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LJ80
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Suzuki LJ80 Service Manual
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Also See for LJ80
:
Owner's manual
(173 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Table of Contents
Table of Contents
General: Contents
Body and Chassis of Suzuki LJ80 and LJ80V
LJ80 and LJ80V Chassis with Engine
Outline Dimensions LJ80
Outline Dimensions LJ80V
Specifications
Locations of Body Number and Engine Number
Standard Shop Practices
Engine Cylinder Numbers
Special Tools
Required Materials
Troubleshooting: Contents
Engine Troubleshooting
Poor Starting
Not Enough Power
Sudden Drop of Speed in High Speed Cruise
Engine Not Responding Quickly to Pedal Control in Picking up Speed
Erratic Idling
Abnormal Detonation
Engine Overheating
Abnormal Engine Noise
High Fuel Consumption
Excessive Engine Oil Consumption
Carburetor Troubleshooting
Exhaust and Muffler Troubleshooting
Clutch Troubleshooting
Transmission Troubleshooting
Differentials Troubleshooting
Propeller Shafts Troubleshooting
Brakes Troubleshooting
Front Suspension and Steering System Troubleshooting
Starting Motor Troubleshooting
Alternator Troubleshooting
Wiper Motor Troubleshooting
Fuel Meter Troubleshooting
Turn Signal Lights Troubleshooting
Speedometer Troubleshooting
Water Temperature Meter Troubleshooting
Oil Pressure Warning Light Troubleshooting
Charge Warning Light Troubleshooting
Horn Troubleshooting
Engine: Contents
Engine: Description
Engine Features
Blowby Gas Recycling System
Engine Services Not Requiring Engine Removal
Dismounting the Engine
Engine Disassembly
Engine Maintenance Service
Cylinder Head
Rocker Arm Shaft and Rocker Arms
Valve Guides
Valves
Valve Seats
Valve Springs
Engine Reassembly
Tightening Torque Data
Oil Seal Housing
Oil Pump
Piston and Piston Rings
Connecting Rods
Oil Pump Strainer
Oil Pan
Flywheel, Cylinder Head
Camshaft
Rocker Arm Shafts
Water Inlet Pipe
Crankshaft Timing Belt Guide
Cylinder Head Front Side Case
Camshaft Timing Belt Pulley
Timing Belt (Valve Timing Adjustment)
Valve Clearance Adjustment
Distributor, Distributor Gear Case
Alternator
Clutch
Engine Inspection and Adjustments
Timing Belt
Measuring/Adjusting Valve Clearance
Oil Pimp Discharge Pressure Measurement
Vacuum Measurement
Compression Pressure Measurement
Engine Oil, Oil Filter, Coolant
Exhaust Line and Muffler
Oil Filler Cap
Crankcase Ventilation Hose
Engine Lubrication
Oil Pump Disassembly, Inspection
Oil Pump Reassembly
Checking Oil Pressure
Oil Filter Servicing
Oil Pump Strainer Servicing
Engine Oil Servicing
Oil Level Gauge
Carburetor: Contents
Carburetor Description, Specifications
Carburetor Circuit Diagram
Carburetor Operation
Float Chamber
Slow/High Speed Mixture
Acceleration Power System
Inspecting and Adjusting
Jets
Choke Valve
Needle Valve
Accelerator and Choke Cables
Fuel Tank Cap
Fuel Level Adjustment
Fuel Hose
Idle Speed and Idle Mixture Adjustment
Air Cleaner, Fuel Pump and Fuel Filter: Contents
Air Cleaner Description
Air Cleaner Element Inspection and Servicing
Use of the Selector Level
Fuel Pump
Fuel Filter Servicing and Installation
Engine Cooling System: Contents
Engine Cooling System: Description
Cooling Water Circuit
Engine Cooling System Removal
Coolant Draining
Radiator Removal
Removal of Cooling Water Pipers, Cooling Fan Removal
Water Pump Removal
Water Reservoir Tank
Thermostat
Radiator Filler Cap
Requirements on Coolant
Water Pump
Golden Cruiser 1200 "Anti-Freeze and Summer Coolant" - Its Effects and Use
Water Temperature Gauge
Anti-Freeze Proportioning Chart
Cooling System Services
Thermostat, Fan Belt
Coolant Level
Radiator
Water Hoses
Important Re-Installing Steps
Filling up the Cooling System
Car Heater: Contents
Car Heater: Description
Car Heater: Electrical Circuit
Heater Services
Fan Resistor
Fan Switch
Ignition System: Contents
Ignition System: Description
Distributor
Ignition Coil
Spark Plugs
Timing Advancer
Maintenance Services
Distributor Cap, Spark Plugs
Distributor Driven Gear
Contact Point Faces
Checking the Primary Circuit for Fault
Ignition Coil, Condenser
Important Reminders for Reassembly and Installation: Distributor
Ignition Timing Specifications
Ignition Timing Checking Methods
Important Reminders for Reassembly and Installation: High Tension Cords
Replacement of Distributor Driven Gear
Starter Motor: Contents
Starter Motor: Description, Specification
Cranking Action
Starting up the Motor
Pinion Meshing with the Ring Gear
Starter Motor Removal
Engine Cranking
Terminating Cranking Operation
Starter Motor Disassembly
Checking the Field Coils
Servicing the Communicator
Checking the Armature
Testing the Magnetic Switch
Servicing the Brush Holders
Servicing the Brushes
Important Reminders for Starter Motor Reassembly
Charging System: Contents
Charging System: Description
Charging Operation
Alternator Description
Alternator Data and Specification
Alternator Removal/Disassembly
Testing the Rotor for Open Circuit
Testing the Rotor for Grounding
Stator, Brushes, Rectifier - Servicing
Alternator Load Performance
Alternator Regulator: Specifications, Maintenance Services
Guide on Regulator Diagnosis
Main Fuse
Battery Specifications
Care of the Battery
Clutch: Contents
Clutch: Description
Clutch: Removal
Clutch Maintenance Services
Clutch Disc Facing Surface Condition
Clutch Facing Wear
Backlash in Disc Serration Fit
Release Bearing
Inspect Shaft Bearing and Oil Seal
Clutch Cover
Clutch Disc and Clutch Cover Installation
Clutch Pedal Height
Clutch Pedal Play
Input Shaft Bearing
Clutch Release Bearing Retainer
Clutch Release Arm
Gearshifting Control: Contents
Gearshifting Control: Description
Gearshifting Control: Removal
Gearshift Lever Adjustment
Guide Plate Inspection
Gearshifting Control Installation
Transmission: Contents
Transmission: Description
Flow of Drive through Transmission
Transmission Gear Ratio
Transmission Dismounting, Disassembly
Removing the Countershaft
Removing the Main Shaft and Input Shaft
Removing the Shifter Fork Shaft and Forks
Transmission: Maintenance Services
Reverse Gears and Idle Gear
Countershaft and Its Bearings
Input Shaft
Combination of Gear and Synchronizer Ring
Chamfered Tooth Ends of Ring and Sleeve
Synchronizer Rings
Transmission: Important Step in Installation
Tightening Torque
Input Shaft and Main Shaft
Extension Case Bush
Shifter Forks and Shafts
Reverse Gears and Idle Gear, Extension Case Oil Seal
Input Shaft and Main Shaft Installation, Putting Together Upper and Lower Cases
Transmission Oil
Transfer Gear Box: Contents
Transfer Gear Box: Description
Selective Flows of Transfer Drive
2-Wheel Drive
4-Wheel Drive High
Gear Ratio Data
Transfer Gear Box Removal
4-Wheel Drive Low
Transfer Gear Box Disassembly
Universal Joint Yoke Flanges
Center Brake
Speedometer Driven Gear, Transfer Gear Control Lever
Upper Transfer Cover
Transfer Front Case, Countershaft
Shifter Fork Shafts
Transfer Gear Box Maintenance Services
Gear Teeth
Output Rear Shaft
Locating Spring
Transfer Gear Box Important Steps in Installation
Parking Brake
Output Rear Shaft, Shifter Fork Shafts and Forks
Locating Spring and Balls for Shifter Fork Shafts
Counter Gear Needle Bearings
Counter Gear Assembly
Counter Gear Stopper Pin
Transfer Case Covers
Lubricating Oil for Transfer Gear
Propeller Shafts: Contents
Propeller Shafts: Description
Propeller Shafts: Removal
Propeller Shafts: Maintenance Services
Universal Joint Noise
Propeller Shafts Installation
Differential: Contents
Differential: Description
Differential: Removal
Differential Disassembly
Differential Maintenance Services
Side Gear Backlash
Determination of Shim Thickness for Bevel Pinion
Bevel Pinion Bearing Preload Adjustment
Bevel Gear Backlash Adjustment
Pinion-To-Gear Tooth Contact Pattern Check and Adjustment
Differential Reassembly Instructions
Drive Bevel Gear Bolts
Bevel Pinion Bearings
Differential Side Bearings
Side Bearing Caps
Differential Gear Oil
Suspension: Contents
Suspension: Description
Barfield Joint Construction and Operation
Removal of Front Wheel and Kuckle
Suspension: Maintenance Services
Barfield Joint
Kingpins
Oil Seal
Suspension: Important Steps in Reassembly
Wheel Spindle, Knuckle
Shock Absorbers and Leaf Spring Specifications
Shock Absorbers and Leaf Spring Tips on Installation
Quick Links
See also:
Owner's Manual
Table of
Contents
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Table of Contents
Troubleshooting
Troubleshooting: Contents
21
Engine Troubleshooting
22
Carburetor Troubleshooting
28
Transmission Troubleshooting
29
Differentials Troubleshooting
30
Propeller Shafts Troubleshooting
31
Front Suspension And Steering System Troubleshooting
32
Starting Motor Troubleshooting
33
Alternator Troubleshooting
34
Wiper Motor Troubleshooting
35
Fuel Meter Troubleshooting
36
Speedometer Troubleshooting
37
Charge Warning Light Troubleshooting
38
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This manual is also suitable for:
Lj80v
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