Suzuki LT160E QuadRunner 1990-2005 Service Manual

The LT-F160 shares the same construction as the larger QuadRunners, but in a lightweight package. It was Suzuki’s smallest working quad, with a front nerf bar, carriers at both ends and a tow hitch, listed at about $2,999 for 2000-2001. A tester found it narrow, with a track of only 730mm, and a little small for a big rider, though it kept up easily with larger quads on test. For 2001 it got new yellow bodywork like the LT80. The LT160E 4x2 is its earlier electric-start version from the first years of the model.

Power comes from a 158cc air-cooled, single-cylinder SOHC four-stroke with a 58mm x 60mm bore and stroke and a 9.2:1 compression ratio. A Mikuni VM20SS carburetor feeds it, and it has electric start with a recoil option. The wet multi-plate clutch is automatic (centrifugal), and the gearbox is a 5-speed with reverse and a foot-operated, all-up shift pattern. Final drive is listed as chain in the Suzuki spec sheets, though one parts retailer calls it shaft drive, so check your bike.

The chassis has independent swing-axle front suspension and a swingarm rear with a single shock adjustable for preload. Brakes are twin front drums and a rear drum that includes the parking brake. Tires are a 20x7-8 front and a 22x10-8 rear, tubeless. Confirmed figures list a 1,670mm (65.7-inch) length, a 1,070mm (42.1-inch) wheelbase, 135mm of ground clearance, a 725mm (28.5-inch) seat height and a dry weight of about 162 kg (357 lbs).

This factory service manual covers the procedures, torque specs, and diagrams needed to keep a Suzuki Quadrunner 160 running the way it was built to.