Chain Drive Inspection and Replacement on the 2020 Suzuki LTZ90
Shop parts for a 2020 Suzuki LTZ90 ATV.
Chain Drive on the LTZ90: Why There Are No CV Boots to Service
Unlike shaft-driven 4WD and independent-suspension ATVs, the 2020 Suzuki LTZ90 routes power to the rear wheel through a chain and sprocket system rather than through CV-jointed axles. That means there are no CV boots to service on this machine—no rear axle boots, no inner or outer joint seals of the CV variety. The maintenance equivalent on the LTZ90 is the chain and sprocket system, which wears in predictable ways and requires inspection and eventual replacement to keep the drivetrain transferring power cleanly. This guide covers what to look for and how to handle the service.
How Chains and Sprockets Wear
The chain on the LTZ90 wears through a combination of pin-and-bushing elongation and sprocket tooth erosion that are directly linked to each other. As the chain elongates from accumulated wear at each link connection, it no longer meshes with the sprocket teeth at the correct pitch. The chain rides up on the tooth profile and loads the tips rather than the flanks, which accelerates both chain and sprocket wear simultaneously. This is why a worn chain and a worn sprocket almost always need to be replaced as a set—installing a new chain on a worn sprocket or vice versa produces rapid accelerated wear on both new components.
Dirt and debris in the chain greatly accelerate wear on the LTZ90. The grit that embeds between links during off-road riding acts as an abrasive at every pin and bushing interface, cutting into the metal with every articulation around the sprocket. Proper lubrication forms a film barrier that keeps grit from reaching the metal surfaces, but it needs to be applied on a consistent schedule—waiting until the chain looks or sounds dry means wear has already been occurring for some time.
Signs It’s Time for Replacement
The most measurable sign of chain wear on the LTZ90 is excessive slack. Check chain tension at the correct measurement point specified for this machine—typically at the midpoint of the lower chain run—and compare the actual slack to the specified range. A chain with slack that exceeds the maximum service limit has elongated beyond usable range and needs replacement. Consistent adjustment intervals that have shortened over time are an early indicator that elongation is progressing faster than expected.
Visual sprocket inspection reveals wear in a specific pattern. A sprocket in acceptable condition has teeth with symmetric, rounded profiles. Teeth that have developed a hooked or shark-fin shape on the leading face have worn past the replacement threshold. A chain that’s hard to push manually through its path, or that develops stiff or binding links visible when laid out flat, has internal damage that lubrication won’t reverse. Unusual drivetrain noise—a rhythmic clicking, slapping, or chattering that wasn’t present when the chain was new—is another reliable indicator that replacement is overdue on the LTZ90.
Tools and Parts for Chain and Sprocket Service
Chain and sprocket service on the LTZ90 calls for: a chain breaker and press tool if replacing the chain; a master link clip or rivet tool depending on the chain type used; front and rear sprocket removal tools (typically a sprocket holder and the appropriate sockets); a torque wrench; and chain lubricant. A complete chain and sprocket kit sized correctly for the LTZ90—matching the OEM chain pitch, link count, and sprocket tooth count—ensures all three worn components are replaced together. Replacing only the chain while leaving a worn sprocket, or vice versa, causes accelerated wear on the new component from the first ride.
Inspection: Chain Slack and Sprocket Teeth
Chain slack inspection on the LTZ90 requires the ATV on level ground, suspension unloaded, and the measurement taken at the correct point—typically the midpoint of the lower chain run. Use a ruler or dedicated slack gauge to measure total vertical play. Compare against the specification for this machine. Also check at multiple points along the chain’s length by rotating the wheel and measuring again—a tight spot in one section indicates a stiff or kinked link that makes chain replacement necessary regardless of average stretch measurement.
For sprocket inspection, look at the tooth profiles from the side under good lighting. Symmetric, gently rounded tooth profiles are acceptable. Hooked or shark-fin shaped leading faces indicate the sprocket is past its service limit. Count the teeth on both front and rear sprockets and confirm they match the specified tooth counts for the LTZ90—a sprocket with the wrong count or with mixed wear rates between front and rear creates chain tension irregularities.
Chain and Sprocket Replacement
Remove the old chain from the LTZ90 by breaking it at a master link or driving out a pin with the chain breaker tool. Remove the front sprocket from the countershaft and the rear sprocket from the hub. Install the new rear sprocket first, torquing the fasteners to specification in a star pattern. Install the new front sprocket and secure it correctly. Thread the new chain around both sprockets and connect it at the master link—install the master link clip with the closed end facing the direction of chain travel. Adjust chain tension to the correct specification for the LTZ90 by moving the rear axle in its adjustment slots. Torque the axle hardware to spec after setting tension.
Verify that the chain tracks straight between the two sprockets and that the rear wheel is properly aligned using the alignment marks on the swingarm. A misaligned rear wheel creates uneven chain wear and handling problems on the LTZ90.
Ongoing Chain Care and Lubrication
Chain lubrication is the highest-impact ongoing maintenance item for drivetrain longevity on the LTZ90. Apply chain lubricant to the inner side of the chain—where it contacts the sprocket teeth and links—while rotating the wheel slowly so the lubricant reaches all link interfaces. Apply after every ride that involved mud, water, or sandy conditions, and on a regular interval during normal dry riding. Allow the lubricant to penetrate before riding. Avoid applying lubricant directly to the outer side of the chain where it will simply fling off under centrifugal force—the target areas are the pin and bushing interfaces at the inner side of each link. Clean visible grit from the chain before lubrication rather than lubricating over accumulated debris on the LTZ90.
Related Shopping Categories
Shop CV Joints for a 2020 Suzuki LTZ90 ATV.
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Shop Lubricants & Solvents for a 2020 Suzuki LTZ90 ATV.
Shop Wheel Bearings for a 2020 Suzuki LTZ90 ATV.
Shop Skid Plates for a 2020 Suzuki LTZ90 ATV.
Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your ATV's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.