v w x y k1 k2 k3 k4 k5.